r2 DA40 NG AMM Complete PDF
Uploaded by
Kaisr2 DA40 NG AMM Complete PDF
Uploaded by
KaisAIRCRAFT
DA 40 NG
AIRPLANE MAINTENANCE MANUAL
Copyright © by DIAMOND AIRCRAFT INDUSTRIES, Wiener Neustadt, Austria
Introduction DA 40 NG 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.
Diamond Aircraft Industries GmbH
N. A. Otto-Str. 5
A-2700 Wiener Neustadt
Austria
Phone: +43-2622-26700
Fax: +43-2622-26780
E-mail: [email protected]
DA 40 NG AMM Table of Contents
AIRCRAFT
TABLE OF CONTENTS
Ch/Sect Title
01-00 Introduction
02-00 Organization and Handling of the Manual
03-00 General Description of the Airplane
04-00 Airworthiness Limitations
05-00 Time Limits and Maintenance Checks
05-10 Time Limits
05-20 Scheduled Maintenance Checks
05-21 Flight-Line Checks
05-25 Drain Holes Inspection Checklist and Report
05-28 Maintenance Checklist DA 40 NG
05-50 Unscheduled Maintenance Checks
06-00 Dimensions and Areas
07-00 Lifting and Shoring
07-10 Jacking
08-00 Weighing and Levelling
08-10 Weighing
08-20 Levelling
09-00 Towing and Taxiing
09-10 Towing
09-20 Taxiing
10-00 Parking, Mooring, Storage and Return to Service
10-10 Parking and Storage
10-20 Mooring
10-30 Return to Service
11-00 Placards and Markings
11-20 Exterior Placards and Markings
11-30 Interior Placards and Markings
12-00 Servicing
12-10 Replenishing
12-20 Scheduled Servicing
12-30 Unscheduled Servicing
20-00 Standard Practices
% 20-10 Standard Practices - Airframe
% 20-30 Standard Practices - Electrical
% 20-70 Standard Practices - Engine
Doc # 6.02.15 Page i
Rev. 2 CONTENTS 15 Apr 2013
Table of Contents DA 40 NG AMM
AIRCRAFT
21-00 Air Conditioning, Heating and Ventilation
21-50 Cooling
% 21-51 Cooling (if OÄM 40-316/i or later is installed)
22-00 Auto Flight
22-10 Autopilot, GFC 700
22-11 Autopilot, KAP 140
23-00 Communications
23-10 Speech Communication with G1000 System Installed
23-11 Speech Communication with Conventional Cockpit Installed
23-50 Audio Integrating with G1000 System Installed
23-51 Audio Integrating with Conventional Cockpit Installed
23-60 Static Discharging
24-00 Electrical Power
24-30 DC Generation
24-31 Battery System
24-32 Emergency Battery System
24-33 Additional Alternator
24-40 External Power
24-60 DC Electrical Load Distribution
25-00 Equipment/Furnishings - General
25-10 Flight Compartment
25-60 Emergency
26-00 Fire Protection
27-00 Flight Controls
27-10 Flight Controls - Ailerons and Tabs
27-20 Flight Controls - Rudder
27-30 Flight Controls - Elevator
27-38 Flight Controls - Elevator Trim
27-39 Stall Warning System
27-50 Flight Controls - Flaps
28-00 Fuel System
28-10 Fuel Storage System
28-20 Fuel Distribution System
28-40 Fuel Quantity Indicating
31-00 Indicating Systems
31-10 Instrument and Control Panels with G1000 System Installed
31-11 Instrument and Control Panels with Conventional Cockpit Installed
31-20 Independent Instruments
31-40 Central Computers
31-51 Central Warning System with Conventional Cockpit Installed
Page ii Doc # 6.02.15
15 Apr 2013 CONTENTS Rev. 2
DA 40 NG AMM Table of Contents
AIRCRAFT
32-00 Landing Gear
32-10 Main Landing Gear
32-20 Nose Landing Gear
32-40 Wheels and Brakes
33-00 Lights
33-10 Lights - Flight Compartment
33-40 Exterior Lights
34-00 Navigation
34-10 Flight Environment Data
34-20 Attitude and Direction with G1000 System Installed
34-21 Attitude and Direction with Conventional Cockpit Installed
34-22 Magnetic Compass with Conventional Cockpit Installed
34-25 Gyro Instruments with Conventional Cockpit Installed
34-30 Landing and Taxiing Aids with G1000 System Installed
34-31 Landing and Taxiing Aids with Conventional Cockpit Installed
34-40 Independent Position Determining with G1000 System Installed
34-41 Stormscope System with G1000 System Installed
% 34-42 Traffic Advisory System (TAS)
34-50 Dependent Position Determining with G1000 System Installed
34-51 Dependent Position Determining with Conventional Cockpit Installed
34-52 VOR/Localizer/Glideslope (VOR/LOC/GS) with Conventional Cockpit Installed
34-56 Transponder (XPDR) with Conventional Cockpit Installed
51-00 Standard Practices and Structure
51-10 Investigation
51-20 Repair Processes
51-30 Materials
51-40 Fasteners
51-60 Control Surface Balancing
51-80 Electrical Bonding
52-00 Doors
52-10 Canopy and Passenger Door
52-40 Access Panels
53-00 Fuselage
53-10 Fuselage Structure
55-00 Stabilizers
55-10 Horizontal Stabilizer
55-20 Elevator
55-30 Lower Fin
55-40 Rudder
Doc # 6.02.15 Page iii
Rev. 2 CONTENTS 15 Apr 2013
Table of Contents DA 40 NG AMM
AIRCRAFT
56-00 Windows
56-10 Flight Compartment Windows
57-00 Wings
57-10 Wing Structure
57-50 Flaps
57-60 Aileron
61-00 Propeller
61-10 Propeller Assembly
61-20 Propeller Control
71-00 Power Plant
71-10 Engine Cowling
71-20 Engine Mounting
71-50 Electrical Cables in the Engine Compartment
71-60 Air Intakes
71-70 Engine Drains
72-00 Engine
73-00 Engine Fuel and Control
75-00 Liquid Cooling System
76-00 Engine Controls
77-00 Engine Indicating with G1000 System Installed
77-01 Engine Indication with Conventional Cockpit Installed
77-40 Engine Indicating System with G1000 System Installed
77-41 Engine Integrated Instrument System with Conventional Cockpit Installed
78-00 Exhaust
79-00 Oil Cooling
80-00 Starting
81-00 Turbo Charger
92-00 Wiring Diagrams
Page iv Doc # 6.02.15
15 Apr 2013 CONTENTS Rev. 2
DA 40 NG AMM Record of Revision
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. Complete the table below when you have put the
revision in the AMM.
Revision Date Inserted Inserted Revision Date Inserted Inserted
Number Issued On By Number Issued On By
Original 01 Apr 2010
% 1 15 Jun 2011
% 2 15 Apr 2013
Doc # 6.02.15 Page v
Rev. 2 ROR 15 Apr 2013
Record of Revision DA 40 NG AMM
AIRCRAFT
2. Record of Incorporated Temporary Revisions
% The following Temporary Revisions are incorporated into the DA 40 NG AMM by Revision 1:
Temporary Revision Number Description of Temporary Revision
AMM-TR-MÄM 40-434 Cowling Redesign
AMM-TR-MÄM 40-434/a Cowling Redesign
AMM-TR-MÄM 40-434/b & Cowling Redesign
AMM-TR-MÄM 40-549
AMM-TR-MÄM 40-436 Shock Mount Installation Torques
AMM-TR-MÄM 40-440 Safety Harnesses
AMM-TR-MÄM 40-442 New Governor Speed Settings
AMM-TR-MÄM 40-468 Fuel Pulsation Damper
AMM-TR-MÄM 40-481 Safety Walk Adhesive Strips
AMM-TR-MÄM 40-524 Maintenance Program Phase 1
AMM-TR-MÄM 40-525 Maintenance Interval GFC 700
AMM-TR-MÄM 40-526 Landing Gear Special Torque Values and Corrections
AMM-TR-MÄM 40-535 Gearbox Oil Inspection
AMM-TR-OÄM 40-310 Exhaust Muffler
AMM-TR-OÄM 40-314/c Additional Alternator
AMM-TR-OÄM 40-316 Recirculating Air - Cabin Cooling (RACC)
AMM-TR-OÄM 40-317 Coated Safety Walk
AMM-TR-OÄM 40-321 Conventional Cockpit DA 40 NG Club
AMM-TR-OÄM 40-326/a Emergency Axe
AMM-TR-OÄM 40-327 Sun Visor for Tall Canopy
AMM-TR-OÄM 40-329 DA 40 NG Retrofit, G1000 with Autopilot KAP 140
AMM-TR-OÄM 40-330 DA 40 NG Retrofit, G1000 without Autopilot GFC 700
AMM-TR-OÄM 40-331 Short Baggage Extension
AMM-TR-OÄM 40-333 DA 40 NG without Autopilot GFC 700
Page vi Doc # 6.02.15
15 Apr 2013 ROR Rev. 2
DA 40 NG AMM Record of Revision
AIRCRAFT
% The following Temporary Revisions are incorporated into the DA 40 NG AMM by Revision 2:
% Temporary Revision Number Description of Temporary Revision
% AMM-TR-MÄM 40-502/a & Replacement of Charged Air Hoses with Tube
% AMM-TR-MÄM 40-506/a
% AMM-TR-MÄM 40-505 Firewall Reinforcements on Engine Mount Holes
% AMM-TR-MÄM 40-519 & Breather Line with Additional Outlet
% AMM-TR-MÄM 40-520
% AMM-TR-MÄM 40-534 Propeller Shipping Plug Removal
% AMM-TR-MÄM 40-537 Fuel Drain Valve Mounting Torque
% AMM-TR-MÄM 40-551 Alternator Regulator E4A-91-200-000
% AMM-TR-MÄM 40-568/a Alternative Engine Shock Mount
% AMM-TR-MÄM 40-574/a & 1280 kg Maximum Landing Mass
% AMM-TR-OÄM 40-334/b & and/or Landing Gear with
% AMM-TR-MÄM 40-631 Large or Small Tires
% AMM-TR-MÄM 40-607 Adaption of Engine Time Limits
% AMM-TR-MÄM 40-629 Rudder Control Cable Installation
% AMM-TR-MÄM 40-630 Turbo Connector and Worm Drive Clamps
% AMM-TR-MÄM 40-632 New AE 300 Gearbox
% AMM-TR-MÄM 40-634 Snow and Ice Removal
% AMM-TR-MÄM 40-636 Additional Greases
% AMM-TR-MÄM 40-639 Charged Air Hoses SG5-0
% AMM-TR-OÄM 40-314/e Additional Alternator
% AMM-TR-OÄM 40-316/a Recirculating Air-Cabin Cooling
% AMM-TR-OÄM 40-339 Foot Step Rear Option
% AMM-TR-OÄM 40-340 Avidyne/Ryan TAS 600 Series
% AMM-TR-OÄM 40-341 Whelen LED Position Lights
Doc # 6.02.15 Page vii
Rev. 2 ROR 15 Apr 2013
Record of Revision DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page viii Doc # 6.02.15
15 Apr 2013 ROR Rev. 2
DA 40 NG AMM List of Effective Pages
AIRCRAFT
LIST OF EFFECTIVE PAGES
1. General
The list of effective pages uses this abbreviation:
) TOC Table of Contents.
) ROR Record of Revisions.
) LOEP List of Effective Pages.
All Sections have a Title Page and a Table of Contents. The TOC can have one page or it can have
many pages.
Each revision to the Airplane Maintenance Manual will have a new List of Effective Pages.
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% TOC i 15 Apr 2013 LOEP 14 15 Apr 2013 02-00 TOC 1 15 Apr 2013
% TOC ii 15 Apr 2013 LOEP 15 15 Apr 2013 02-00 TOC 2 15 Apr 2013
% TOC iii 15 Apr 2013 LOEP 16 15 Apr 2013 02-00 1 15 Apr 2013
% TOC iv 15 Apr 2013 LOEP 17 15 Apr 2013 02-00 2 15 Apr 2013
% ROR v 15 Apr 2013 LOEP 18 15 Apr 2013 02-00 3 15 Apr 2013
% ROR vi 15 Apr 2013 LOEP 19 15 Apr 2013 02-00 4 15 Apr 2013
% LOEP 1 15 Apr 2013 LOEP 20 15 Apr 2013 02-00 5 15 Apr 2013
% LOEP 2 15 Apr 2013 01-00 Title 1 15 Apr 2013 02-00 6 15 Apr 2013
% LOEP 3 15 Apr 2013 01-00 Title 2 15 Apr 2013 02-00 7 15 Apr 2013
% LOEP 4 15 Apr 2013 01-00 TOC 1 15 Apr 2013 02-00 8 15 Apr 2013
% LOEP 5 15 Apr 2013 01-00 TOC 2 15 Apr 2013 03-00 Title 1 15 Apr 2013
% LOEP 6 15 Apr 2013 01-00 1 15 Apr 2013 03-00 Title 2 15 Apr 2013
% LOEP 7 15 Apr 2013 01-00 2 15 Apr 2013 03-00 TOC 1 15 Apr 2013
% LOEP 8 15 Apr 2013 01-00 3 15 Apr 2013 03-00 TOC 2 15 Apr 2013
% LOEP 9 15 Apr 2013 01-00 4 15 Apr 2013 03-00 1 15 Apr 2013
% LOEP 10 15 Apr 2013 01-00 5 15 Apr 2013 03-00 2 15 Apr 2013
% LOEP 11 15 Apr 2013 01-00 6 15 Apr 2013 03-00 3 15 Apr 2013
% LOEP 12 15 Apr 2013 02-00 Title 1 15 Apr 2013 03-00 4 15 Apr 2013
% LOEP 13 15 Apr 2013 02-00 Title 2 15 Apr 2013 03-00 5 15 Apr 2013
Doc # 6.02.15 Page 1
Rev. 2 LOEP 15 Apr 2013
List of Effective Pages DA 40 NG AMM
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 03-00 6 15 Apr 2013 05-10 5 15 Apr 2013 05-28-50 2 15 Apr 2013
% 03-00 7 15 Apr 2013 05-10 6 15 Apr 2013 05-28-50 3 15 Apr 2013
% 03-00 8 15 Apr 2013 05-20 1 15 Apr 2013 05-28-50 4 15 Apr 2013
% 04-00 Title 1 15 Apr 2013 05-20 2 15 Apr 2013 05-28-50 5 15 Apr 2013
% 04-00 Title 2 15 Apr 2013 05-20 3 15 Apr 2013 05-28-50 6 15 Apr 2013
% 04-00 TOC 1 15 Apr 2013 05-20 4 15 Apr 2013 05-28-50 7 15 Apr 2013
% 04-00 TOC 2 15 Apr 2013 05-21 1 15 Apr 2013 05-28-50 8 15 Apr 2013
% 04-00 1 15 Apr 2013 05-21 2 15 Apr 2013 05-28-50 9 15 Apr 2013
% 04-00 2 15 Apr 2013 05-25 1 15 Apr 2013 05-28-50 10 15 Apr 2013
% 04-00 3 15 Apr 2013 05-25 2 15 Apr 2013 05-28-50 11 15 Apr 2013
% 04-00 4 15 Apr 2013 05-25 3 15 Apr 2013 05-28-50 12 15 Apr 2013
% 04-00 5 15 Apr 2013 05-25 4 15 Apr 2013 05-28-50 13 15 Apr 2013
% 04-00 6 15 Apr 2013 05-25 5 15 Apr 2013 05-28-50 14 15 Apr 2013
% 05-00 Title 1 15 Apr 2013 05-25 6 15 Apr 2013 05-28-50 15 15 Apr 2013
% 05-00 Title 2 15 Apr 2013 05-25 7 15 Apr 2013 05-28-50 16 15 Apr 2013
% 05-00 TOC 1 15 Apr 2013 05-25 8 15 Apr 2013 05-28-50 17 15 Apr 2013
% 05-00 TOC 2 15 Apr 2013 05-25 9 15 Apr 2013 05-28-50 18 15 Apr 2013
% 05-00 TOC 3 15 Apr 2013 05-25 10 15 Apr 2013 05-28-50 19 15 Apr 2013
% 05-00 TOC 4 15 Apr 2013 05-28-00 1 15 Apr 2013 05-28-50 20 15 Apr 2013
% 05-00 1 15 Apr 2013 05-28-00 2 15 Apr 2013 05-28-50 21 15 Apr 2013
% 05-00 2 15 Apr 2013 05-28-00 3 15 Apr 2013 05-28-50 22 15 Apr 2013
% 05-00 3 15 Apr 2013 05-28-00 4 15 Apr 2013 05-28-50 23 15 Apr 2013
% 05-00 4 15 Apr 2013 05-28-00 5 15 Apr 2013 05-28-50 24 15 Apr 2013
% 05-00 5 15 Apr 2013 05-28-00 6 15 Apr 2013 05-28-50 25 15 Apr 2013
% 05-00 6 15 Apr 2013 05-28-00 7 15 Apr 2013 05-28-50 26 15 Apr 2013
% 05-10 1 15 Apr 2013 05-28-00 8 15 Apr 2013 05-28-50 27 15 Apr 2013
% 05-10 2 15 Apr 2013 05-28-00 9 15 Apr 2013 05-28-50 28 15 Apr 2013
% 05-10 3 15 Apr 2013 05-28-00 10 15 Apr 2013 05-28-90 1 15 Apr 2013
% 05-10 4 15 Apr 2013 05-28-50 1 15 Apr 2013 05-28-90 2 15 Apr 2013
Page 2 Doc # 6.02.15
15 Apr 2013 LOEP Rev. 2
DA 40 NG AMM List of Effective Pages
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 05-28-91 1 15 Apr 2013 06-00 TOC 2 15 Apr 2013 08-10 7 15 Apr 2013
% 05-28-91 2 15 Apr 2013 06-00 1 15 Apr 2013 08-10 8 15 Apr 2013
% 05-28-92 1 15 Apr 2013 06-00 2 15 Apr 2013 08-10 9 15 Apr 2013
% 05-28-92 2 15 Apr 2013 06-00 3 15 Apr 2013 08-10 10 15 Apr 2013
% 05-28-92 3 15 Apr 2013 06-00 4 15 Apr 2013 08-10 11 15 Apr 2013
% 05-28-92 4 15 Apr 2013 06-00 5 15 Apr 2013 08-10 12 15 Apr 2013
% 05-28-93 1 15 Apr 2013 06-00 6 15 Apr 2013 08-10 13 15 Apr 2013
% 05-28-93 2 15 Apr 2013 07-00 Title 1 15 Apr 2013 08-10 14 15 Apr 2013
% 05-28-93 3 15 Apr 2013 07-00 Title 2 15 Apr 2013 08-20 1 15 Apr 2013
% 05-28-93 4 15 Apr 2013 07-00 TOC 1 15 Apr 2013 08-20 2 15 Apr 2013
% 05-50 1 15 Apr 2013 07-00 TOC 2 15 Apr 2013 08-20 3 15 Apr 2013
% 05-50 2 15 Apr 2013 07-00 1 15 Apr 2013 08-20 4 15 Apr 2013
% 05-50 3 15 Apr 2013 07-00 2 15 Apr 2013 09-00 Title 1 15 Apr 2013
% 05-50 4 15 Apr 2013 07-10 1 15 Apr 2013 09-00 Title 2 15 Apr 2013
% 05-50 5 15 Apr 2013 07-10 2 15 Apr 2013 09-00 TOC 1 15 Apr 2013
% 05-50 6 15 Apr 2013 07-10 3 15 Apr 2013 09-00 TOC 2 15 Apr 2013
% 05-50 7 15 Apr 2013 07-10 4 15 Apr 2013 09-00 1 15 Apr 2013
% 05-50 8 15 Apr 2013 08-00 Title 1 15 Apr 2013 09-00 2 15 Apr 2013
% 05-50 9 15 Apr 2013 08-00 Title 2 15 Apr 2013 09-10 1 15 Apr 2013
% 05-50 10 15 Apr 2013 08-00 TOC 1 15 Apr 2013 09-10 2 15 Apr 2013
% 05-50 11 15 Apr 2013 08-00 TOC 2 15 Apr 2013 09-20 1 15 Apr 2013
% 05-50 12 15 Apr 2013 08-00 1 15 Apr 2013 09-20 2 15 Apr 2013
% 05-50 13 15 Apr 2013 08-00 2 15 Apr 2013 09-20 3 15 Apr 2013
% 05-50 14 15 Apr 2013 08-10 1 15 Apr 2013 09-20 4 15 Apr 2013
% 05-50 15 15 Apr 2013 08-10 2 15 Apr 2013 10-00 Title 1 15 Apr 2013
% 05-50 16 15 Apr 2013 08-10 3 15 Apr 2013 10-00 Title 2 15 Apr 2013
% 06-00 Title 1 15 Apr 2013 08-10 4 15 Apr 2013 10-00 TOC 1 15 Apr 2013
% 06-00 Title 2 15 Apr 2013 08-10 5 15 Apr 2013 10-00 TOC 2 15 Apr 2013
% 06-00 TOC 1 15 Apr 2013 08-10 6 15 Apr 2013 10-00 1 15 Apr 2013
Doc # 6.02.15 Page 3
Rev. 2 LOEP 15 Apr 2013
List of Effective Pages DA 40 NG AMM
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 10-00 2 15 Apr 2013 12-00 Title 1 15 Apr 2013 12-30 4 15 Apr 2013
% 10-10 1 15 Apr 2013 12-00 Title 2 15 Apr 2013 20-00 Title 1 15 Apr 2013
% 10-10 2 15 Apr 2013 12-00 TOC 1 15 Apr 2013 20-00 Title 2 15 Apr 2013
% 10-10 3 15 Apr 2013 12-00 TOC 2 15 Apr 2013 20-00 TOC 1 15 Apr 2013
% 10-10 4 15 Apr 2013 12-00 1 15 Apr 2013 20-00 TOC 2 15 Apr 2013
% 10-10 5 15 Apr 2013 12-00 2 15 Apr 2013 20-00 1 15 Apr 2013
% 10-10 6 15 Apr 2013 12-10 1 15 Apr 2013 20-00 2 15 Apr 2013
% 10-20 1 15 Apr 2013 12-10 2 15 Apr 2013 20-10 1 15 Apr 2013
% 10-20 2 15 Apr 2013 12-10 3 15 Apr 2013 20-10 2 15 Apr 2013
% 10-30 1 15 Apr 2013 12-10 4 15 Apr 2013 20-10 3 15 Apr 2013
% 10-30 2 15 Apr 2013 12-10 5 15 Apr 2013 20-10 4 15 Apr 2013
% 11-00 Title 1 15 Apr 2013 12-10 6 15 Apr 2013 20-30 1 15 Apr 2013
% 11-00 Title 2 15 Apr 2013 12-10 7 15 Apr 2013 20-30 2 15 Apr 2013
% 11-00 TOC 1 15 Apr 2013 12-10 8 15 Apr 2013 20-30 3 15 Apr 2013
% 11-00 TOC 2 15 Apr 2013 12-10 9 15 Apr 2013 20-30 4 15 Apr 2013
% 11-00 1 15 Apr 2013 12-10 10 15 Apr 2013 20-70 1 15 Apr 2013
% 11-00 2 15 Apr 2013 12-10 11 15 Apr 2013 20-70 2 15 Apr 2013
% 11-20 1 15 Apr 2013 12-10 12 15 Apr 2013 20-70 3 15 Apr 2013
% 11-20 2 15 Apr 2013 12-10 13 15 Apr 2013 20-70 4 15 Apr 2013
% 11-20 201 15 Apr 2013 12-10 14 15 Apr 2013 20-70 5 15 Apr 2013
% 11-20 202 15 Apr 2013 12-20 1 15 Apr 2013 20-70 6 15 Apr 2013
% 11-20 203 15 Apr 2013 12-20 2 15 Apr 2013 20-70 7 15 Apr 2013
% 11-20 204 15 Apr 2013 12-20 3 15 Apr 2013 20-70 8 15 Apr 2013
% 11-30 1 15 Apr 2013 12-20 4 15 Apr 2013 21-00 Title 1 15 Apr 2013
% 11-30 2 15 Apr 2013 12-20 5 15 Apr 2013 21-00 Title 2 15 Apr 2013
% 11-30 3 15 Apr 2013 12-20 6 15 Apr 2013 21-00 TOC 1 15 Apr 2013
% 11-30 4 15 Apr 2013 12-30 1 15 Apr 2013 21-00 TOC 2 15 Apr 2013
% 11-30 5 15 Apr 2013 12-30 2 15 Apr 2013 21-00 1 15 Apr 2013
% 11-30 6 15 Apr 2013 12-30 3 15 Apr 2013 21-00 2 15 Apr 2013
Page 4 Doc # 6.02.15
15 Apr 2013 LOEP Rev. 2
DA 40 NG AMM List of Effective Pages
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 21-00 3 15 Apr 2013 21-50 210 15 Apr 2013 22-10 3 15 Apr 2013
% 21-00 4 15 Apr 2013 21-50 211 15 Apr 2013 22-10 4 15 Apr 2013
% 21-00 101 15 Apr 2013 21-50 212 15 Apr 2013 22-10 201 15 Apr 2013
% 21-00 102 15 Apr 2013 21-51 1 15 Apr 2013 22-10 202 15 Apr 2013
% 21-00 201 15 Apr 2013 21-51 2 15 Apr 2013 22-10 203 15 Apr 2013
% 21-00 202 15 Apr 2013 21-51 3 15 Apr 2013 22-10 204 15 Apr 2013
% 21-00 203 15 Apr 2013 21-51 4 15 Apr 2013 22-10 205 15 Apr 2013
% 21-00 204 15 Apr 2013 21-51 101 15 Apr 2013 22-10 206 15 Apr 2013
% 21-00 205 15 Apr 2013 21-51 102 15 Apr 2013 22-10 207 15 Apr 2013
% 21-00 206 15 Apr 2013 21-51 201 15 Apr 2013 22-10 208 15 Apr 2013
% 21-00 207 15 Apr 2013 21-51 202 15 Apr 2013 22-10 209 15 Apr 2013
% 21-00 208 15 Apr 2013 21-51 203 15 Apr 2013 22-10 210 15 Apr 2013
% 21-00 209 15 Apr 2013 21-51 204 15 Apr 2013 22-10 211 15 Apr 2013
% 21-00 210 15 Apr 2013 21-51 205 15 Apr 2013 22-10 212 15 Apr 2013
% 21-50 1 15 Apr 2013 21-51 206 15 Apr 2013 22-10 213 15 Apr 2013
% 21-50 2 15 Apr 2013 21-51 207 15 Apr 2013 22-10 214 15 Apr 2013
% 21-50 3 15 Apr 2013 21-51 208 15 Apr 2013 22-11 1 15 Apr 2013
% 21-50 4 15 Apr 2013 21-51 209 15 Apr 2013 22-11 2 15 Apr 2013
% 21-50 101 15 Apr 2013 21-51 210 15 Apr 2013 22-11 3 15 Apr 2013
% 21-50 102 15 Apr 2013 21-51 211 15 Apr 2013 22-11 4 15 Apr 2013
% 21-50 201 15 Apr 2013 21-51 212 15 Apr 2013 22-11 5 15 Apr 2013
% 21-50 202 15 Apr 2013 22-00 Title 1 15 Apr 2013 22-11 6 15 Apr 2013
% 21-50 203 15 Apr 2013 22-00 Title 2 15 Apr 2013 22-11 7 15 Apr 2013
% 21-50 204 15 Apr 2013 22-00 TOC 1 15 Apr 2013 22-11 8 15 Apr 2013
% 21-50 205 15 Apr 2013 22-00 TOC 2 15 Apr 2013 22-11 201 15 Apr 2013
% 21-50 206 15 Apr 2013 22-00 1 15 Apr 2013 22-11 202 15 Apr 2013
% 21-50 207 15 Apr 2013 22-00 2 15 Apr 2013 22-11 203 15 Apr 2013
% 21-50 208 15 Apr 2013 22-10 1 15 Apr 2013 22-11 204 15 Apr 2013
% 21-50 209 15 Apr 2013 22-10 2 15 Apr 2013 22-11 205 15 Apr 2013
Doc # 6.02.15 Page 5
Rev. 2 LOEP 15 Apr 2013
List of Effective Pages DA 40 NG AMM
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 22-11 206 15 Apr 2013 23-10 205 15 Apr 2013 23-51 102 15 Apr 2013
% 22-11 207 15 Apr 2013 23-10 206 15 Apr 2013 23-51 201 15 Apr 2013
% 22-11 208 15 Apr 2013 23-11 1 15 Apr 2013 23-51 202 15 Apr 2013
% 22-11 209 15 Apr 2013 23-11 2 15 Apr 2013 23-51 203 15 Apr 2013
% 22-11 210 15 Apr 2013 23-11 3 15 Apr 2013 23-51 204 15 Apr 2013
% 22-11 211 15 Apr 2013 23-11 4 15 Apr 2013 23-60 1 15 Apr 2013
% 22-11 212 15 Apr 2013 23-11 5 15 Apr 2013 23-60 2 15 Apr 2013
% 22-11 213 15 Apr 2013 23-11 6 15 Apr 2013 24-00 Title 1 15 Apr 2013
% 22-11 214 15 Apr 2013 23-11 101 15 Apr 2013 24-00 Title 2 15 Apr 2013
% 22-11 215 15 Apr 2013 23-11 102 15 Apr 2013 24-00 TOC 1 15 Apr 2013
% 22-11 216 15 Apr 2013 23-11 201 15 Apr 2013 24-00 TOC 2 15 Apr 2013
% 23-00 Title 1 15 Apr 2013 23-11 202 15 Apr 2013 24-00 TOC 3 15 Apr 2013
% 23-00 Title 2 15 Apr 2013 23-11 203 15 Apr 2013 24-00 TOC 4 15 Apr 2013
% 23-00 TOC 1 15 Apr 2013 23-11 204 15 Apr 2013 24-00 1 15 Apr 2013
% 23-00 TOC 2 15 Apr 2013 23-50 1 15 Apr 2013 24-00 2 15 Apr 2013
% 23-00 TOC 3 15 Apr 2013 23-50 2 15 Apr 2013 24-00 3 15 Apr 2013
% 23-00 TOC 4 15 Apr 2013 23-50 3 15 Apr 2013 24-00 4 15 Apr 2013
% 23-00 1 15 Apr 2013 23-50 4 15 Apr 2013 24-00 5 15 Apr 2013
% 23-00 2 15 Apr 2013 23-50 5 15 Apr 2013 24-00 6 15 Apr 2013
% 23-10 1 15 Apr 2013 23-50 6 15 Apr 2013 24-00 7 15 Apr 2013
% 23-10 2 15 Apr 2013 23-50 101 15 Apr 2013 24-00 8 15 Apr 2013
% 23-10 3 15 Apr 2013 23-50 102 15 Apr 2013 24-00 9 15 Apr 2013
% 23-10 4 15 Apr 2013 23-50 201 15 Apr 2013 24-00 10 15 Apr 2013
% 23-10 101 15 Apr 2013 23-50 202 15 Apr 2013 24-30 1 15 Apr 2013
% 23-10 102 15 Apr 2013 23-51 1 15 Apr 2013 24-30 2 15 Apr 2013
% 23-10 201 15 Apr 2013 23-51 2 15 Apr 2013 24-30 3 15 Apr 2013
% 23-10 202 15 Apr 2013 23-51 3 15 Apr 2013 24-30 4 15 Apr 2013
% 23-10 203 15 Apr 2013 23-51 4 15 Apr 2013 24-30 101 15 Apr 2013
% 23-10 204 15 Apr 2013 23-51 101 15 Apr 2013 24-30 102 15 Apr 2013
Page 6 Doc # 6.02.15
15 Apr 2013 LOEP Rev. 2
DA 40 NG AMM List of Effective Pages
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 24-30 201 15 Apr 2013 24-33 102 15 Apr 2013 24-60 207 15 Apr 2013
% 24-30 202 15 Apr 2013 24-33 201 15 Apr 2013 24-60 208 15 Apr 2013
% 24-30 203 15 Apr 2013 24-33 202 15 Apr 2013 25-00 Title 1 15 Apr 2013
% 24-30 204 15 Apr 2013 24-33 203 15 Apr 2013 25-00 Title 2 15 Apr 2013
% 24-31 1 15 Apr 2013 24-33 204 15 Apr 2013 25-00 TOC 1 15 Apr 2013
% 24-31 2 15 Apr 2013 24-40 1 15 Apr 2013 25-00 TOC 2 15 Apr 2013
% 24-31 3 15 Apr 2013 24-40 2 15 Apr 2013 25-00 1 15 Apr 2013
% 24-31 4 15 Apr 2013 24-40 3 15 Apr 2013 25-00 2 15 Apr 2013
% 24-31 101 15 Apr 2013 24-40 4 15 Apr 2013 25-10 1 15 Apr 2013
% 24-31 102 15 Apr 2013 24-40 101 15 Apr 2013 25-10 2 15 Apr 2013
% 24-31 201 15 Apr 2013 24-40 102 15 Apr 2013 25-10 3 15 Apr 2013
% 24-31 202 15 Apr 2013 24-40 201 15 Apr 2013 25-10 4 15 Apr 2013
% 24-31 203 15 Apr 2013 24-40 202 15 Apr 2013 25-10 5 15 Apr 2013
% 24-31 204 15 Apr 2013 24-40 203 15 Apr 2013 25-10 6 15 Apr 2013
% 24-31 205 15 Apr 2013 24-40 204 15 Apr 2013 25-10 7 15 Apr 2013
% 24-31 206 15 Apr 2013 24-60 1 15 Apr 2013 25-10 8 15 Apr 2013
% 24-32 1 15 Apr 2013 24-60 2 15 Apr 2013 25-10 201 15 Apr 2013
% 24-32 2 15 Apr 2013 24-60 3 15 Apr 2013 25-10 202 15 Apr 2013
% 24-32 101 15 Apr 2013 24-60 4 15 Apr 2013 25-10 203 15 Apr 2013
% 24-32 102 15 Apr 2013 24-60 5 15 Apr 2013 25-10 204 15 Apr 2013
% 24-32 201 15 Apr 2013 24-60 6 15 Apr 2013 25-10 205 15 Apr 2013
% 24-32 202 15 Apr 2013 24-60 101 15 Apr 2013 25-10 206 15 Apr 2013
% 24-32 203 15 Apr 2013 24-60 102 15 Apr 2013 25-10 207 15 Apr 2013
% 24-32 204 15 Apr 2013 24-60 201 15 Apr 2013 25-10 208 15 Apr 2013
% 24-33 1 15 Apr 2013 24-60 202 15 Apr 2013 25-10 209 15 Apr 2013
% 24-33 2 15 Apr 2013 24-60 203 15 Apr 2013 25-10 210 15 Apr 2013
% 24-33 3 15 Apr 2013 24-60 204 15 Apr 2013 25-10 211 15 Apr 2013
% 24-33 4 15 Apr 2013 24-60 205 15 Apr 2013 25-10 212 15 Apr 2013
% 24-33 101 15 Apr 2013 24-60 206 15 Apr 2013 25-10 213 15 Apr 2013
Doc # 6.02.15 Page 7
Rev. 2 LOEP 15 Apr 2013
List of Effective Pages DA 40 NG AMM
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 25-10 214 15 Apr 2013 27-00 3 15 Apr 2013 27-20 202 15 Apr 2013
% 25-60 1 15 Apr 2013 27-00 4 15 Apr 2013 27-20 203 15 Apr 2013
% 25-60 2 15 Apr 2013 27-00 201 15 Apr 2013 27-20 204 15 Apr 2013
% 25-60 3 15 Apr 2013 27-00 202 15 Apr 2013 27-20 205 15 Apr 2013
% 25-60 4 15 Apr 2013 27-10 1 15 Apr 2013 27-20 206 15 Apr 2013
% 25-60 101 15 Apr 2013 27-10 2 15 Apr 2013 27-20 207 15 Apr 2013
% 25-60 102 15 Apr 2013 27-10 3 15 Apr 2013 27-20 208 15 Apr 2013
% 25-60 201 15 Apr 2013 27-10 4 15 Apr 2013 27-20 209 15 Apr 2013
% 25-60 202 15 Apr 2013 27-10 5 15 Apr 2013 27-20 210 15 Apr 2013
% 25-60 203 15 Apr 2013 27-10 6 15 Apr 2013 27-20 211 15 Apr 2013
% 25-60 204 15 Apr 2013 27-10 101 15 Apr 2013 27-20 212 15 Apr 2013
% 25-60 205 15 Apr 2013 27-10 102 15 Apr 2013 27-30 1 15 Apr 2013
% 25-60 206 15 Apr 2013 27-10 201 15 Apr 2013 27-30 2 15 Apr 2013
% 25-60 207 15 Apr 2013 27-10 202 15 Apr 2013 27-30 3 15 Apr 2013
% 25-60 208 15 Apr 2013 27-10 203 15 Apr 2013 27-30 4 15 Apr 2013
% 26-00 Title 1 15 Apr 2013 27-10 204 15 Apr 2013 27-30 101 15 Apr 2013
% 26-00 Title 2 15 Apr 2013 27-10 205 15 Apr 2013 27-30 102 15 Apr 2013
% 26-00 TOC 1 15 Apr 2013 27-10 206 15 Apr 2013 27-30 201 15 Apr 2013
% 26-00 TOC 2 15 Apr 2013 27-10 207 15 Apr 2013 27-30 202 15 Apr 2013
% 26-00 1 15 Apr 2013 27-10 208 15 Apr 2013 27-30 203 15 Apr 2013
% 26-00 2 15 Apr 2013 27-20 1 15 Apr 2013 27-30 204 15 Apr 2013
% 27-00 Title 1 15 Apr 2013 27-20 2 15 Apr 2013 27-30 205 15 Apr 2013
% 27-00 Title 2 15 Apr 2013 27-20 3 15 Apr 2013 27-30 206 15 Apr 2013
% 27-00 TOC 1 15 Apr 2013 27-20 4 15 Apr 2013 27-38 1 15 Apr 2013
% 27-00 TOC 2 15 Apr 2013 27-20 5 15 Apr 2013 27-38 2 15 Apr 2013
% 27-00 TOC 3 15 Apr 2013 27-20 6 15 Apr 2013 27-38 3 15 Apr 2013
% 27-00 TOC 4 15 Apr 2013 27-20 101 15 Apr 2013 27-38 4 15 Apr 2013
% 27-00 1 15 Apr 2013 27-20 102 15 Apr 2013 27-38 5 15 Apr 2013
% 27-00 2 15 Apr 2013 27-20 201 15 Apr 2013 27-38 6 15 Apr 2013
Page 8 Doc # 6.02.15
15 Apr 2013 LOEP Rev. 2
DA 40 NG AMM List of Effective Pages
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 27-38 101 15 Apr 2013 27-50 104 15 Apr 2013 28-10 7 15 Apr 2013
% 27-38 102 15 Apr 2013 27-50 201 15 Apr 2013 28-10 8 15 Apr 2013
% 27-38 201 15 Apr 2013 27-50 202 15 Apr 2013 28-10 101 15 Apr 2013
% 27-38 202 15 Apr 2013 27-50 203 15 Apr 2013 28-10 102 15 Apr 2013
% 27-38 203 15 Apr 2013 27-50 204 15 Apr 2013 28-10 201 15 Apr 2013
% 27-38 204 15 Apr 2013 27-50 205 15 Apr 2013 28-10 202 15 Apr 2013
% 27-38 205 15 Apr 2013 27-50 206 15 Apr 2013 28-10 203 15 Apr 2013
% 27-38 206 15 Apr 2013 27-50 207 15 Apr 2013 28-10 204 15 Apr 2013
% 27-39 1 15 Apr 2013 27-50 208 15 Apr 2013 28-10 205 15 Apr 2013
% 27-39 2 15 Apr 2013 27-50 209 15 Apr 2013 28-10 206 15 Apr 2013
% 27-39 3 15 Apr 2013 27-50 210 15 Apr 2013 28-10 207 15 Apr 2013
% 27-39 4 15 Apr 2013 28-00 Title 1 15 Apr 2013 28-10 208 15 Apr 2013
% 27-39 101 15 Apr 2013 28-00 Title 2 15 Apr 2013 28-10 209 15 Apr 2013
% 27-39 102 15 Apr 2013 28-00 TOC 1 15 Apr 2013 28-10 210 15 Apr 2013
% 27-39 201 15 Apr 2013 28-00 TOC 2 15 Apr 2013 28-10 211 15 Apr 2013
% 27-39 202 15 Apr 2013 28-00 1 15 Apr 2013 28-10 212 15 Apr 2013
% 27-39 203 15 Apr 2013 28-00 2 15 Apr 2013 28-10 213 15 Apr 2013
% 27-39 204 15 Apr 2013 28-00 3 15 Apr 2013 28-10 214 15 Apr 2013
% 27-50 1 15 Apr 2013 28-00 4 15 Apr 2013 28-10 215 15 Apr 2013
% 27-50 2 15 Apr 2013 28-00 5 15 Apr 2013 28-10 216 15 Apr 2013
% 27-50 3 15 Apr 2013 28-00 6 15 Apr 2013 28-10 217 15 Apr 2013
% 27-50 4 15 Apr 2013 28-00 7 15 Apr 2013 28-10 218 15 Apr 2013
% 27-50 5 15 Apr 2013 28-00 8 15 Apr 2013 28-20 1 15 Apr 2013
% 27-50 6 15 Apr 2013 28-10 1 15 Apr 2013 28-20 2 15 Apr 2013
% 27-50 7 15 Apr 2013 28-10 2 15 Apr 2013 28-20 3 15 Apr 2013
% 27-50 8 15 Apr 2013 28-10 3 15 Apr 2013 28-20 4 15 Apr 2013
% 27-50 101 15 Apr 2013 28-10 4 15 Apr 2013 28-20 5 15 Apr 2013
% 27-50 102 15 Apr 2013 28-10 5 15 Apr 2013 28-20 6 15 Apr 2013
% 27-50 103 15 Apr 2013 28-10 6 15 Apr 2013 28-20 101 15 Apr 2013
Doc # 6.02.15 Page 9
Rev. 2 LOEP 15 Apr 2013
List of Effective Pages DA 40 NG AMM
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 28-20 102 15 Apr 2013 31-00 Title 1 15 Apr 2013 31-40 2 15 Apr 2013
% 28-20 201 15 Apr 2013 31-00 Title 2 15 Apr 2013 31-40 3 15 Apr 2013
% 28-20 202 15 Apr 2013 31-00 TOC 1 15 Apr 2013 31-40 4 15 Apr 2013
% 28-20 203 15 Apr 2013 31-00 TOC 2 15 Apr 2013 31-40 5 15 Apr 2013
% 28-20 204 15 Apr 2013 31-00 TOC 3 15 Apr 2013 31-40 6 15 Apr 2013
% 28-20 205 15 Apr 2013 31-00 TOC 4 15 Apr 2013 31-40 7 15 Apr 2013
% 28-20 206 15 Apr 2013 31-00 1 15 Apr 2013 31-40 8 15 Apr 2013
% 28-20 207 15 Apr 2013 31-00 2 15 Apr 2013 31-40 9 15 Apr 2013
% 28-20 208 15 Apr 2013 31-10 1 15 Apr 2013 31-40 10 15 Apr 2013
% 28-20 209 15 Apr 2013 31-10 2 15 Apr 2013 31-40 11 15 Apr 2013
% 28-20 210 15 Apr 2013 31-10 3 15 Apr 2013 31-40 12 15 Apr 2013
% 28-20 211 15 Apr 2013 31-10 4 15 Apr 2013 31-40 101 15 Apr 2013
% 28-20 212 15 Apr 2013 31-10 5 15 Apr 2013 31-40 102 15 Apr 2013
% 28-20 213 15 Apr 2013 31-10 6 15 Apr 2013 31-40 201 15 Apr 2013
% 28-20 214 15 Apr 2013 31-10 101 15 Apr 2013 31-40 202 15 Apr 2013
% 28-20 215 15 Apr 2013 31-10 102 15 Apr 2013 31-40 203 15 Apr 2013
% 28-20 216 15 Apr 2013 31-10 201 15 Apr 2013 31-40 204 15 Apr 2013
% 28-40 1 15 Apr 2013 31-10 202 15 Apr 2013 31-40 205 15 Apr 2013
% 28-40 2 15 Apr 2013 31-10 203 15 Apr 2013 31-40 206 15 Apr 2013
% 28-40 3 15 Apr 2013 31-10 204 15 Apr 2013 31-40 207 15 Apr 2013
% 28-40 4 15 Apr 2013 31-11 1 15 Apr 2013 31-40 208 15 Apr 2013
% 28-40 101 15 Apr 2013 31-11 2 15 Apr 2013 31-40 209 15 Apr 2013
% 28-40 102 15 Apr 2013 31-11 3 15 Apr 2013 31-40 210 15 Apr 2013
% 28-40 201 15 Apr 2013 31-11 4 15 Apr 2013 31-40 211 15 Apr 2013
% 28-40 202 15 Apr 2013 31-20 1 15 Apr 2013 31-40 212 15 Apr 2013
% 28-40 203 15 Apr 2013 31-20 2 15 Apr 2013 31-40 213 15 Apr 2013
% 28-40 204 15 Apr 2013 31-20 201 15 Apr 2013 31-40 214 15 Apr 2013
% 28-40 205 15 Apr 2013 31-20 202 15 Apr 2013 31-40 215 15 Apr 2013
% 28-40 206 15 Apr 2013 31-40 1 15 Apr 2013 31-40 216 15 Apr 2013
Page 10 Doc # 6.02.15
15 Apr 2013 LOEP Rev. 2
DA 40 NG AMM List of Effective Pages
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 31-40 217 15 Apr 2013 32-10 204 15 Apr 2013 32-40 101 15 Apr 2013
% 31-40 218 15 Apr 2013 32-10 205 15 Apr 2013 32-40 102 15 Apr 2013
% 31-40 219 15 Apr 2013 32-10 206 15 Apr 2013 32-40 201 15 Apr 2013
% 31-40 220 15 Apr 2013 32-10 207 15 Apr 2013 32-40 202 15 Apr 2013
% 31-40 221 15 Apr 2013 32-10 208 15 Apr 2013 32-40 203 15 Apr 2013
% 31-40 222 15 Apr 2013 32-10 209 15 Apr 2013 32-40 204 15 Apr 2013
% 31-51 1 15 Apr 2013 32-10 210 15 Apr 2013 32-40 205 15 Apr 2013
% 31-51 2 15 Apr 2013 32-20 1 15 Apr 2013 32-40 206 15 Apr 2013
% 31-51 3 15 Apr 2013 32-20 2 15 Apr 2013 32-40 207 15 Apr 2013
% 31-51 4 15 Apr 2013 32-20 3 15 Apr 2013 32-40 208 15 Apr 2013
% 31-51 101 15 Apr 2013 32-20 4 15 Apr 2013 32-40 209 15 Apr 2013
% 31-51 102 15 Apr 2013 32-20 101 15 Apr 2013 32-40 210 15 Apr 2013
% 31-51 201 15 Apr 2013 32-20 102 15 Apr 2013 32-40 211 15 Apr 2013
% 31-51 202 15 Apr 2013 32-20 201 15 Apr 2013 32-40 212 15 Apr 2013
% 32-00 Title 1 15 Apr 2013 32-20 202 15 Apr 2013 32-40 213 15 Apr 2013
% 32-00 Title 2 15 Apr 2013 32-20 203 15 Apr 2013 32-40 214 15 Apr 2013
% 32-00 TOC 1 15 Apr 2013 32-20 204 15 Apr 2013 32-40 215 15 Apr 2013
% 32-00 TOC 2 15 Apr 2013 32-20 205 15 Apr 2013 32-40 216 15 Apr 2013
% 32-00 1 15 Apr 2013 32-20 206 15 Apr 2013 32-40 217 15 Apr 2013
% 32-00 2 15 Apr 2013 32-20 207 15 Apr 2013 32-40 218 15 Apr 2013
% 32-10 1 15 Apr 2013 32-20 208 15 Apr 2013 33-00 Title 1 15 Apr 2013
% 32-10 2 15 Apr 2013 32-40 1 15 Apr 2013 33-00 Title 2 15 Apr 2013
% 32-10 3 15 Apr 2013 32-40 2 15 Apr 2013 33-00 TOC 1 15 Apr 2013
% 32-10 4 15 Apr 2013 32-40 3 15 Apr 2013 33-00 TOC 2 15 Apr 2013
% 32-10 101 15 Apr 2013 32-40 4 15 Apr 2013 33-00 1 15 Apr 2013
% 32-10 102 15 Apr 2013 32-40 5 15 Apr 2013 33-00 2 15 Apr 2013
% 32-10 201 15 Apr 2013 32-40 6 15 Apr 2013 33-00 3 15 Apr 2013
% 32-10 202 15 Apr 2013 32-40 7 15 Apr 2013 33-00 4 15 Apr 2013
% 32-10 203 15 Apr 2013 32-40 8 15 Apr 2013 33-10 1 15 Apr 2013
Doc # 6.02.15 Page 11
Rev. 2 LOEP 15 Apr 2013
List of Effective Pages DA 40 NG AMM
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 33-10 2 15 Apr 2013 34-00 TOC 1 15 Apr 2013 34-20 102 15 Apr 2013
% 33-10 3 15 Apr 2013 34-00 TOC 2 15 Apr 2013 34-20 201 15 Apr 2013
% 33-10 4 15 Apr 2013 34-00 TOC 3 15 Apr 2013 34-20 202 15 Apr 2013
% 33-10 101 15 Apr 2013 34-00 TOC 4 15 Apr 2013 34-20 203 15 Apr 2013
% 33-10 102 15 Apr 2013 34-00 TOC 5 15 Apr 2013 34-20 204 15 Apr 2013
% 33-10 201 15 Apr 2013 34-00 TOC 6 15 Apr 2013 34-20 205 15 Apr 2013
% 33-10 202 15 Apr 2013 34-00 1 15 Apr 2013 34-20 206 15 Apr 2013
% 33-10 203 15 Apr 2013 34-00 2 15 Apr 2013 34-21 1 15 Apr 2013
% 33-10 204 15 Apr 2013 34-00 3 15 Apr 2013 34-21 2 15 Apr 2013
% 33-40 1 15 Apr 2013 34-00 4 15 Apr 2013 34-22 1 15 Apr 2013
% 33-40 2 15 Apr 2013 34-10 1 15 Apr 2013 34-22 2 15 Apr 2013
% 33-40 3 15 Apr 2013 34-10 2 15 Apr 2013 34-22 101 15 Apr 2013
% 33-40 4 15 Apr 2013 34-10 3 15 Apr 2013 34-22 102 15 Apr 2013
% 33-40 5 15 Apr 2013 34-10 4 15 Apr 2013 34-22 201 15 Apr 2013
% 33-40 6 15 Apr 2013 34-10 101 15 Apr 2013 34-22 202 15 Apr 2013
% 33-40 101 15 Apr 2013 34-10 102 15 Apr 2013 34-22 203 15 Apr 2013
% 33-40 102 15 Apr 2013 34-10 201 15 Apr 2013 34-22 204 15 Apr 2013
% 33-40 201 15 Apr 2013 34-10 202 15 Apr 2013 34-25 1 15 Apr 2013
% 33-40 202 15 Apr 2013 34-10 203 15 Apr 2013 34-25 2 15 Apr 2013
% 33-40 203 15 Apr 2013 34-10 204 15 Apr 2013 34-25 3 15 Apr 2013
% 33-40 204 15 Apr 2013 34-10 205 15 Apr 2013 34-25 4 15 Apr 2013
% 33-40 205 15 Apr 2013 34-10 206 15 Apr 2013 34-25 101 15 Apr 2013
% 33-40 206 15 Apr 2013 34-10 207 15 Apr 2013 34-25 102 15 Apr 2013
% 33-40 207 15 Apr 2013 34-10 208 15 Apr 2013 34-25 201 15 Apr 2013
% 33-40 208 15 Apr 2013 34-10 209 15 Apr 2013 34-25 202 15 Apr 2013
% 33-40 209 15 Apr 2013 34-10 210 15 Apr 2013 34-30 1 15 Apr 2013
% 33-40 210 15 Apr 2013 34-20 1 15 Apr 2013 34-30 2 15 Apr 2013
% 34-00 Title 1 15 Apr 2013 34-20 2 15 Apr 2013 34-31 1 15 Apr 2013
% 34-00 Title 2 15 Apr 2013 34-20 101 15 Apr 2013 34-31 2 15 Apr 2013
Page 12 Doc # 6.02.15
15 Apr 2013 LOEP Rev. 2
DA 40 NG AMM List of Effective Pages
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 34-40 1 15 Apr 2013 34-51 2 15 Apr 2013 51-10 1 15 Apr 2013
% 34-40 2 15 Apr 2013 34-52 1 15 Apr 2013 51-10 2 15 Apr 2013
% 34-41 1 15 Apr 2013 34-52 2 15 Apr 2013 51-10 3 15 Apr 2013
% 34-41 2 15 Apr 2013 34-52 101 15 Apr 2013 51-10 4 15 Apr 2013
% 34-41 101 15 Apr 2013 34-52 102 15 Apr 2013 51-20 1 15 Apr 2013
% 34-41 102 15 Apr 2013 34-52 201 15 Apr 2013 51-20 2 15 Apr 2013
% 34-41 201 15 Apr 2013 34-52 202 15 Apr 2013 51-20 3 15 Apr 2013
% 34-41 202 15 Apr 2013 34-56 1 15 Apr 2013 51-20 4 15 Apr 2013
% 34-42 1 15 Apr 2013 34-56 2 15 Apr 2013 51-20 201 15 Apr 2013
% 34-42 2 15 Apr 2013 34-56 3 15 Apr 2013 51-20 202 15 Apr 2013
% 34-42 101 15 Apr 2013 34-56 4 15 Apr 2013 51-20 203 15 Apr 2013
% 34-42 102 15 Apr 2013 34-56 101 15 Apr 2013 51-20 204 15 Apr 2013
% 34-42 201 15 Apr 2013 34-56 102 15 Apr 2013 51-20 205 15 Apr 2013
% 34-42 202 15 Apr 2013 34-56 201 15 Apr 2013 51-20 206 15 Apr 2013
% 34-42 203 15 Apr 2013 34-56 202 15 Apr 2013 51-20 207 15 Apr 2013
% 34-42 204 15 Apr 2013 34-56 203 15 Apr 2013 51-20 208 15 Apr 2013
% 34-50 1 15 Apr 2013 34-56 204 15 Apr 2013 51-20 209 15 Apr 2013
% 34-50 2 15 Apr 2013 34-56 205 15 Apr 2013 51-20 210 15 Apr 2013
% 34-50 101 15 Apr 2013 34-56 206 15 Apr 2013 51-20 211 15 Apr 2013
% 34-50 102 15 Apr 2013 51-00 Title 1 15 Apr 2013 51-20 212 15 Apr 2013
% 34-50 201 15 Apr 2013 51-00 Title 2 15 Apr 2013 51-20 213 15 Apr 2013
% 34-50 202 15 Apr 2013 51-00 TOC 1 15 Apr 2013 51-20 214 15 Apr 2013
% 34-50 203 15 Apr 2013 51-00 TOC 2 15 Apr 2013 51-20 215 15 Apr 2013
% 34-50 204 15 Apr 2013 51-00 TOC 3 15 Apr 2013 51-20 216 15 Apr 2013
% 34-50 205 15 Apr 2013 51-00 TOC 4 15 Apr 2013 51-20 217 15 Apr 2013
% 34-50 206 15 Apr 2013 51-00 1 15 Apr 2013 51-20 218 15 Apr 2013
% 34-50 207 15 Apr 2013 51-00 2 15 Apr 2013 51-20 219 15 Apr 2013
% 34-50 208 15 Apr 2013 51-00 3 15 Apr 2013 51-20 220 15 Apr 2013
% 34-51 1 15 Apr 2013 51-00 4 15 Apr 2013 51-20 221 15 Apr 2013
Doc # 6.02.15 Page 13
Rev. 2 LOEP 15 Apr 2013
List of Effective Pages DA 40 NG AMM
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 51-20 222 15 Apr 2013 51-80 201 15 Apr 2013 52-10 206 15 Apr 2013
% 51-20 223 15 Apr 2013 51-80 202 15 Apr 2013 52-10 207 15 Apr 2013
% 51-20 224 15 Apr 2013 51-80 203 15 Apr 2013 52-10 208 15 Apr 2013
% 51-20 225 15 Apr 2013 51-80 204 15 Apr 2013 52-10 209 15 Apr 2013
% 51-20 226 15 Apr 2013 52-00 Title 1 15 Apr 2013 52-10 210 15 Apr 2013
% 51-30 1 15 Apr 2013 52-00 Title 2 15 Apr 2013 52-10 211 15 Apr 2013
% 51-30 2 15 Apr 2013 52-00 TOC 1 15 Apr 2013 52-10 212 15 Apr 2013
% 51-30 3 15 Apr 2013 52-00 TOC 2 15 Apr 2013 52-40 1 15 Apr 2013
% 51-30 4 15 Apr 2013 52-00 1 15 Apr 2013 52-40 2 15 Apr 2013
% 51-30 5 15 Apr 2013 52-00 2 15 Apr 2013 53-00 Title 1 15 Apr 2013
% 51-30 6 15 Apr 2013 52-10 1 15 Apr 2013 53-00 Title 2 15 Apr 2013
% 51-30 7 15 Apr 2013 52-10 2 15 Apr 2013 53-00 TOC 1 15 Apr 2013
% 51-30 8 15 Apr 2013 52-10 3 15 Apr 2013 53-00 TOC 2 15 Apr 2013
% 51-40 1 15 Apr 2013 52-10 4 15 Apr 2013 53-00 1 15 Apr 2013
% 51-40 2 15 Apr 2013 52-10 5 15 Apr 2013 53-00 2 15 Apr 2013
% 51-40 201 15 Apr 2013 52-10 6 15 Apr 2013 53-10 1 15 Apr 2013
% 51-40 202 15 Apr 2013 52-10 7 15 Apr 2013 53-10 2 15 Apr 2013
% 51-60 1 15 Apr 2013 52-10 8 15 Apr 2013 53-10 3 15 Apr 2013
% 51-60 2 15 Apr 2013 52-10 9 15 Apr 2013 53-10 4 15 Apr 2013
% 51-60 3 15 Apr 2013 52-10 10 15 Apr 2013 53-10 5 15 Apr 2013
% 51-60 4 15 Apr 2013 52-10 11 15 Apr 2013 53-10 6 15 Apr 2013
% 51-60 5 15 Apr 2013 52-10 12 15 Apr 2013 53-10 7 15 Apr 2013
% 51-60 6 15 Apr 2013 52-10 101 15 Apr 2013 53-10 8 15 Apr 2013
% 51-60 7 15 Apr 2013 52-10 102 15 Apr 2013 53-10 9 15 Apr 2013
% 51-60 8 15 Apr 2013 52-10 201 15 Apr 2013 53-10 10 15 Apr 2013
% 51-80 1 15 Apr 2013 52-10 202 15 Apr 2013 53-10 201 15 Apr 2013
% 51-80 2 15 Apr 2013 52-10 203 15 Apr 2013 53-10 202 15 Apr 2013
% 51-80 3 15 Apr 2013 52-10 204 15 Apr 2013 53-10 203 15 Apr 2013
% 51-80 4 15 Apr 2013 52-10 205 15 Apr 2013 53-10 204 15 Apr 2013
Page 14 Doc # 6.02.15
15 Apr 2013 LOEP Rev. 2
DA 40 NG AMM List of Effective Pages
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 53-10 205 15 Apr 2013 55-20 206 15 Apr 2013 57-00 Title 1 15 Apr 2013
% 53-10 206 15 Apr 2013 55-30 1 15 Apr 2013 57-00 Title 2 15 Apr 2013
% 53-10 207 15 Apr 2013 55-30 2 15 Apr 2013 57-00 TOC 1 15 Apr 2013
% 53-10 208 15 Apr 2013 55-30 201 15 Apr 2013 57-00 TOC 2 15 Apr 2013
% 55-00 Title 1 15 Apr 2013 55-30 202 15 Apr 2013 57-00 1 15 Apr 2013
% 55-00 Title 2 15 Apr 2013 55-40 1 15 Apr 2013 57-00 2 15 Apr 2013
% 55-00 TOC 1 15 Apr 2013 55-40 2 15 Apr 2013 57-10 1 15 Apr 2013
% 55-00 TOC 2 15 Apr 2013 55-40 3 15 Apr 2013 57-10 2 15 Apr 2013
% 55-00 1 15 Apr 2013 55-40 4 15 Apr 2013 57-10 3 15 Apr 2013
% 55-00 2 15 Apr 2013 55-40 201 15 Apr 2013 57-10 4 15 Apr 2013
% 55-10 1 15 Apr 2013 55-40 202 15 Apr 2013 57-10 201 15 Apr 2013
% 55-10 2 15 Apr 2013 55-40 203 15 Apr 2013 57-10 202 15 Apr 2013
% 55-10 201 15 Apr 2013 55-40 204 15 Apr 2013 57-10 203 15 Apr 2013
% 55-10 202 15 Apr 2013 56-00 Title 1 15 Apr 2013 57-10 204 15 Apr 2013
% 55-10 203 15 Apr 2013 56-00 Title 2 15 Apr 2013 57-10 205 15 Apr 2013
% 55-10 204 15 Apr 2013 56-00 TOC 1 15 Apr 2013 57-10 206 15 Apr 2013
% 55-10 205 15 Apr 2013 56-00 TOC 2 15 Apr 2013 57-10 207 15 Apr 2013
% 55-10 206 15 Apr 2013 56-00 1 15 Apr 2013 57-10 208 15 Apr 2013
% 55-10 207 15 Apr 2013 56-00 2 15 Apr 2013 57-10 209 15 Apr 2013
% 55-10 208 15 Apr 2013 56-10 1 15 Apr 2013 57-10 210 15 Apr 2013
% 55-20 1 15 Apr 2013 56-10 2 15 Apr 2013 57-10 211 15 Apr 2013
% 55-20 2 15 Apr 2013 56-10 3 15 Apr 2013 57-10 212 15 Apr 2013
% 55-20 3 15 Apr 2013 56-10 4 15 Apr 2013 57-10 213 15 Apr 2013
% 55-20 4 15 Apr 2013 56-10 201 15 Apr 2013 57-10 214 15 Apr 2013
% 55-20 201 15 Apr 2013 56-10 202 15 Apr 2013 57-10 215 15 Apr 2013
% 55-20 202 15 Apr 2013 56-10 203 15 Apr 2013 57-10 216 15 Apr 2013
% 55-20 203 15 Apr 2013 56-10 204 15 Apr 2013 57-10 217 15 Apr 2013
% 55-20 204 15 Apr 2013 56-10 205 15 Apr 2013 57-10 218 15 Apr 2013
% 55-20 205 15 Apr 2013 56-10 206 15 Apr 2013 57-10 219 15 Apr 2013
Doc # 6.02.15 Page 15
Rev. 2 LOEP 15 Apr 2013
List of Effective Pages DA 40 NG AMM
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 57-10 220 15 Apr 2013 61-10 5 15 Apr 2013 61-20 102 15 Apr 2013
% 57-10 221 15 Apr 2013 61-10 6 15 Apr 2013 61-20 201 15 Apr 2013
% 57-10 222 15 Apr 2013 61-10 101 15 Apr 2013 61-20 202 15 Apr 2013
% 57-50 1 15 Apr 2013 61-10 102 15 Apr 2013 71-00 Title 1 15 Apr 2013
% 57-50 2 15 Apr 2013 61-10 201 15 Apr 2013 71-00 Title 2 15 Apr 2013
% 57-50 201 15 Apr 2013 61-10 202 15 Apr 2013 71-00 TOC 1 15 Apr 2013
% 57-50 202 15 Apr 2013 61-10 203 15 Apr 2013 71-00 TOC 2 15 Apr 2013
% 57-50 203 15 Apr 2013 61-10 204 15 Apr 2013 71-00 TOC 3 15 Apr 2013
% 57-50 204 15 Apr 2013 61-10 205 15 Apr 2013 71-00 TOC 4 15 Apr 2013
% 57-50 205 15 Apr 2013 61-10 206 15 Apr 2013 71-00 1 15 Apr 2013
% 57-50 206 15 Apr 2013 61-10 207 15 Apr 2013 71-00 2 15 Apr 2013
% 57-60 1 15 Apr 2013 61-10 208 15 Apr 2013 71-00 3 15 Apr 2013
% 57-60 2 15 Apr 2013 61-10 209 15 Apr 2013 71-00 4 15 Apr 2013
% 57-60 201 15 Apr 2013 61-10 210 15 Apr 2013 71-00 5 15 Apr 2013
% 57-60 202 15 Apr 2013 61-10 211 15 Apr 2013 71-00 6 15 Apr 2013
% 57-60 203 15 Apr 2013 61-10 212 15 Apr 2013 71-00 101 15 Apr 2013
% 57-60 204 15 Apr 2013 61-10 213 15 Apr 2013 71-00 102 15 Apr 2013
% 57-60 205 15 Apr 2013 61-10 214 15 Apr 2013 71-00 201 15 Apr 2013
% 57-60 206 15 Apr 2013 61-10 215 15 Apr 2013 71-00 202 15 Apr 2013
% 61-00 Title 1 15 Apr 2013 61-10 216 15 Apr 2013 71-00 203 15 Apr 2013
% 61-00 Title 2 15 Apr 2013 61-10 217 15 Apr 2013 71-00 204 15 Apr 2013
% 61-00 TOC 1 15 Apr 2013 61-10 218 15 Apr 2013 71-00 205 15 Apr 2013
% 61-00 TOC 2 15 Apr 2013 61-20 1 15 Apr 2013 71-00 206 15 Apr 2013
% 61-00 1 15 Apr 2013 61-20 2 15 Apr 2013 71-00 207 15 Apr 2013
% 61-00 2 15 Apr 2013 61-20 3 15 Apr 2013 71-00 208 15 Apr 2013
% 61-10 1 15 Apr 2013 61-20 4 15 Apr 2013 71-00 209 15 Apr 2013
% 61-10 2 15 Apr 2013 61-20 5 15 Apr 2013 71-00 210 15 Apr 2013
% 61-10 3 15 Apr 2013 61-20 6 15 Apr 2013 71-00 211 15 Apr 2013
% 61-10 4 15 Apr 2013 61-20 101 15 Apr 2013 71-00 212 15 Apr 2013
Page 16 Doc # 6.02.15
15 Apr 2013 LOEP Rev. 2
DA 40 NG AMM List of Effective Pages
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 71-00 213 15 Apr 2013 71-60 102 15 Apr 2013 72-00 203 15 Apr 2013
% 71-00 214 15 Apr 2013 71-60 201 15 Apr 2013 72-00 204 15 Apr 2013
% 71-00 215 15 Apr 2013 71-60 202 15 Apr 2013 72-00 205 15 Apr 2013
% 71-00 216 15 Apr 2013 71-60 203 15 Apr 2013 72-00 206 15 Apr 2013
% 71-10 1 15 Apr 2013 71-60 204 15 Apr 2013 73-00 Title 1 15 Apr 2013
% 71-10 2 15 Apr 2013 71-60 205 15 Apr 2013 73-00 Title 2 15 Apr 2013
% 71-10 3 15 Apr 2013 71-60 206 15 Apr 2013 73-00 TOC 1 15 Apr 2013
% 71-10 4 15 Apr 2013 71-60 207 15 Apr 2013 73-00 TOC 2 15 Apr 2013
% 71-10 101 15 Apr 2013 71-60 208 15 Apr 2013 73-00 1 15 Apr 2013
% 71-10 102 15 Apr 2013 71-60 209 15 Apr 2013 73-00 2 15 Apr 2013
% 71-10 201 15 Apr 2013 71-60 210 15 Apr 2013 73-00 3 15 Apr 2013
% 71-10 202 15 Apr 2013 71-70 1 15 Apr 2013 73-00 4 15 Apr 2013
% 71-10 203 15 Apr 2013 71-70 2 15 Apr 2013 73-00 101 15 Apr 2013
% 71-10 204 15 Apr 2013 71-70 3 15 Apr 2013 73-00 102 15 Apr 2013
% 71-20 1 15 Apr 2013 71-70 4 15 Apr 2013 73-00 201 15 Apr 2013
% 71-20 2 15 Apr 2013 71-70 201 15 Apr 2013 73-00 202 15 Apr 2013
% 71-20 3 15 Apr 2013 71-70 202 15 Apr 2013 75-00 Title 1 15 Apr 2013
% 71-20 4 15 Apr 2013 72-00 Title 1 15 Apr 2013 75-00 Title 2 15 Apr 2013
% 71-20 101 15 Apr 2013 72-00 Title 2 15 Apr 2013 75-00 TOC 1 15 Apr 2013
% 71-20 102 15 Apr 2013 72-00 TOC 1 15 Apr 2013 75-00 TOC 2 15 Apr 2013
% 71-20 201 15 Apr 2013 72-00 TOC 2 15 Apr 2013 75-00 1 15 Apr 2013
% 71-20 202 15 Apr 2013 72-00 1 15 Apr 2013 75-00 2 15 Apr 2013
% 71-50 1 15 Apr 2013 72-00 2 15 Apr 2013 75-00 3 15 Apr 2013
% 71-50 2 15 Apr 2013 72-00 3 15 Apr 2013 75-00 4 15 Apr 2013
% 71-60 1 15 Apr 2013 72-00 4 15 Apr 2013 75-00 5 15 Apr 2013
% 71-60 2 15 Apr 2013 72-00 101 15 Apr 2013 75-00 6 15 Apr 2013
% 71-60 3 15 Apr 2013 72-00 102 15 Apr 2013 75-00 101 15 Apr 2013
% 71-60 4 15 Apr 2013 72-00 201 15 Apr 2013 75-00 102 15 Apr 2013
% 71-60 101 15 Apr 2013 72-00 202 15 Apr 2013 75-00 201 15 Apr 2013
Doc # 6.02.15 Page 17
Rev. 2 LOEP 15 Apr 2013
List of Effective Pages DA 40 NG AMM
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision
Section Date Section Date Section Date
% 75-00 202 15 Apr 2013 76-00 205 15 Apr 2013 77-41 2 15 Apr 2013
% 75-00 203 15 Apr 2013 76-00 206 15 Apr 2013 77-41 3 15 Apr 2013
% 75-00 204 15 Apr 2013 76-00 207 15 Apr 2013 77-41 4 15 Apr 2013
% 75-00 205 15 Apr 2013 76-00 208 15 Apr 2013 77-41 101 15 Apr 2013
% 75-00 206 15 Apr 2013 76-00 209 15 Apr 2013 77-41 102 15 Apr 2013
% 75-00 207 15 Apr 2013 76-00 210 15 Apr 2013 78-00 Title 1 15 Apr 2013
% 75-00 208 15 Apr 2013 77-00 Title 1 15 Apr 2013 78-00 Title 2 15 Apr 2013
% 75-00 209 15 Apr 2013 77-00 Title 2 15 Apr 2013 78-00 TOC 1 15 Apr 2013
% 75-00 210 15 Apr 2013 77-00 TOC 1 15 Apr 2013 78-00 TOC 2 15 Apr 2013
% 75-00 211 15 Apr 2013 77-00 TOC 2 15 Apr 2013 78-00 1 15 Apr 2013
% 75-00 212 15 Apr 2013 77-00 1 15 Apr 2013 78-00 2 15 Apr 2013
% 76-00 Title 1 15 Apr 2013 77-00 2 15 Apr 2013 78-00 101 15 Apr 2013
% 76-00 Title 2 15 Apr 2013 77-01 1 15 Apr 2013 78-00 102 15 Apr 2013
% 76-00 TOC 1 15 Apr 2013 77-01 2 15 Apr 2013 78-00 201 15 Apr 2013
% 76-00 TOC 2 15 Apr 2013 77-40 1 15 Apr 2013 78-00 202 15 Apr 2013
% 76-00 1 15 Apr 2013 77-40 2 15 Apr 2013 79-00 Title 1 15 Apr 2013
% 76-00 2 15 Apr 2013 77-40 3 15 Apr 2013 79-00 Title 2 15 Apr 2013
% 76-00 3 15 Apr 2013 77-40 4 15 Apr 2013 79-00 TOC 1 15 Apr 2013
% 76-00 4 15 Apr 2013 77-40 101 15 Apr 2013 79-00 TOC 2 15 Apr 2013
% 76-00 5 15 Apr 2013 77-40 102 15 Apr 2013 79-00 1 15 Apr 2013
% 76-00 6 15 Apr 2013 77-40 201 15 Apr 2013 79-00 2 15 Apr 2013
% 76-00 7 15 Apr 2013 77-40 202 15 Apr 2013 79-00 101 15 Apr 2013
% 76-00 8 15 Apr 2013 77-40 203 15 Apr 2013 79-00 102 15 Apr 2013
% 76-00 101 15 Apr 2013 77-40 204 15 Apr 2013 80-00 Title 1 15 Apr 2013
% 76-00 102 15 Apr 2013 77-40 205 15 Apr 2013 80-00 Title 2 15 Apr 2013
% 76-00 201 15 Apr 2013 77-40 206 15 Apr 2013 80-00 TOC 1 15 Apr 2013
% 76-00 202 15 Apr 2013 77-40 207 15 Apr 2013 80-00 TOC 2 15 Apr 2013
% 76-00 203 15 Apr 2013 77-40 208 15 Apr 2013 80-00 1 15 Apr 2013
% 76-00 204 15 Apr 2013 77-41 1 15 Apr 2013 80-00 2 15 Apr 2013
Page 18 Doc # 6.02.15
15 Apr 2013 LOEP Rev. 2
DA 40 NG AMM List of Effective Pages
AIRCRAFT
Chapter Page Revision Chapter Page Revision
Section Date Section Date
% 80-00 101 15 Apr 2013 92-00 TOC 2 15 Apr 2013
% 80-00 102 15 Apr 2013 92-00 1 15 Apr 2013
% 80-00 201 15 Apr 2013 92-00 2 15 Apr 2013
% 80-00 202 15 Apr 2013 wiring diagrams as listed in
Chapter 92
% 80-00 203 15 Apr 2013
% 80-00 204 15 Apr 2013
% 80-00 205 15 Apr 2013
% 80-00 206 15 Apr 2013
% 81-00 Title 1 15 Apr 2013
% 81-00 Title 2 15 Apr 2013
% 81-00 TOC 1 15 Apr 2013
% 81-00 TOC 2 15 Apr 2013
% 81-00 1 15 Apr 2013
% 81-00 2 15 Apr 2013
% 81-00 3 15 Apr 2013
% 81-00 4 15 Apr 2013
% 81-00 5 15 Apr 2013
% 81-00 6 15 Apr 2013
% 81-00 101 15 Apr 2013
% 81-00 102 15 Apr 2013
% 81-00 201 15 Apr 2013
% 81-00 202 15 Apr 2013
% 81-00 203 15 Apr 2013
% 81-00 204 15 Apr 2013
% 81-00 205 15 Apr 2013
% 81-00 206 15 Apr 2013
% 92-00 Title 1 15 Apr 2013
% 92-00 Title 2 15 Apr 2013
% 92-00 TOC 1 15 Apr 2013
Doc # 6.02.15 Page 19
Rev. 2 LOEP 15 Apr 2013
List of Effective Pages DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 20 Doc # 6.02.15
15 Apr 2013 LOEP Rev. 2
DA 40 NG AMM Introduction
AIRCRAFT
CHAPTER 01
INTRODUCTION
Doc # 6.02.15 Page 1
Rev. 2 01-TITLE 15 Apr 2013
Introduction DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 01-TITLE Rev. 2
DA 40 NG AMM Introduction
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 01
INTRODUCTION
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Revision Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Manual Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. Page Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7. Record of Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8. List of Effective Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Doc # 6.02.15 Page 1
Rev. 2 01-CONTENTS 15 Apr 2013
Introduction DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 01-CONTENTS Rev. 2
DA 40 NG AMM Introduction
AIRCRAFT
CHAPTER 01
INTRODUCTION
1. General
This Airplane Maintenance Manual contains the data necessary to do the maintenance of the
DA 40 NG. It contains a full description of the systems, trouble shooting procedures, removal and
installation procedures and maintenance instructions. It does not contain maintenance data for
components removed from the airplane (maintenance shop data).
The Airplane Maintenance Manual contains wiring diagrams for the electrical system.
% Use the DA 40 NG Airplane Flight Manual, latest revision with the Airplane Maintenance Manual, and
% the related Service Bulletins. Additional maintenance data is referenced in Chapter 05-00.
2. Revision Service
The manufacturer provides a revision service for the Airplane Maintenance Manual. The revision
shows design changes to the airplane or changes in procedures. Each page of the manual shows the
date of first issue. If the page has changed, it shows the date of the revision.
3. Warnings, Cautions and Notes
Obey all the usual safety precautions and maintenance instructions when doing maintenance.
This Airplane Maintenance Manual also contains warnings, cautions and notes before applicable
instructions:
WARNING: A WARNING TELLS THE PERSON DOING THE MAINTENANCE THAT
INJURY OR DEATH IS POSSIBLE IF THEY DO NOT FOLLOW THE
INSTRUCTIONS.
CAUTION: A CAUTION TELLS THE PERSON DOING THE MAINTENANCE THAT
DAMAGE TO EQUIPMENT IS POSSIBLE IF THEY DO NOT FOLLOW
THE INSTRUCTIONS.
Note: A Note tells the person doing the maintenance how to make the task easier.
Doc # 6.02.15 Page 1
Rev. 2 01-00-00 15 Apr 2013
Introduction DA 40 NG AMM
AIRCRAFT
4. Manual Configuration
This manual is written using the regulations of the Air Transport Association of America
Specification 100 (ATA 100). Each system is given a chapter number from the ATA 100. Where
applicable, a chapter contains sections for each sub-system.
The Specification AECMA Simplified English has been used to write this Airplane Maintenance
Manual. This is a mandatory requirement of the Air Transport Association of America Specification 100
(ATA 100).
There are only 3 sources of words available to use in Simplified English (SE).
) Approved words from the SE Guide. These have defined meanings and selected parts of
speech.
) Technical names as defined in the SE Guide. Used only as Adjectives or Nouns.
) Manufacturing processes as defined in the SE Guide. Always used as Verbs.
To obtain a copy of the SE Guide contact ASD-STAN, Avenue de Tervuren, B-1150 Brussels, Belgium.
Tel: +32-2775-81-26, Fax:+32-2763-35-65, Email: [email protected]
% This manual does not use the ATA 100 Airplane Maintenance Task Oriented Support System
(ATMOSS).
Page 2 Doc # 6.02.15
15 Apr 2013 01-00-00 Rev. 2
DA 40 NG AMM Introduction
AIRCRAFT
A. The ATA100 Numbering System
The ATA100 numbering system uses 3 pairs of numbers, for example:
57-50-xx
Chapter / System Section / Subsystem Unit / Subject Number
(Wings) (Flaps) (Not normally used)
The first pair of numbers show the system. System 57 is the Wings. Chapter 57 contains the data
for the wings.
The second pair of numbers show the subsystem. Subsystem 50 is Flaps. Chapter 57, Section 50
contains the data for the flaps installation.
The third pair of numbers show a unit. A unit could be the flap itself. Only complex systems use unit
numbers.
For simple systems, the main chapter has all of the data and there are no section/subsystem
break-downs.
B. Groups of Chapters
The chapters are put together in these groups:
Group A Introduction Chapters 01 - 02
Group B Airplane General Chapters 03 - 12
Group C Airframe Systems Chapters 20 - 37
Group D Structure Chapters 51 - 57
Group E Propeller Chapter 61
Group F Power Plant Chapters 71 - 81
A separation sheet divides each chapter. The separation sheet shows the number of the chapter
and the title.
Doc # 6.02.15 Page 3
Rev. 2 01-00-00 15 Apr 2013
Introduction DA 40 NG AMM
AIRCRAFT
The main contents of each group of chapters is given below:
(1) Group A - Introduction
Chapter 1 tells you about the Airplane Maintenance Manual, and Chapter 2 tells you how to use
the Airplane Maintenance Manual.
(2) Group B - Airplane General
Chapter 05 contains the Scheduled Maintenance Checklist. Some tasks require a maintenance
procedure. The Scheduled Maintenance Checklist identifies the chapter in the manual that gives
the maintenance procedure for the task. It also tells you where to find general information.
Chapters 06 to 10 tell you about general procedures such as towing, parking and weighing.
Chapter 11 tells you about the placards and markings which are important for operating the
airplane.
Chapter 12 contains servicing tasks such as refueling and lubrication. It also contains data
about cleaning.
(3) Group C - Airframe Systems
Chapter 20 contains the standard practices for airframe maintenance.
Chapters 21 to 37 tells you about the airframe systems. They include the avionics systems
(such as communications (23)) and the mechanical systems (such as flight controls (27)).
Chapter 31 shows the location of the instruments. The chapter which is applicable to the system
gives the details. For example, Chapter 27 gives the details for the flap position indicator.
(4) Group D - Structure
Chapter 51 contains data about the design of the airframe. It also gives instructions for minor
repairs to the structure.
Chapters 52 to 57 tell you about each part of the structure.
Page 4 Doc # 6.02.15
15 Apr 2013 01-00-00 Rev. 2
DA 40 NG AMM Introduction
AIRCRAFT
(5) Group E - Propeller
Chapter 61 contains the maintenance procedures for the propeller. Refer to the propeller
manufacturer’s manual for other data.
(6) Group F - Power Plant
This group of chapters describes the engine and its systems which make the Power Plant. It
contains the maintenance procedures for maintenance on the airplane. Refer to the engine
manufacturer’s manual for other data.
C. Chapter Configuration
The first page of each Chapter shows the number of the chapter and the title. The second page
shows the contents. Where applicable, each chapter and section contains the topics that follow:
) Description and Operation.
) Trouble Shooting.
) Maintenance Practices. Where applicable the Maintenance Practices give data on these
procedures:
Servicing.
Removal and Installation.
Adjustment/Tests.
Checking/Testing.
Cleaning/Painting.
Repairs.
Doc # 6.02.15 Page 5
Rev. 2 01-00-00 15 Apr 2013
Introduction DA 40 NG AMM
AIRCRAFT
5. Page Numbering System
This manual uses the ATA 100 page block-numbering system. The page number is at the bottom on
the outer edge. It is adjacent to the chapter/section number.
Each topic in a section has numbers from these page blocks:
) Description and Operation - Pages 1 to 99.
) Trouble-Shooting - Pages 101 to 199.
) Maintenance Practices - Pages 201 to 299.
6. Figures
Figures are given numbers in sequence. The first Figure in a Chapter or Section is Figure 1.
7. Record of Revisions
This Airplane Maintenance Manual has a Record of Revisions. Use the Record of Revisions to show
when changes were included in the Airplane Maintenance Manual.
8. List of Effective Pages
This Airplane Maintenance Manual has a List of Effective Pages. The List of Effective Pages shows
you the number and effective date of each page contained in the Airplane Maintenance Manual.
Page 6 Doc # 6.02.15
15 Apr 2013 01-00-00 Rev. 2
DA 40 NG AMM Manual Organization
AIRCRAFT
CHAPTER 02
ORGANIZATION AND HANDLING OF
THE MANUAL
Doc # 6.02.15 Page 1
Rev. 2 02-TITLE 15 Apr 2013
DA 40 NG
Manual Organization
AIRCRAFT AMM
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 02-TITLE Rev. 2
DA 40 NG AMM Manual Organization
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 02
ORGANIZATION AND HANDLING OF THE MANUAL
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Temporary Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5. Service Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6. Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7. Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8. Conversion Factors and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9. Torque Conversion Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Doc # 6.02.15 Page 1
Rev. 2 02-CONTENTS 15 Apr 2013
DA 40 NG
Manual Organization
AIRCRAFT AMM
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 02-CONTENTS Rev. 2
DA 40 NG AMM Manual Organization
AIRCRAFT
CHAPTER 02
ORGANIZATION AND HANDLING OF THE MANUAL
1. General
For data about a system, look in the list of chapters and find the chapter number. The first page of
each chapter after the title page shows the contents.
2. Applicability
Data applicable to a series of airplane is marked with an applicability note. For example:
Valid for S/N 40.N001 thru 40.N099.
This shows that you can use this data for airplane with serial numbers 40.N001 through 40.N099
inclusive.
3. Revisions
The manufacturer makes changes to the Airplane Maintenance Manual to show design changes,
maintenance procedure changes or other changes. Each group of changes is called a ‘Revision’.
A manual revision contains these items:
) The changed pages.
) The reason for the revision.
) Instructions for putting the revision into the Airplane Maintenance Manual.
) A new List of Effective Pages (LOEP).
A vertical bar in the left margin of the page shows the changes. Where a figure is changed, a small
hand points to the change if necessary.
4. Temporary Revisions
Temporary revisions correct errors, or they give temporary instructions. The manufacturer sends them
to the airplane owners quickly. The manufacturer uses yellow paper for temporary revisions. The
manufacturer usually puts the contents of a temporary revision in the next approved revision.
Doc # 6.02.15 Page 1
Rev. 2 02-00-00 15 Apr 2013
DA 40 NG
Manual Organization
AIRCRAFT AMM
5. Service Bulletins
Service Bulletins get issued when necessary. They give the operator more information on inspections,
maintenance, repairs or modifications.
Service Bulletins have 4 categories:
A. Alert Service Bulletins
Alert Service Bulletins are issued if there is an immediate danger (risk of damage or total loss).
They are sent immediately by the fastest means to all known addresses of operators and service
stations which are affected.
B. Mandatory Service Bulletins
Mandatory Service Bulletins include the description of a problem and the solution. If you do not
follow a mandatory Service Bulletin, failures or malfunctions can result during further operation.
You must do the work given in a Mandatory Service Bulletin.
C. Recommended Service Bulletins
Recommended Service Bulletins give data about:
) A minor problem and its correction.
) A better technical design.
If you do not follow a Recommended Service Bulletin, it will not cause a failure. But it may cause
increased maintenance work.
If you do follow a Recommended Service Bulletin:
) The maintenance work may be reduced (for example, reduced wear, increased life).
) The operational behavior will be improved (for example, easier engine starting).
D. Optional Service Bulletins
Optional Service Bulletins give data about optional equipment that you can install in an airplane (for
example, sailplane towing device).
The airplane owner makes the decision to follow an Optional Service Bulletin.
6. Service Instructions
A Service Instruction tells the operator about permitted installations or additional equipment. It also
gives the applicable technical data.
Page 2 Doc # 6.02.15
15 Apr 2013 02-00-00 Rev. 2
DA 40 NG AMM Manual Organization
AIRCRAFT
7. Abbreviations
Where possible, the abbreviations used correspond with the related regulations.
A Ampere
ACL Anti-Collision Light
ADF Automatic Direction Finder
A.M.E. Aircraft Maintenance Engineer
Ah Ampere-Hour
A&P Aircraft and Power Plant Mechanic
ASI Airspeed Indicator
CAN Controller Area Network
CFRP Carbon Fiber Reinforced Plastic
DME Distance Measuring Equipment
EECU Electric Engine Control Unit
ELT Emergency Locator Transmitter
FRP Fiber Reinforced Plastic
GFRP Glass Fiber Reinforced Plastic
GPS Global Positioning System
G/S Glide Slope
IAU Integrated Avionics Unit
ICS Integrated Cockpit Unit
IFR Instrument Flight Rules
HSI Horizontal Situation Indicator
LOC Localizer
% MED Main Engine Display
% MFD Multi-Function Display
MSI Major Structural Inspection
OAT Outside Air Temperature
PFD Primary Flight Display
P/N Part Number
SB Service Bulletin
Doc # 6.02.15 Page 3
Rev. 2 02-00-00 15 Apr 2013
DA 40 NG
Manual Organization
AIRCRAFT AMM
% SED Secondary Engine Display
S/N Serial Number
TBO Time Between Overhaul
TSMOH Time Since Major Overhaul
UHF Ultra High Frequency
TTSN Total Time Since New
TTSO Total Time Since Overhaul
V Volt
VFR Visual Flight Rules
VHF Very High Frequency
VOR VHF Omni-directional Ranging
VSI Vertical Speed Indicator
Page 4 Doc # 6.02.15
15 Apr 2013 02-00-00 Rev. 2
DA 40 NG AMM Manual Organization
AIRCRAFT
8. Conversion Factors and Abbreviations
Dimension Conversion Factor Conversion Factor
Unit [Abbreviation] SI to US/Imperial US/Imperial to SI
Length
Meter [m] [m] / 0.3048 = [ft]
Millimeter [mm] [mm] / 25.4 = [in]
Kilometer [km] [km] / 1.852 = [nm]
[km] / 1.609 = [sm]
Inch [in] [in] x 25.4 = [mm]
Foot [ft] [ft] x 0.3048 = [m]
Nautical mile [nm] [nm] x 1.852 = [km]
Statute mile [sm] [sm] x 1.609 = [km]
Velocity
Kilometers per hour [km/h] [km/h] / 1.852 = [kts]
[km/h] / 1.609 = [mph]
Meters per second [m/s] [m/s] x 196.85 = [fpm]
Miles per hour [mph] [mph] x 1.609 = [km/h]
Knots [kts] [kts] x 1.852 = [km/h]
Feet per minute [fpm] [fpm] / 196.85 = [m/s]
Rotational Speed
Revolutions per minute [RPM] [RPM] = [min-1]
Pressure
Bar [bar] [bar] x 14.5038 = [psi]
Hectopascal [hPa] = Millibar [mbar] [hPa] / 33.864 = [inHg]
[mbar] / 33.864 = [inHg]
Pounds per square inch [psi] [psi] / 14.5038 = [bar]
Inches of mercury column [inHg] [inHg] x 33.864 = [hPa]
[inHg] x 33.864 = [mbar]
Doc # 6.02.15 Page 5
Rev. 2 02-00-00 15 Apr 2013
DA 40 NG
Manual Organization
AIRCRAFT AMM
Dimension Conversion Factor Conversion Factor
Unit [Abbreviation] SI to US/Imperial US/Imperial to SI
Force or Weight
Newton [N] [N] / 4.448 = [lb]
Decanewton [daN] [daN] / 0.4448 = [lb]
Pound [lb] [lb] x 4.448 = [N]
[lb] x 0.4448 = [daN]
Mass ('Weight')
Kilogram [kg] [kg] / 0.45359 = [lb]
Pound [lb] [lb] x 0.45359 = [kg]
Volume
Liter [l] [l] / 3.7854 = [US gal]
[l] / 0.9464 = [US qts]
[l] / 4.5461 = [Imp gal]
[l] / 61.024 = [in3]
US gallon [US gal] [US gal] x 3.7854 = [l]
US quart [US qt] [US qt] x 0.9464 = [l]
Imperial gallon [Imp gal] [Imp gal] x 4.5461 = [l]
Cubic inch [in3] [in3] x 61.024 = [l]
Torque
Newton meter [Nm] [Nm] / 1.3558 = [lbf.ft.]
[Nm] x 8.851 = [lbf.in.]
Foot pound [lbf.ft.] [lbf.ft.] x 1.3558 = [Nm]
Inch pound [lbf.in.] [lbf.in.] / 8.851 = [Nm]
Temperature
Degree Celsius [°C] [°C] x 1.8 + 32 = [°F]
Degree Fahrenheit [°F] ([°F] - 32) / 1.8 = [°C]
Note: In this Airplane Maintenance Manual masses are referred to as weights. The
authors accept that this is technically incorrect but have used the expression for
simplicity and convenience.
Page 6 Doc # 6.02.15
15 Apr 2013 02-00-00 Rev. 2
DA 40 NG AMM Manual Organization
AIRCRAFT
9. Torque Conversion Graphs
Use Figure 1 for conversion of torque values Nm - lbf.ft. Use Figure 2 for conversion of Nm - lbf.in.
70
65
60
55
Pound-Force Foot (lbf.ft)
50
45
40
35
30
25
20
15
10
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Newton.Metre (Nm)
Figure 1: Nm - lbf.ft.
Find the Nm value on the horizontal axis. Move vertically to the solid black diagonal line. Then move
horizontally to the vertical axis. Read the value in lbf.ft.
Example: To convert 24 Nm to lbf.ft., find 24 Nm on the horizontal axis (see the dashed line). Follow
the dashed line vertically to the solid black diagonal line. Then follow the dashed line horizontally to
the vertical axis. Read the value of 17.7 lbf.ft.
Doc # 6.02.15 Page 7
Rev. 2 02-00-00 15 Apr 2013
DA 40 NG
Manual Organization
AIRCRAFT AMM
90
85
80
75
70
65
Pound-Force Inch (lbf.in.)
60
55
50
45
40
35
30
25
20
15
10
0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0
Newton.Metre (Nm)
Figure 2: Nm - lbf.in.
Find the Nm value on the horizontal axis. Move vertically to the solid black diagonal line. Then move
horizontally to the vertical axis. Read the value in lbf.in.
Example: To convert 4.4 Nm to lbf.in., find 4.4 Nm on the horizontal axis (see the dashed line). Follow
the dashed line vertically to the solid black diagonal line. Then follow the dashed line horizontally to
the vertical axis. Read the value of 39 lbf.in.
Page 8 Doc # 6.02.15
15 Apr 2013 02-00-00 Rev. 2
DA 40 NG AMM General Description
AIRCRAFT
CHAPTER 03
GENERAL DESCRIPTION OF THE
AIRPLANE
Doc # 6.02.15 Page 1
Rev. 2 03-TITLE 15 Apr 2013
General Description DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 03-TITLE Rev. 2
DA 40 NG AMM General Description
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 03
GENERAL DESCRIPTION OF THE AIRPLANE
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Equipment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Handling of Identification Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Doc # 6.02.15 Page 1
Rev. 2 03-CONTENTS 15 Apr 2013
General Description DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 03-CONTENTS Rev. 2
DA 40 NG AMM General Description
AIRCRAFT
CHAPTER 03
GENERAL DESCRIPTION OF THE AIRPLANE
1. General
Diamond Aircraft Industries GmbH, N. A. Otto-Straße 5, A-2700 Wiener Neustadt, Austria, is the
manufacturer of the DA 40 NG airplane.
2. Description
The DA 40 NG is a single-engine, four seat, low-wing monoplane. It has a cantilever wing and a ‘T’ tail.
The airplane structure is fiber-reinforced plastic composite. This gives a very strong but light structure.
Figure 1: DA 40 NG Airplane
Doc # 6.02.15 Page 1
Rev. 2 03-00-00 15 Apr 2013
General Description DA 40 NG AMM
AIRCRAFT
The semi-monocoque fuselage is a glass-fiber reinforced-plastic (GFRP) shell with GFRP bulkheads
and stiffeners. Uni-directional carbon fiber bands give extra strength and stiffness in many areas. Left
and right half-shells bond together with a center section to make the fuselage. The center section
makes the bottom of the cockpit. It has the main bulkheads which connect to the spars in each wing.
The vertical stabilizer has two GFRP half-shells that are part of the fuselage shells.
The cantilever wing is a semi-monocoque structure. Each wing has two I-shaped spars with webs
made form GFRP/rigid foam sandwich and caps made from CFRP bands. Each wing has top and
bottom shells made of CFRP/GFRP/rigid foam sandwich which bond to the spars. GFRP ribs and
webs bond to the spars and shells to complete the structure.
The wings attach to the fuselage center section. Each wing has two stump-spars. Four large bolts
attach each wing to the fuselage main bulkheads. Standard ailerons and electrically operated flaps
attach to the trailing edge of the wing.
The horizontal stabilizer is a semi-monocoque structure. It has top and bottom shells made of GFRP.
The shells bond to GFRP spars and ribs. The trailing edge has a conventional elevator and a trim tab.
The one-piece canopy has a large quantity of wrap-around glazing. This gives a good all-round view
from the cockpit. A glazed rear passenger door gives access to the rear seats from the left side of the
airplane.
A polyurethane paint finish protects the outside skin from ultraviolet rays and humidity.
The fixed tricycle landing gear has fairings attached to each leg. The main legs attach to the fuselage
center-section. The nose leg attaches to the forward fuselage. Each main wheel has a disc brake on
the inside. Hydraulic pressure operates each disc brake.
The flight control system uses conventional ailerons, elevator and rudder. The DA 40 NG has two
control sticks and two rudder pedal assemblies to operate the primary flight-controls. Push-pull rods
operate the ailerons and elevator. Cables operate the rudder. An electric motor operates the wing
flaps. A hand wheel and Bowden cable operate the elevator trim.
The DA 40 NG is powered by an Austro Engine E4-A liquid-cooled, in-line four-stroke four cylinder
engine with double overhead camshaft (DOHC) with four valves per cylinder. The valves are actuated
by the cam follower. The direct fuel injection is realized by means of a common rail technique and the
engine is charged by a turbo-charger in combination with an intercooler. The propeller is activated by
an integrated gearbox with an integral torsional vibration damper. All engine components are controlled
by an EECU system.
Page 2 Doc # 6.02.15
15 Apr 2013 03-00-00 Rev. 2
DA 40 NG AMM General Description
AIRCRAFT
The airplane has an aluminum fuel tank in each wing. Each tank consists of one (standard tank) or two
(long range tank) chambers. The fuel tanks are inboard between the spars. The tank assemblies have
fuel fillers at or near the outboard end. Flexible hoses connect the tanks to a fuel selector and shut-off
valve under the cockpit floor. An electrically driven pump supplies fuel to the engine. The tanks have
fuel quantity probes which operate the cockpit indicating systems.
The airplane has two sources of electrical power. A 24 Volt battery supplies power when the engine
is not running. An alternator provides power when the engine is running. Switches and circuit breakers
control all electrical devices. A starter key controls the engine starter motor. It also serves as
ELECTRIC MASTER key switch.
The DA 40 NG has a full range of flight instruments. These include Pitot/static instruments to show
airspeed and altitude, as well as electrically driven instruments to show direction. If the G1000 system
is installed most indications are shown on the G1000 and only the backup instruments are installed
on the instrument panel.
The airplane has all the usual engine instruments, except a load indication instead of a manifold
pressure indication.
The airplane also has radio and navigation aids installed.
Doc # 6.02.15 Page 3
Rev. 2 03-00-00 15 Apr 2013
General Description DA 40 NG AMM
AIRCRAFT
3. Equipment Data
The table below gives you the name and address of the manufacturers who supply systems and/or
equipment for the DA 40 NG. This will help you get more data on a system and/or equipment.
ATA
Equipment/System Address
Chapter
22, 23, Garmin G1000 System and Garmin International Inc.
31, 34 GFC 700 A/P: 1200 E. 151st Street
Olathe, KS 66062
USA
Tel: (913) 397-8200
Fax: (913) 397-8282
Homepage: www.garmin.com
Cooling Fans for Integrated Cockpit SANDIA aerospace
System: 3700 Osuna Road NE, Suite 711
Albuquerque, NM 87109
USA
Tel: (505) 341-2930
Fax: (505) 341-2927
Website: www.sandiaaerospace.com
% 22 Autopilot System Bendix/King
% (if KAP 140 A/P is installed): 400 North Rogers Road
% Olathe, Kansas 66062-1212
% USA
% Tel: (913) 782-0400 (USA and Canada)
% (913) 782-0700 (other countries)
% Website: www.bendixking.com
24 Battery: Concorde Battery Corp.
2009 San Bernardino Road
West Covina, California 91790
USA
Tel: (626) 813-1234
Website: www.concordebattery.com
Page 4 Doc # 6.02.15
15 Apr 2013 03-00-00 Rev. 2
DA 40 NG AMM General Description
AIRCRAFT
ATA
Equipment/System Address
Chapter
25 Emergency Locator Transmitter Artex Aircraft Supplies
(ELT): 14405 Keil Road NE
Aurora, Oregon 97002
USA
Tel: (503) 678-7929
Fax: (503) 678-7930
Website: www.artex.net
Note: The airspeed indicator must have the markings specified in Chapter 2 of the
Airplane Flight Manual, Doc. No. 6.01.15-E, latest revision.
31 Backup Airspeed Indicator, United Instruments Inc.
Backup Altimeter: 3625 Comotara Avenue
Wichita, Kansas 67226
USA
Tel: (316) 636-9203
Fax: (316) 636-9243
% Website: www.unitedinst.com
31 Backup Attitude Gyro: Mid-Continent Instrument Co., Inc.
7706 E, Osie,
Wichita, Kansas 67207
USA
Tel: (316) 683-5619
Fax: (316) 683-1861
Website: www.mcico.com
% 32 Wheels and Brakes: Parker Hannifin Corporation
% Aircraft Wheel and Brake Division
% 1160 Center Road
% Avon, Ohio 44011
% USA
% Tel: (440) 9376211
Doc # 6.02.15 Page 5
Rev. 2 03-00-00 15 Apr 2013
General Description DA 40 NG AMM
AIRCRAFT
ATA
Equipment/System Address
Chapter
33 Position / Strobe Lights: Whelen Engineering Company, Inc.
Route 145, Winthrop Rd.
Chester, CT 06412-0684
USA
Tel: (860) 526-9504
Fax: (860) 526-2009
Website: www.whelen.com
61 Propeller: MT-Propeller Entwicklung GmbH
Flugplatzstr. 1
D-94348 Atting
Germany
Tel.: +49 (9429) 94090
Fax: +49 (9429)8432
Homepage: www.mt-propeller.de
MT-Propeller USA, Inc.
1180 Airport Terminal Drive
DeLand, FL 32724
Tel.: (386) 736- 7762
Fax: (386) 736-7696
E-mail: [email protected]
72 Austro Engines E4-A Engine: Austro Engine GmbH
Rudolf Diesel-Str. 11
A-2700 Wiener Neustadt
Austria
Tel: +43 (2622) 23 000
Fax: +43 (2622) 23 000 - 2711
Homepage: www.austroengine.at
Page 6 Doc # 6.02.15
15 Apr 2013 03-00-00 Rev. 2
DA 40 NG AMM General Description
AIRCRAFT
4. Handling of Identification Data
No person shall remove, change, or place identification information on any airplane, engine, propeller,
propeller blade, or propeller hub, without the approval of the competent national Airworthiness
Authority.
If a deviation from the procedure above is necessary, any person performing maintenance work may
in consultation with the competent national Airworthiness Authority:
) Remove, change, or place the identification plate on any airplane, engine, propeller, propeller
blade, or propeller hub.
) Remove an identification plate, when necessary during maintenance operations.
) No person shall install an identification plate, removed in accordance with the procedures above,
on any aircraft, engine, propeller, propeller blade, or propeller hub other than the one from which
it was removed.
Doc # 6.02.15 Page 7
Rev. 2 03-00-00 15 Apr 2013
General Description DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 8 Doc # 6.02.15
15 Apr 2013 03-00-00 Rev. 2
Airworthiness
DA 40 NG AMM
Limitations
CHAPTER 04
AIRWORTHINESS LIMITATIONS
Doc # 6.02.15 Page 1
Rev. 2 04-TITLE 15 Apr 2013
Airworthiness
DA 40 NG AMM
Limitations AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 04-TITLE Rev. 2
Airworthiness
DA 40 NG AMM
Limitations
TABLE OF CONTENTS
CHAPTER 04
AIRWORTHINESS LIMITATIONS
1. Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Continued Airworthiness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Doc # 6.02.15 Page 1
Rev. 2 04-CONTENTS 15 Apr 2013
Airworthiness
DA 40 NG AMM
Limitations AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 04-CONTENTS Rev. 2
Airworthiness
DA 40 NG AMM
Limitations
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 23.
THIS AIRPLANE MAINTENANCE MANUAL CHAPTER 04 (AIRWORTHINESS LIMITATIONS) IS
% APPROVED WITH EASA APPROVAL NO. 10025781 and 10044960.
THE AIRWORTHINESS LIMITATIONS SECTION IS FAA APPROVED AND SPECIFIES
MAINTENANCE REQUIRED UNDER SECS. 43.16 AND 91.403 OF THE FEDERAL AVIATION
REGULATIONS UNLESS AN ALTERNATIVE PROGRAM HAS BEEN FAA APPROVED.
SERVICE BULLETINS OR OTHER DOCUMENTS REVISING THIS SECTION WHICH CONTAIN A
STATEMENT THAT THE DOCUMENT IS AUSTRO CONTROL GMBH (ACG) / EUROPEAN
AVIATION SAFETY AGENCY (EASA ) APPROVED ARE CONSIDERED FAA APPROVED.
Doc # 6.02.15 Page 1
Rev. 2 04-00-00 15 Apr 2013
Airworthiness
DA 40 NG AMM
Limitations AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 04-00-00 Rev. 2
Airworthiness
DA 40 NG AMM
Limitations
1. Airworthiness Limitations
% This Chapter is approved and shows the mandatory limitations which were established as a result of
% the certification process.
% The time limits given in Chapter 04 must be applied to ensure Continued Airworthiness of the
% DA 40 NG.
% Note: Regular inspections of the airplane including replacement and overhaul of certain
% components are required to ensure Continued Airworthiness of the DA 40 NG.
% For possible airworthiness limitations of engine, propeller, components and vendor equipment refer
% to the applicable Maintenance data as listed in Section 05-00.
A. Certification Maintenance Requirements
(1) Component and System Checks
The component and system checks under this paragraph are also included in Section 05-10.
The following table lists airplane components and systems which require monitoring through
scheduled maintenance.
Where an interval is given in both flight time and calendar years, the limit which is reached first
must be applied.
VFR in the "Kind of Operation" column means that this limit applies to day VFR, night VFR and
IFR operation. NVFR in the "Kind of Operation" column means that this limit applies to night
VFR and IFR operation. IFR in the "Kind of Operation" column means that this limit applies to
IFR operation.
Interval Kind
ATA
Component Maintenance Requirement of
Ch. hrs. yrs. Ope.
24 Essential bus. Verify proper function. 1000
NVFR
(Refer to Section 24-60). ± 50
51 Bonding system and static Resistance measurements. 1000
NVFR
discharging system. (Refer to Section 51-80). ± 50
(2) Life Time Limit / Structure Checks
There is no structural life limit.
% Note: The DA 40 NG has been designed and tested under a 'damage tolerant structure'
philosophy. Therefore the structural inspections given in Chapter 05 cover all
required structure checks.
Doc # 6.02.15 Page 3
Rev. 2 04-00-00 15 Apr 2013
Airworthiness
DA 40 NG AMM
Limitations AIRCRAFT
B. Replacement Requirements
The following table lists life limited airplane components which must be replaced at a specific time.
Where an interval is given in both flight time and calendar years, the limit which is reached first
must be applied.
% Note: The replacement requirements under this paragraph are also included in
Section 05-10.
VFR in the "Kind of Operation" column means that this limit applies to day VFR, night VFR and IFR
operation. NVFR in the "Kind of Operation" column means that this limit applies to night VFR and
IFR operation. IFR in the "Kind of Operation" column means that this limit applies to IFR operation.
Replacement Time Kind
ATA
Component of
Ch. hrs. yrs. Ope.
24 Emergency battery. 2 years, or upon
reaching the date
marked on the IFR
package, or after use,
whichever comes first.
24 ECU backup battery. 1
VFR
± 30 days
Page 4 Doc # 6.02.15
15 Apr 2013 04-00-00 Rev. 2
Airworthiness
DA 40 NG AMM
Limitations
C. Color of Airframe
It is mandatory to paint the DA 40 NG white as described in Chapter 51 of this manual. This will
prevent the temperature of the structure from becoming too high. Examples of approves shades
are:
) RAL 9016
) Mercedes DB 147
) BMW 218
) Volvo XG28
) Volvo BC76
) Saab 5AC6
) Alfa Romeo 230
Before painting the DA 40 NG in a different shade than listed above the manufacturer must be
contacted.
Only certain areas which are defined in Chapter 51 of this manual (for example, registration
markings, placards and warning markings) may have a different color.
D. Repairs
Repairs which are not described in Chapter 51 of this manual may only be carried out in
accordance with a repair scheme which has been approved by the manufacturer or the competent
National Airworthiness Authority.
Doc # 6.02.15 Page 5
Rev. 2 04-00-00 15 Apr 2013
Airworthiness
DA 40 NG AMM
Limitations AIRCRAFT
Intentionally left blank
Page 6 Doc # 6.02.15
15 Apr 2013 04-00-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
CHAPTER 05
TIME LIMITS AND MAINTENANCE
CHECKS
Doc # 6.02.15 Page 1
Rev. 2 05-TITLE 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 05-TITLE Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
TABLE OF CONTENTS
CHAPTER 05
TIME LIMITS AND MAINTENANCE CHECKS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Chapter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
% 3. Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section 05-10
Time Limits
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Scheduled Maintenance Time Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Component Time Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Component Time Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Section 05-20
Scheduled Maintenance Checks
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
% 2. Maintenance Checklist Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Major Structural Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section 05-21
Flight-Line Checks
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Flight-Line Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Post-Flight Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Doc # 6.02.15 Page 1
Rev. 2 05-CONTENTS 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Section 05-25
Drain Holes Inspection Checklist and Report
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Drain Holes Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 05-28
Maintenance Checklist DA 40 NG
Section 05-28-00
Maintenance Checklist Engine
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Engine Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Engine Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Section 05-28-50
Maintenance Checklist Airframe
1. Front Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Cockpit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. Center Fuselage, Internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4. Rear Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5. Tail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6. Wings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Section 05-28-90
Maintenance Report
1. Maintenance Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Page 2 Doc # 6.02.15
15 Apr 2013 05-CONTENTS Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Section 05-28-91
Engine Ground Test Report
1. Engine Ground Test Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 05-28-92
Check Flight Report
1. Check Flight Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 05-28-93
Major Structural Inspection Check Findings Report
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 05-50
Unscheduled Maintenance Checks
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Hard Landing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Propeller Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Engine Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6. Over Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7. High Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8. Oil Pressure Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9. Hang Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Doc # 6.02.15 Page 3
Rev. 2 05-CONTENTS 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 05-CONTENTS Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
CHAPTER 05
TIME LIMITS AND MAINTENANCE CHECKS
1. General
This Chapter will help to do the maintenance of the DA 40 NG correctly. Refer to Sections 04-00 and
05-00 for maintenance and inspections.
The times given in this Chapter are times recommended by the airplane manufacturer. Do the
scheduled maintenance at the given times, because they are the minimum required to keep the
airplane in a good technical condition.
Time limits and maintenance checks were established for operation in a moderate climate and on
paved runways. For operation under rough conditions (extreme temperatures, saline air, wind-borne
sand, operation on grass runways, etc.) it may be necessary to make changes to the maintenance
requirements given in this Chapter. You can decrease the time between scheduled maintenance
checks if the airplane's operation makes it necessary. You must not extend the time between
scheduled maintenance checks without the Airworthiness Authority's approval.
These checks do not over-ride the requirements of the Airworthiness Authority of the country where
the airplane is registered. You must ensure that all Airworthiness Directives, Service Bulletins and any
other requirements of the Airworthiness Authority are completed as required.
The airplane manufacturer can change the time between checks. If this happens, the airplane
manufacturer will publish the change as a revision to the Airplane Maintenance Manual.
2. Chapter Configuration
A. Section 05-10
Section 05-10 contains the recommended time limits for maintenance checks. It also contains the
recommended time between overhaul for components. Use the data in Section 05-10 to find when
to do the maintenance.
B. Section 05-20
Section 05-20 contains information about the Maintenance Checklist structure.
C. Section 05-21
Section 05-21 contains information about the Flight-Line Checks.
D. Section 05-25
Section 05-25 contains the Drain Holes Inspection Checklist.
Doc # 6.02.15 Page 1
Rev. 2 05-00-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
E. Section 05-28
Section 05-28 contains the Maintenance Checklist for the DA 40 NG airplane. The Section is
subdivided into engine and airframe sections and provides checklists for the engines and the
airframe and the corresponding reports.
(1) Section 05-28-00
Maintenance Checklist for the engine:
% ) Maintenance checks schedule for 100, 200, 1000, and 2000 hour checks on the engine.
) Data for the annual check (if necessary) for national regulations on the engine.
(2) Section 05-28-50
Maintenance Checklist for the airframe:
% ) Maintenance checks schedule for 100, 200, 1000, and 2000 hour checks and the Major
structural inspection (MSI) on the airframe.
) Data for the annual check (if necessary) for national regulations on the airframe.
(3) Section 05-28-90
Maintenance Report.
(4) Section 05-28-91
Engine Ground Test Report.
(5) Section 05-28-92
Check Flight Report.
(6) Section 05-28-93
Major Structural Inspection (MSI) Findings Report.
F. Section 05-50
Section 05-50 contains the unscheduled maintenance checks. Do these checks after hard landings,
propeller damage, engine fire and lightning strike.
Page 2 Doc # 6.02.15
15 Apr 2013 05-00-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
% G. Referenced Maintenance Data
% Use latest revision of referenced maintenance data.
% Supplier Document Name Document No.
% Artex Installation and Maintenance Manual for the 570-1600
% ME406 ELT
% Austro Engine Austro Engine Operation Manual AE300 E4.01.01
% Austro Engine Austro Engine Maintenance Manual AE300 E4.08.04
% Cleveland/Parker Cleveland/Parker Maintenance Manual AWBCMM0001
% Cleveland/Parker Cleveland/Parker Product Catalog AWBPC0001
% Cleveland/Parker Cleveland/Parker Technician’s Service Guide AWBTSG0001
% Concorde ®
RG Series Main Aircraft Batteries Component 5-0171
% Maintenance Manual
% Garmin Garmin G1000 System Maintenance Manual 190-00907-00
% Honeywell Honeywell Flightline Maintenance Manual 006-15574-0002
% Bendix/King KAP 140 Flight Control System
% L-3 Stormscope WX-500 Installation Manual 009-11500-001
% mt-Propeller mt-Propeller Operation and Installation Manual E-124,
% ATA 61-01-24
% mt-Propeller mt-Propeller Operation and Installation Manual for E-1048,
% the Hydraulic Constant Speed Governor ATA 61-20-48
% Goodyear Aircraft Tire Care & Maintenance
Doc # 6.02.15 Page 3
Rev. 2 05-00-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
% 3. Definitions
In this Airplane Maintenance Manual, the words that follow have special meanings:
Adjust. To put to a specified position or condition. For example, adjust the clearance to
1 mm.
Check. A technical name for a group of maintenance tasks. For example, the 100 hour
check.
Examine. To look carefully at an item. It includes steps such as these:
- Make sure that the item:
Is complete.
Is correctly attached.
Has no loose parts.
Shows no signs of leaks.
Is not cracked or damaged.
Is not worn.
- Make sure that:
The surface protection is not damaged.
All locking devices are installed correctly.
- Make sure that items such as pipes and cables:
Look serviceable.
Do not rub against other items.
- For log books and other technical records:
To find outstanding faults.
To make sure they are up-to-date and correctly maintained.
Inspection. The procedure which compares an object with its standard or specification.
Measure. To find out the dimensions, capacity or quantity of something.
Monitor. To look at something during a time. For example, monitor the engine speed indicator.
Record. (1) Technical name for something that shows what was done. For example, write the
result of the test in the engine record.
(2) The act of making a record. For example, record the result of the test in the
Airplane Maintenance Log.
Replace. To remove an unserviceable item and install a serviceable item in the same location.
Set. To put equipment into a given adjustment, condition or mode. For example, set the
altimeter scale to 1013 mbar (= 1013 hPa).
Page 4 Doc # 6.02.15
15 Apr 2013 05-00-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Task. An assigned work or a procedure. For example, each step of the task has an
identification letter.
Test. That which you do when you operate or examine an item to make sure that it agrees
with the applicable specifications. For example, disconnect the systems which are not
necessary for the test. Or do an engine test.
Doc # 6.02.15 Page 5
Rev. 2 05-00-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Intentionally left blank
Page 6 Doc # 6.02.15
15 Apr 2013 05-00-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Section 05-10
Time Limits
1. General
% This Section lists time limits for scheduled Maintenance on airframe and components, and replacement
% or overhaul of components directly or by reference.
% Obey the time limits in this Section to keep the airplane in a technical good condition.
Note: National Regulatory Authorities can have different requirements. You must make sure that you
meet the requirements of the Regulatory Authority of the country where the airplane is
registered.
2. Scheduled Maintenance Time Limits
(Refer to Sections 05-20 through 05-28).
The following recommended hourly and calendar time limits apply to the scheduled maintenance
checks which are necessary to maintain the airplane in a good technical condition. Do the scheduled
maintenance at the intervals and within the tolerances shown below:
Scheduled Maintenance Maximum
Do At These Times
Check (Hourly) Tolerance
100 Hour Check At 100 hours since new and every 100 hour intervals. ± 10 %
200 Hour Check At 200 hours since new and every 200 hour intervals. ±5%
1000 Hour Check At 1000 hours since new and
every 1000 hour intervals or ±5%
12 years, whichever comes first.
% 2000 Hour Check At 2000 hours since new and
% every 2000 hour intervals or ±5%
% 12 years, whichever comes first.
First Major Structural At 6000 hours or ± 50 hours
Inspection (MSI). 12 years since new, ± 6 months
whichever comes first
Subsequent Major At 4000 hours or ± 50 hours
Structural Inspections. 12 years intervals, ± 6 months
whichever comes first
The intervals between the inspections must be adhered to within the tolerances shown. These
tolerances must not be added up. For example: if the 100 hour inspection was done at 110 hours, the
next inspection must be done at 200 ±10 hours, not 210 ±10 hours.
Doc # 6.02.15 Page 1
Rev. 2 05-10-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
If an inspection is carried out earlier than allowed by the specified tolerance, all subsequent inspection
intervals are counted from that inspection. For example: If the 100 hour inspection was done at
83 hours, the next inspection must be done at 183 hours.
If the airplane was flown less than 200 hours for the last 12 months:
Scheduled Maintenance Check Maximum
Do At These Times
(Calendar) Tolerance
Annual Inspection (for airplanes At 12 months since new and every 12 month
registered in the USA). interval do a 100 Hour Check.
Annual Inspection (for airplanes At 12 months since new and every 12 month 30 days
registered in other countries). interval do a 200 Hour Check, if no 200 Hour
Check was performed during the last
12 months due to flight time.
Note: For maintenance of airplanes registered in the USA, do the items marked X and
the items marked X* in the Maintenance Checklist.
For maintenance of airplanes registered in other countries, do only the items
marked X in the Maintenance Checklist.
Page 2 Doc # 6.02.15
15 Apr 2013 05-10-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
3. Component Time Limits
A. Maintenance Requirements
The following table lists airplane components and systems which require overhaul or specific
checks.
Where an interval is given in both flight time and calendar years, the limit which is reached first
% must be used.
% For possible maintenance requirements of engine, propeller, components and vendor equipment
% refer to the applicable Maintenance data as listed in Section 05-00.
VFR in the "Kind of Operation" column means that this limit applies to day VFR, night VFR and IFR
operation. NVFR in the "Kind of Operation" column means that this limit applies to night VFR and
IFR operation. IFR in the "Kind of Operation" column means that this limit applies to IFR operation.
Note: Components marked with an asterisk (*) are Airworthiness Limitation items. The
Airworthiness Limitation items are listed in Chapter 4 and Chapter 5 of the AMM.
Interval Kind
ATA
Component Maintenance Requirement of
Ch. hrs. yrs. Ope.
% Note: The mechanical check of the GFC 700 autopilot system (if installed) is
% mandatory.
%
22 Autopilot system. (GFC 700). Mechanical check. 1 yr
(Refer to Section 22-10). - ± 30 VFR
days
% Note: The mechanical check of the KAP 140 autopilot system (if installed) is not
% mandatory. It is however recommended to do this check at the times shown
% below.
%
22 Autopilot system. (KAP 140). Mechanical check. 1000
- VFR
(Refer to Section 22-11). ± 50
24 Essential bus.* Verify proper function. 1000
- NVFR
(Refer to Section 24-60). ± 50
26 Fire extinguisher. Overhaul. 10
- ± 60 VFR
days
Doc # 6.02.15 Page 3
Rev. 2 05-10-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Interval Kind
ATA
Component Maintenance Requirement of
Ch. hrs. yrs. Ope.
34 Pitot-static system. Clean system, perform
1000
leakage test. 2 NVFR
± 50
(Refer to Section 34-10).
34 Airspeed indicators including Check for correct indication. 4
% airspeed indicator on G1000. - ± 60 IFR
days
34 Vertical speed indicator. Check for correct indication. 4
% - ± 60 IFR
days
34 Altimeter(s) including altimeter Check for correct indication. 2
% on G1000. - ± 30 VFR
days
34 Magnetic compass. Compensate. 1
- ± 30 IFR
days
% 34 Transponder (on G1000) and System check. 2
1000
blind altitude encoder (altitude ± 30 IFR
± 50
digitizer). days
51 Bonding system and static Resistance measurements. 1000
- NVFR
discharging system.* (Refer to Section 51-80). ± 50
Page 4 Doc # 6.02.15
15 Apr 2013 05-10-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
B. Airplane Life-Limited Components
The following table lists life limited airplane components which must be replaced at a specific time.
Where an interval is given in both flight time and calendar years, the limit which is reached first
must be applied.
% For possible life-limits of engine, propeller, components and vendor equipment refer to the
% applicable Maintenance data as listed in Section 05-00.
VFR in the "Kind of Operation" column means that this limit applies to day VFR, night VFR and IFR
operation. NVFR in the "Kind of Operation" column means that this limit applies to night VFR and
IFR operation. IFR in the "Kind of Operation" column means that this limit applies to IFR operation.
% Note: Components marked with an asterisk (*) are Airworthiness Limitation items. The
Airworthiness Limitation items are listed in Chapter 4 and Chapter 5 of the AMM.
ATA Replacement Time Kind of
Component
Ch. hrs. yrs. Operation
2 years, or upon reaching
the date marked on the
24 Emergency battery.* IFR
package, or after use,
whichever comes first.
24 ECU backup battery.* - 1 ± 30 days VFR
% 24 V-belt of additional alternator (if installed). 2000 ± 50 - VFR
25 Safety harnesses, front and rear. - 12 ± 90 days VFR
First aid kit. Upon reaching the date
25 VFR
Replace aseptic items. marked on the kit.
% Rudder cables, non-stainless steel, 3.2 mm
27 3000 ± 50 5 ± 60 days VFR
(1/8 in) diameter.
% Rudder cables, stainless steel, 3.2 mm (1/8 in)
% 27 On condition. VFR
% diameter.
% Note: If material of rudder cables is unknown, assume non-stainless steel.
%
% Electrical fuel pumps (2 pcs).
% 2400 hours, or after failure
% 28 including check valves (1 pc. per pump), if VFR
of one fuel pump.
% installed (MÄM 40-480).
Doc # 6.02.15 Page 5
Rev. 2 05-10-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
ATA Replacement Time Kind of
Component
Ch. hrs. yrs. Operation
% Co-incident
% 28 Fuel bypass valve. with engine - VFR
% TBO.
28 Fuel tank vent hoses. - 8 ± 60 days IFR
28 Fuel filter element. 100 ± 10 1 ± 30 days VFR
Fuel hoses interconnecting the individual fuel
28 tank chambers, and fuel hoses connecting fuel - 8 ± 60 days VFR
tank chambers to filler assemblies.
% Co-incident
% Fuel pressure pulsation damper, if installed
% 28 with engine - VFR
% (MÄM 40-468).
% TBO.
32 Brake fluid, fluid 4. - 3 ± 60 days VFR
% V-belt of the additional alternator, if installed
% 61 2000 ± 50 - VFR
% (OÄM 40-314).
% Co-incident
Engine shock mounts (including bolts, washers
% 71 with engine - VFR
and lock nuts).
% TBO.
71 Air filter. 200 ± 10 - VFR
4. Component Time Tracking
To make sure that components overhaul/replacement is done at the correct time you must record the
data that follows in the Airplane Maintenance Log for each component requiring overhaul/replacement:
) Serial Number.
) Flight hours and date at installation.
) Flight hours and date at removal.
Page 6 Doc # 6.02.15
15 Apr 2013 05-10-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Section 05-20
Scheduled Maintenance Checks
1. General
Do the scheduled maintenance checks in this Section at the intervals (flight hours and calendar time)
stated in Section 05-10, Paragraph 3.
Note: Only persons or maintenance organizations authorized by national Regulatory
Authorities of the country where the airplane is registered may do these checks.
The inspection level for each item is a general visual inspection unless differently
specified.
Note: Only AE authorized maintenance organizations may carry out maintenance and
inspection work on the AE engine. Any engine malfunction must be reported to AE.
% 2. Maintenance Checklist Organization
Do the scheduled maintenance checks with reference to the Maintenance Checklist in this Section.
Before starting a check, complete the requirements of Paragraphs 2 and 3 of the checklist. In parallel
do the scheduled drain hole checks with reference to the Drain Holes Inspection Checklist and Report.
Do all the applicable tasks on the checklists.
Note: For maintenance of airplanes registered in the USA, do the items marked X and
the items marked X* in the Maintenance Checklist.
For maintenance of airplanes registered in other countries, do only the items
marked X in the Maintenance Checklist.
% Note: The interval columns "100", "200", “1000", and "2000" are used for maintenance
% items which must be done at intervals of 100, 200, 1000, or 2000 flight hours. The
interval column "time" is used for maintenance items which must be done at certain
calendar time intervals, or during a Major Structural Inspection (MSI).
Note: Where an interval is given in both flight time and calendar years, the limit which is
reached first must be applied.
Note: Some inspection items must be done at other intervals than the standard intervals
% (100, 200, 1000, or 2000 hrs.). In these cases, the maintenance interval is shown
in the column for the next shorter interval instead of an X. For example, an item
which must be done every 400 hours is identified by the words "400 hrs." in the
200 hrs. column.
Doc # 6.02.15 Page 1
Rev. 2 05-20-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
All of the applicable items must be signed by authorized maintenance personnel. Record the
completion of the check in the airplane log book. Complete a copy of the Maintenance Report (refer
to Section 05-28-90).
The Maintenance Checklist is divided into the following Sections:
A. Section 05-28-00 - Engine Compartment:
All items forward of the firewall. It includes the cowlings and the propeller.
B. Section 05-28-50 - Airframe:
(1) Front Fuselage
All items on the outside of the front fuselage from the firewall to the trailing edge of the wing. It
includes the nose landing gear, the main landing gear, the canopy and rear door.
(2) Cockpit
All items inside the fuselage shell from the aft face of the firewall to the aft face of the rear main
bulkhead. It also includes the internal parts of the brake system.
(3) Center Fuselage, Internal
All items inside the fuselage shell below the rear seats from the aft face of the rear main
bulkhead to the baggage compartment. It includes the control systems on the aft main bulkhead
and the baggage compartment.
(4) Rear Fuselage
All items on the outside of the fuselage from the trailing edge of the wing to the front of the
vertical stabilizer.
(5) Tail
All items of the fuselage aft of the rear fuselage, vertical stabilizer and horizontal stabilizer.
(6) Wings
All items on the left and right wings. It includes the ailerons, flaps and Pitot head.
(7) General
Those items which include more than one zone at the same time. It includes items such as
control checks which need one person in the cockpit and another person at the control surface.
Page 2 Doc # 6.02.15
15 Apr 2013 05-20-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
3. Major Structural Inspection
The Major Structural Inspection (MSI) is an important part of the infinite lifetime concept of the
DA 40 NG. It is required to prove the structural integrity of the airframe. It must be carried out at the
intervals shown in Section 05-20.
% Since the MSI is intended to coincide with a 2000 hour inspection, the inspection items are included
in the maintenance checklist, and are identified by the term ‘MSI' in the ‘time’ column.
Doc # 6.02.15 Page 3
Rev. 2 05-20-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 05-20-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Section 05-21
Flight-Line Checks
1. General
These checks include the pre-flight and post-flight checks. Do these checks each day the airplane is
used.
2. Flight-Line Checks
The Daily Check must be done before the first flight of the day. It shows the pilot the general condition
of the airplane and the engine. It is important for flight safety. Look in the airplane log-book for
problems before doing the daily check.
WARNING: DO ALL THE STEPS OF THE DAILY CHECK CAREFULLY. ACCIDENTS
CAN OCCUR IF THE DAILY CHECK IS NOT DONE CORRECTLY.
The schedule for the pilot's daily check is in the Airplane Flight Manual for the DA 40 NG.
3. Post-Flight Check
Do the post-flight check after the last flight of the day. The post-flight check includes all the steps of
the daily check.
You must also:
) Refuel the airplane (Section 12-10).
) Record in the log book each problem found in flight and during the post-flight check.
) Park the airplane (Sections 10-00 and 10-10).
) If necessary, moor the airplane (Section 10-20).
Doc # 6.02.15 Page 1
Rev. 2 05-21-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 05-21-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Section 05-25
Drain Holes Inspection Checklist and Report
1. General
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.
All drain holes should be drilled with a diameter of 5 mm (+2 mm / -0 mm) or 0.2 in (+0.08 in / -0.00 in).
The holes should be circular, deburred, not frayed and cleaned.
At drain holes marked with an asterisk (*) the adhesive bonding is recessed.
Refer to the corresponding indication on the figures to identify the locations of the drain holes listed
below.
2. Drain Holes Inspection Checklist
Drain Holes Inspection Checklist
Ref. Drain Hole Location Hours Initials
1 FUSELAGE
1.01 Flange top hat section, LH & RH 100
1.02 Lower fuselage shell in the wing nose area, outboard of top 100
hat section, LH & RH
1.03 Lower fuselage shell, in front of front spar flange, center 100
position
1.04 Lower fuselage shell, next to front spar, LH & RH 100
1.05 Lower fuselage shell, aft of front spar flange, center position 100
1.06 Lower fuselage shell, next to rear spar, LH & RH 100
1.07 Lower fuselage shell, aft of rear spar flange, center position 100
1.08 Lower fuselage shell, in front of flaps torsion rod, center 100
position
1.09 Lower fuselage shell, fuselage rib reinforcement section, 100
LH & RH
1.10 Lower fuselage shell, inner corner of fuel duct flange, 100
LH & RH
1.11 Footwell cockpit to the clearance, LH & RH 100
1.12 Lower fuselage shell, aft of baggage compartment frame 100
base
1.13 Lower fuselage shell, in front of baggage compartment frame 100
base, LH & RH
Doc # 6.02.15 Page 1
Rev. 2 05-25-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Drain Holes Inspection Checklist
Ref. Drain Hole Location Hours Initials
1.14 On lowest point of the fin 100
1.15 On lowest point of the EPC connector 100
1.16 In rudder bolt mounting shell (on top of the rudder) 100
1.17 In rib of vertical stabilizer, in front of rear web 200
1.18 In rib of vertical stabilizer, in front of front web 200
1.19 On bottom of the vertical stabilizer front web 200
1.20 Lower fuselage shell, aft of vertical stabilizer rear web 200
1.21 On nose wheel strut, LH & RH 200
1.22 Through roll over bar duct and baggage compartment frame 200
1.23 Through lower end of ring frame 1 200
1.24 Through baggage compartment frame, center position 200
above lower fuselage shell
1.25 Through lower end of ring frame 2 200
1.26 Through lower end of ring frame 3 200
2 CANOPY AND DOOR
2.01 Lower canopy frame, in front of Bowden cable guide, 100
LH & RH
2.02 Lower canopy frame, aft of the canopy locking mechanism, 100
LH & RH
2.03 Inner door shell, below the front locking bolt 100
3 HORIZONTAL STABILIZER
% 3.01 Lower shell, next to the mid inspection hole, LH & RH 200
% 3.02 Lower shell, next to the front inspection hole, LH & RH 200
3.03 On the lowest point of the horizontal stabilizer tips, 100
LH & RH
3.04 Elevator end rib, next to the rear spar, next to lower shell, 200
LH & RH
3.05 LH & RH rib, in front of the rear spar, above the lower shell 200
3.06 LH & RH rib, behind the front spar, above the lower shell 200
3.07 LH & RH rib, in front of the front spar, above the lower shell 200
% 3.08 Mid, LH & RH rib, behind the rear spar, above the lower shell 2000
% 3.09 Mid, LH & RH rib, behind the front spar, above the lower shell 2000
4 ELEVATOR
4.01 Lower shell, leading edge section, LH & RH 100
4.02 Lower shell, in front of trailing edge, LH & RH 100
Page 2 Doc # 6.02.15
15 Apr 2013 05-25-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Drain Holes Inspection Checklist
Ref. Drain Hole Location Hours Initials
5 ELEVATOR TRIM TAB
5.01 Lower shell, leading edge section, LH & RH 100
5.02 Lower shell, in front of trailing edge bonding, LH & RH 100
6 RUDDER
6.01 Lower edge, at the left and right shell of the rudder 100
7 WINGS
7.01 In outer wing end rib at aileron mass balance cut out 100
7.02 Wing tip in front of rear bonding (LH & RH wing) 100
7.03 First fuel tank rib, next to front and rear spar and lower shell 100
(LH & RH wing)*
7.04 In flap rib rear spar next to lower shell (LH & RH wing) 200
7.05 In rear root rib next to rear spar and lower shell 200
(LH & RH wing)*
7.06 In aileron rib next to rear spar and lower shell (LH & RH wing) 200
7.07 Second fuel tank rib, next to front and rear spar and lower 200
shell (LH & RH wing)*
7.08 Third fuel tank rib, next to front and rear spar and lower shell 200
(LH & RH wing)*
7.09 Fourth fuel tank rib, next to front and rear spar and lower 200
shell (LH & RH wing)*
7.10 Fifth fuel tank rib, next to frond and rear spar and lower shell 200
(LH & RH wing)*
% 7.11 In front root rib, next to front spar and lower shell 2000
(LH & RH wing)
% 7.12 Vent hole on face side of wing spar (LH & RH wing) 2000
8 FLAPS
8.01 Root rib, next to trailing edge bonding, LH & RH 100
9 AILERONS
9.01 Inner root rib, next to the trailing edge bonding, LH & RH 100
9.02 Lower shell, aft of mass balance weight, LH & RH 100
9.03 Lower shell, in front of mass balance hingeline, LH & RH 100
9.04 Outer root rib, at the leading edge, LH & RH 100
At drain holes marked with an asterisk (*) the bonding is recessed. At drain holes marked with an
asterisk (*) the bonding is recessed.
Doc # 6.02.15 Page 3
Rev. 2 05-25-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
1.22
To be checked only 1.16
in production or repair
1.15 1.18
1.17
1.20
1.21 1.26 1.19
1.23 1.25
1.11 1.14
1.12
To be checked only Maintenance Access
in production or repair
X 100 Hours Check Horizontal Drainage Hole
X 200 Hours Check Vertical Drainage Hole
X 2000 Hours Check Exterior Drainage Hole
Drainage Hole Inside the Structure
Figure 1: Drain Holes Fuselage (Part 1)
Page 4 Doc # 6.02.15
15 Apr 2013 05-25-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
1.02
1.10
1.06 1.09
1.01
1.04
1.07 1.13
1.03 1.24
1.05 1.08
1.01 1.13
1.04
1.06
1.10
1.09
1.02
X 100 Hours Check Horizontal Drainage Hole
X 200 Hours Check Vertical Drainage Hole
X 2000 Hours Check Exterior Drainage Hole
Drainage Hole Inside the Structure
Figure 2: Drain Holes Fuselage (Part 2)
Doc # 6.02.15 Page 5
Rev. 2 05-25-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
2.02
2.01
2.01
2.02
X 100 Hours Check Horizontal Drainage Hole
X 200 Hours Check Vertical Drainage Hole
X 2000 Hours Check Exterior Drainage Hole
Drainage Hole Inside the Structure
Figure 3: Drain Holes Canopy
Page 6 Doc # 6.02.15
15 Apr 2013 05-25-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
2.03
X 100 Hours Check Horizontal Drainage Hole
X 200 Hours Check Vertical Drainage Hole
X 2000 Hours Check Exterior Drainage Hole
Drainage Hole Inside the Structure
Figure 4: Drain Holes Passenger Door
Doc # 6.02.15 Page 7
Rev. 2 05-25-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
3.07 3.02 3.07
3.06 3.06
3.09 3.09
3.05 3.01 3.05
3.08 3.04 3.04 3.08
4.01 4.01
4.02 4.02
3.03 3.07
5.01 5.01
5.02 5.02
X 100 Hours Check Horizontal Drainage Hole
X 200 Hours Check Vertical Drainage Hole
X 2000 Hours Check Exterior Drainage Hole
Drainage Hole Inside the Structure
Figure 5: Drain Holes Horizontal Stabilizer, Elevator and Elevator Trim Tab
Page 8 Doc # 6.02.15
15 Apr 2013 05-25-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
View on Arrow A
6.01 6.01
X 100 Hours Check Horizontal Drainage Hole
X 200 Hours Check Vertical Drainage Hole
X 2000 Hours Check Exterior Drainage Hole
Drainage Hole Inside the Structure
Figure 6: Drain Holes Rudder
Doc # 6.02.15 Page 9
Rev. 2 05-25-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Maintenance Access Maintenance Access
7.11
7.09 7.08 7.07
7.12
7.10 A A A 7.03
7.01 9.02
7.09 7.08 7.07 7.04 7.12
9.04 7.05
7.06
9.03
7.02
9.01
8.01
View A
7.06 to 7.09
X 100 Hours Check Horizontal Drainage Hole
X 200 Hours Check Vertical Drainage Hole
X 2000 Hours Check Exterior Drainage Hole
Drainage Hole Inside the Structure
Figure 7: Drain Holes Wings, Flaps and Ailerons
Page 10 Doc # 6.02.15
15 Apr 2013 05-25-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Section 05-28
Maintenance Checklist DA 40 NG
Section 05-28-00
Maintenance Checklist Engine
1. General
Enter the applicable data in the blocks below:
Registration _________________ Date _________________
Airplane S/N _________________ Engine S/N _________________
Airplane Engine hours,
Operating Hours _________________ TTSN/TSMOH _________________
Check _________________
Propeller S/N _________________
% (100, 200, 1000, 2000 hr, Annual Inspection) Propeller hours,
TTSN/TSMOH _________________
Doc # 6.02.15 Page 1
Rev. 2 05-28-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
2. Preparation
CAUTION: OBSERVE THE COMPONENT TIME LIMITS STATED IN SECTIONS
04-00 AND 05-10 OF THIS AIRPLANE MAINTENANCE MANUAL.
Do the following items before you start the applicable check:
Interval (Flight Hours)
Inspection Items 100 200 1000 2000 Initials
% 1. Before you do the inspection: X X X X
S Read the applicable Airworthiness Directives.
S Read the applicable Service Bulletins.
% 2. Examine the Log Books. Look specially for: X X X X
S Life limited parts.
S Reported problems.
% 3. Clean the airplane fully. (Refer to Section 12-30). X X X X
Page 2 Doc # 6.02.15
15 Apr 2013 05-28-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
3. Engine Ground Test
Do an engine ground test as follows (complete a copy of the Engine Ground Test Record as part of
the engine ground test. (Refer to Section 05-28-91):
Interval
Inspection Items 100 200 1000 2000 Time Initials
WARNING: DO NOT LET PERSONS GO INTO THE DANGER AREA OF THE
PROPELLER. PROPELLERS CAN CAUSE INJURY OR DEATH.
WARNING: SET THE PARKING BRAKE TO ON. IF YOU DO NOT DO THIS, THE
AIRPLANE CAN MOVE. THIS CAN CAUSE INJURY OR DEATH.
% 1. Do an operational test of the parking brake. X X X
% 2. Set the parking brake to ON. X X X X
% 3. Put the chocks against the airplane main wheels. X X X X
% 4. Do an engine ground run. (Refer to Section 71-00 X X X X
and AE Maintenance Manual, latest revision).
% 5. Check engine instruments. X X X X
% 6. Shut engine down. X X X X
% 7. Examine the engine for oil/fuel/coolant leaks. X X X X
% 8. Read out the ECU (engine event log, refer to Section X X X X
72-00) and send the event log to Austro Engine
GmbH per e-mail).
Doc # 6.02.15 Page 3
Rev. 2 05-28-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
4. Engine Maintenance Checklist
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items, Engine 100 200 1000 2000 Time 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.
WARNING: DO NOT GET OIL ON YOU. OIL CAN CAUSE SKIN DISEASE.
WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE. DO
NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN CAUSE
INJURY TO PEOPLE AND DAMAGE TO EQUIPMENT.
1. Remove the top and bottom cowling. 50 X X X
(Refer to Section 71-10). hrs.
Examine the cowlings. Make sure that the fasteners
are serviceable. Look for cracks and areas that have
been exposed to high temperatures. Check rubber
seals.
2. Visual inspection of the air intake and turbo-charging 50 X X X
system: hrs.
S Look specifically for signs of chafing or damage.
% 3. Examine the engine and airplane fuel system. X X X X
S Look for signs of leakage, material deterioration,
chafing or damage of the flexible fuel hoses.
Refer also to the AE Maintenance Manual, latest
revision.
% 4. Clean the engine and engine compartment. X X X X
%
Refer to Section 12-30 and the AE Maintenance
Manual, latest revision.
% 5. Do engine maintenance in accordance with AE X X X X
% Maintenance Manual, latest revision.
Page 4 Doc # 6.02.15
15 Apr 2013 05-28-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items, Engine 100 200 1000 2000 Time Initials
% 6. Cut open the used oil filter: X X X X
S Look for contamination and metal abrasion.
S If the filter contains particles of metal, refer to the
engine manufacturer.
% 7. Verify proper mixture ratio of the coolant. X* X X X
Refer to the AE Maintenance Manual, latest revision.
8. Check gascolator filter. X X X X
S If filter is contaminated, wash in clean fuel.
% 9. Examine the exhaust end pipe incl. muffler (if X X X X
% installed). Look specially for cracks and heat damage
% or incorrect attachment.
10. Examine the alternator mounting bracket and electrical X X X X
connections.
11. Examine the mounting bracket , pulley assembly and X X X X
electrical connections of the additional alternator
(if OÄM 40-314 is installed):
S Visual inspection of mounting bracket and pulley
assembly for corrosion and cracks.
S Examine the electrical connections. Look
especially for rub marks, damage and corrosion.
Pull lightly to make sure they are not loose.
12. Examine the v-belt of the additional alternator X X X X
(if OÄM 40-314 is installed):
S Visual inspection for damage and material
deterioration.
S Check the v-belt tension. Refer to Chapter 61.
Doc # 6.02.15 Page 5
Rev. 2 05-28-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items, Engine 100 200 1000 2000 Time Initials
% 13. Examine the cable ties and all electrical connectors in X X X X
the engine area:
S Look specially for rub marks and damage.
S Pull lightly to make sure they are not loose.
% 14. Examine the bonding cables and their connectors in X X X X
the engine area:
S Look specially for rub marks and damage.
S Pull lightly to make sure they are not loose.
% 15. Examine the oil breather line. X X X X
Refer to the AE Maintenance Manual, latest revision.
% 16. Examine the propeller control system: X X X X
S Look specially for leakage and damage.
Page 6 Doc # 6.02.15
15 Apr 2013 05-28-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items, Engine 100 200 1000 2000 Time Initials
17. Examine the air intake and turbo-charging system: X X X X
% Look specially for signs of chafing or damage on these
% items:
% S Air filter.
% S Hose from air filter to turbo charger.
% S Turbo-charger.
% On the pressure side of the turbo-charger:
% S Hoses and hose clamps.
% S Aluminum pipes.
% S Look specially for signs of damage.
% S Make sure that the air hoses and ducts are
% correctly attached and the torque seal on the hose
% clamps is intact.
% S Intercooler.
% Do NOT re-tighten the worm drive clamps once they
% have been installed unless they are loose. Re-
% tightening of worm drive clamps will lead to damage on
% silicone hoses and possible loss of engine power.
% 18. Check cooling system for leaks. Look specially at X X X X
these items:
S Hoses and worm drive clamps.
S Aluminum pipes.
% 19. Examine the coolant radiator: X X X X
S Look specially for leakage, damage, and loose
attachments.
S Make sure the cooling air flow through the radiator
is not blocked due to bent fins.
Doc # 6.02.15 Page 7
Rev. 2 05-28-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items, Engine 100 200 1000 2000 Time Initials
% 20. Examine the coolant tank: X X X X
S Look specially for leakage and damage.
S Check the attachment brackets for cracks.
% 21. Examine the alternate air valve assembly: X X X X
S Check correct movement when the alternate air
lever in the cockpit is operated.
S Examine the FOD screen for contamination.
(Refer to Section 71-60).
% 22. Examine the engine mounts. Look specially for: X X X X
S Cracks or corrosion. No cracks or corrosion
allowed.
S Damaged surface protection. Repair damaged
surface protection.
S Mounting bolts:
S Incorrect attachment.
S Damage. No damage allowed.
S Incorrect torque value. (Refer to Section 20-10).
S Loose or missing lock devices.
S Damaged shock mounts. Replace damaged shock
mounts.
% 23. Check bolts engine mount to firewall. Torque to the X
value given in Section 20-10.
S At the first 100 hrs. check. (X)
% 24. Do an engine ground test run. X X X X
%
% After the engine test run, read the EECU data out and
% send them via email to Austro Engine GmbH.
% Refer to AE Maintenance Manual, latest revision.
Page 8 Doc # 6.02.15
15 Apr 2013 05-28-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
5. Propeller
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items, Propeller 100 200 1000 2000 Time 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.
% 1. Inspection in accordance with mt-Propeller X* X X X
% Maintenance Manual, latest revision.
Doc # 6.02.15 Page 9
Rev. 2 05-28-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Intentionally left blank
Page 10 Doc # 6.02.15
15 Apr 2013 05-28-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Section 05-28-50
Maintenance Checklist Airframe
Note: The items of the Major Structural Inspection (MSI) are included in the maintenance
checklist of the airframe and identified by the term ‘MSI’ in the ‘Time’ column.
% Note: If the airplane is operated on rough terrain it is recommended to perform additional
% inspections of items marked () at intervals half the intervals marked.
1. Front Fuselage
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 1. Examine the complete surface of the front fuselage. X* X X X
Look specially for damage (dents, cracks, holes and
delamination).
Examine the paint coat.
% 2. Do a coin-tap test for delamination of the fuselage MSI
shell.
% 3. Examine these NACA air inlets for blockage: X X X X
S One in the left stub wing.
S Two in the forward fuselage, LH and RH.
% 4. Examine the canopy: X* X X X
S Make sure the canopy lock mechanism operates
correctly. (Refer to Section 52-10).
S Examine the acrylic glass window for damage.
Look specially for cracks.
S Examine the bonding between the window and
the canopy frame. (Refer to Section 56-10).
S Examine the emergency windows and their
hinges for damage.
S Examine the 'pop out' windows and their hinges
% for damage, if installed. Check hinges for
improper friction, correct if necessary.
% 5. Do a function test of the door unlocked warning light X* X X X
system. (Refer to Section 52-10).
Doc # 6.02.15 Page 1
Rev. 2 05-28-50 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 6. Examine the rear passenger door: X* X X X
% S Make sure the door lock mechanism operate
correctly. (Refer to Section 52-10).
S Examine the acrylic glass window for damage.
Look specially for cracks.
S Examine the bonding between the window and
the door frame. (Refer to Section 56-10).
% 7. Examine the safety hook mechanism. (Refer to X X X X
% Section 52-10).
% 8. Examine the carbon hinges for cracks. (Refer to X X X X
% Section 52-10).
% 9. Examine the rear window on the RH side: X* X X X
S Examine the acrylic glass window for damage.
Look specially for cracks.
S Examine the bonding between the window and
the frame. (Refer to Section 56-10).
% 10. Examine all antennas. Look specially for damage X* X X X
and incorrect attachment.
% 11. Remove the wheel fairings. Look for cracks on the X* X X X
fairing mounts. (Refer to Section 32-40).
% 12. Lift the airplane on jacks. (Refer to Section 07-10). X X X
% 13. Examine the tires. Look specially for cuts and wear. X X X X
Measure the tire pressure. (Refer to Section 12-10).
% 14. Examine the rims of the main and the nose wheels. X* X X X
Look specially for cracks and deformation of the
flanges.
% 15. Examine the wheel bearings. Look specially for play, X X X
corrosion and irregular operation.
Page 2 Doc # 6.02.15
15 Apr 2013 05-28-50 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 16. Remove the main and nose wheels. X* X X X
S Clean and lubricate the bearings.
(Refer to Section 12-20).
S Install the main and nose wheels.
(Refer to Section 32-40).
% 17. Examine the brake lining. Look specially for wear. X X X X
% Minimum thickness according to Cleveland/Parker
% Maintenance Manual, latest revision.
% 18. Examine the brake disks. Look specially for wear. X X X
% Minimum thickness according to Cleveland/Parker
% Maintenance Manual, latest revision.
% 19. Remove the access panels for the main landing gear X X
legs. (Refer to Section 52-40).
% 20. Examine the mounting for the landing gear. Look X X
specially for:
S Incorrect attachment.
S Loose or missing lock devices.
% 21. Examine the main landing gear. Look specially for X X
cracks and deformation.
% 22. Do a test for toe-in and camber. X X
(Refer to Section 32-10).
% 23. Examine the wing main bolts. Look specially for X* X X X
incorrect locking.
Doc # 6.02.15 Page 3
Rev. 2 05-28-50 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 24. Examine these components on LH and RH sides for X
% dis-bonding, delamination and damage:
S The center section top and bottom shells.
S The outer faces of the front and rear main
bulkheads. Look specially in the area of the
bushes for the main pins.
S The front, middle and rear outer ribs.
S The main landing gear ribs.
% S The front and rear closing ribs.
S The rear web.
% 25. Examine the inner faces of the front and rear main X
bulkheads with the wings removed. Look specially in
the area of the bushes for the main bolts. (See also
Paragraph 6).
% 26. Install the access panels for the main landing gear X X
legs. (Refer to Section 52-40).
% 27. Install the wheel fairings. X* X X X
% 28. Remove the access panel for the nose landing gear X X
leg. (Refer to Section 52-40).
% 29. Examine the nose-wheel assembly. Look specially X X
for incorrect attachment, cracks and deformation.
% 30. Examine the nose-gear journal-bearings in the X X
bottom of the fuselage. Look specially for play.
% 31. Examine the journals in the elastomeric spring. Look X X X X
specially for play.
% 32. Examine the spherical bearing at the top of the X X X X
elastomeric spring. Look specially for play.
% 33. Examine the elastomeric spring. Look specially for: X X X X
S Looseness. Tighten if necessary. (Refer to
Section 32-20).
S Damage. Replace elastomer donuts if necessary.
(Refer to Section 32-20).
Page 4 Doc # 6.02.15
15 Apr 2013 05-28-50 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 34. Examine the elastomer pack center tube: X X
S Remove elastomer pack. (Refer to
Section 32-20).
S Remove elastomer elements. (Refer to
Section 32-20).
S Check center tube. If center tube shows signs of
wear or deformation replace center tube. No
asymmetric wear allowed.
S Replace the elastomer elements in the event that
they are worn or cracks are found. (Refer to
Section 32-20).
S Adjustment and installation of damper. (Refer to
Section 32-20).
35. Examine the nose-wheel fork. Do a test for play and X X X
caster friction. (Refer to Section 32-20):
S The friction force should be 30 - 50 N
(6.75 - 11.25 lbf) at the axle.
36. Examine all fuel system components: X X X X
S Look specifically for signs of leakage and
damage, chafings, or material deterioration.
S Make sure they are correctly attached.
37. Examine the gascolator: X X X X
S Remove and clean the fuel filter bowl.
S Install the filter bowl. (Refer to Section 28-20).
S Do a check for fuel leakage.
% 38. Examine the fuel pump electrical cables. Look X* X X X
specially for rub marks.
% 39. Examine the top hat profile and the closing rib. Look X
specially for dis-bonding, delamination and damage.
Doc # 6.02.15 Page 5
Rev. 2 05-28-50 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 40. Install the access panel for the nose landing gear X X
leg. (Refer to Section 52-40).
2. Cockpit
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 1. Remove the front seats and the access panels in rear X* X X X
seat (if installed). (Refer to Section 25-10).
% 2. Remove the rear seat shells. X X
(Refer to Section 25-10).
% 3. Examine the seats for damage. X* X X X
% 4. Examine the safety belts. Make sure the lock X* X X X
mechanism operates correctly:
S Insert the tongue into the buckle.
S Pull on the strap. Make sure the ratchet holds the
tongue in the buckle.
S Operate the release button. The tongue must pull
freely from buckle.
% 5. Examine the cable ties and electrical connectors. Pull X* X X X
lightly to make sure they are not loose.
% 6. Examine the control sticks. Make sure that the control X* X X X
stick attachments are not loose and do not catch.
% 7. Examine the control stick stops. X* X X X
% 8. Examine the aileron and elevator control system. X* X X X
Look specially for incorrect attachment and loose or
missing lock devices. (Refer to Sections 27-10 and
27-30).
% 9. Examine the Pitot-static system water traps. X* X X X
% 10. Examine the stall-warning hose. Look specially for X* X X X
% contamination by water. (Refer to Section 27-39).
Page 6 Doc # 6.02.15
15 Apr 2013 05-28-50 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 11. Examine the rudder pedals. Look specially for: X* X X X
%
S Incorrect attachment and function.
%
(Refer to Section 27-20).
% 12. Examine the rudder pedals S-tube. Look specially for: X* X X X
% S Wear on cable inlets and outlets.
% S Wear in inner radius of tube (no deformation
% visible or tactile).
% (Refer to Section 27-20).
% 13. Examine the rudder cables and pulleys. Look X* X X X
specially for:
S Incorrect attachment and function.
(Refer to Section 27-20).
S Rub marks.
S Defective safety plates.
S Worn out pulleys.
% 14. Examine the brake pipes/hoses and components. X X X X
Look specially for leakage.
% 15. Examine the brake fluid reservoirs on the co-pilot's X* X X X
side. Make sure the fluid level is correct:
S The fluid level must be 12 mm to 25 mm (½ in to
1 in) below the top face of the reservoir filler hole.
% 16. Examine the instruments. Make sure that: X* X X X
S The markings are clear.
S The function is correct.
S Switches are correctly attached.
S The instrument lights operate correctly.
Doc # 6.02.15 Page 7
Rev. 2 05-28-50 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 17. Examine the placards. Make sure that: X* X X X
S They are not damaged.
S None are missing. (Refer to Chapter 11).
% 18. Remove the instrument panel cover. X* X X X
% 19. Examine the instrument panel. Make sure that: X* X X X
S The wiring is correctly attached.
S The instruments are correctly attached.
S The hoses are correctly attached.
S The circuit breakers are correctly attached.
S The cooling fans are operative and correctly
attached.
% 20. Examine the emergency battery system (if installed): X* X X X
S Measure the voltage of the emergency battery on
the EMERGENCY switch. Replace emergency
battery if the voltage is below 30 V.
% 21. Make sure that the seal on the EMERGENCY switch X X X X
% is intact.
% 22. Examine the alternate static valve. Make sure that: X* X X X
S The valve is correctly attached.
S The valve is not blocked.
S The hoses are correctly attached.
% 23. Examine the compass. Make sure that: X X X
S The compass is correctly attached.
S The fluid level is correct.
Page 8 Doc # 6.02.15
15 Apr 2013 05-28-50 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 24. Examine the controls in the center console. Make X* X X X
sure that for each control lever:
S There is full and free movement.
S There is no unusual play.
S The friction is correct.
% 25. Inspect universal joints in fuel selector shaft (upper X X
and lower) very carefully for:
S Excessive wear.
S Uneven movement.
S Pins not completely pressed in.
S Loose pins.
% 26. Examine the control cables in the center console: X* X X X
S Remove the retaining screws for the center
console cover plate.
S Lift the center console cover plate and visually
examine the cables. Look specially for wear and
kinks in the cables.
S Lower the center console cover plate into the
correct position, install the retaining screws.
% 27. Examine the trim control in the center console. Make X* X X X
sure that:
S There is full and free movement.
S There is no unusual play.
Doc # 6.02.15 Page 9
Rev. 2 05-28-50 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 28. If the autopilot system is installed, then examine the X* X X X
trim servo assembly. Look specially for:
S Wear and corrosion.
S Insecure attachment of servo.
S Damaged, deformed, or worn out cardan shaft
and chain gears.
(Refer to Section 22-10 for GFC 700 autopilot or
Section 22-11 for KAP 140 autopilot).
% 29. Examine the front cockpit structure. Look for X
dis-bonding, delamination and damage, specially to
these components:
S The fuselage shells.
S The firewall.
S The floor.
S The control bulkhead.
S The fuel pipe channels.
S The front main bulkhead.
S The rear main bulkhead.
% S The inner faces of the front and rear closing ribs.
% 30. Check for damage, cracks, delamination and X X
% disbonding from the fuselage skin. Inspect the
% following components:
% S Front and rear seat crash elements.
%
% 31. If the emergency axe (OÄM 40-326) is installed: X X X
S Check attachments for looseness.
S Check release mechanism for interference or
improper function.
Page 10 Doc # 6.02.15
15 Apr 2013 05-28-50 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
32. If the sun visors (OÄM 40-327) are installed: X X X
S Check for obvious damage.
S Check press-studs for lack of retention force.
3. Center Fuselage, Internal
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 1. Examine the fire extinguisher. Make sure that: X* X X X
S The fire extinguisher will release from the mounting
bracket.
S The fire extinguisher is full.
% 2. Examine the cabin baggage compartment. Look X* X X X
% specially for damage and insecure attachment. Inspect
% the following components:
% S Baggage compartment structure.
% S Baggage restraint net.
% S D-rings for the attachment of the baggage restraint
% net.
% S Door to the baggage extension.
% S Lid for the tray on the floor.
%
Doc # 6.02.15 Page 11
Rev. 2 05-28-50 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 3. If the autopilot system is installed, then examine the X* X X X
pitch servo assembly. Look specially for:
S Wear and corrosion.
S Insecure attachment of servo.
S Defective bridle cable assembly.
S Loose bridle cables or clamps on the elevator
push-rod.
(Refer to Section 22-10 for GFC 700 autopilot or
Section 22-11 for KAP 140 autopilot).
% 4. Examine the cable ties and electrical connectors. Pull X* X X X
lightly to make sure they are not loose.
% 5. Examine the push rod guides for the elevator push-rod. X* X X X
Look specially for incorrect attachment and
interference.
% 6. Examine the flap control mechanism on the aft main X* X X X
bulkhead. Look specially for:
S Damage and corrosion.
S Incorrect attachment and loose or missing lock
devices.
% 7. Examine the flap-actuator indicator and position X* X X X
switches. Look specially for incorrect attachment and
operation.
% 8. Examine the aileron control system on the aft main X* X X X
bulkhead. Look specially for:
S Damage and corrosion.
S Incorrect attachment and loose or missing lock
devices.
Page 12 Doc # 6.02.15
15 Apr 2013 05-28-50 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 9. If the autopilot system is installed, then examine the X* X X X
roll servo assembly. Look specially for:
S Wear and corrosion.
S Insecure attachment of servo.
S Defective bridle cable assembly.
S Loose bridle cables or clamps on the aileron push-
rod.
(Refer to Section 22-10 for GFC 700 autopilot or
Section 22-11 for KAP 140 autopilot).
% 10. Do a cable tension test of the rudder control cable. X* X X X
(Refer to Section 27-20).
% 11. Examine the center fuselage structure. Look for X
% dis-bonding, delamination and damage, specially to the
% fuselage shells.
% 12. Examine the baggage compartment frame. Look for X X
% dis-bonding, delamination and damage.
% 13. Do a coin-tap test for delamination of the center MSI
section of the top and bottom shells.
% 14. Examine the Garmin G1000 unit behind the baggage X* X X X
compartment frame, if installed. Look specially for:
S Insecure cable ties and connections.
S Insecure attachment.
% 15. Check the following components for wear and/or X* X X X
% corrosion, if installed:
%
S Servo.
%
% S Servo mount (capstan).
% S Bridge cable assemblies.
Doc # 6.02.15 Page 13
Rev. 2 05-28-50 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 16. If the RACC system (OÄM 40-316) is installed: X X X
Examine the RACC central unit. Look specially for:
S Defective bonding of side brackets.
S Incorrect attachment of mounting panel.
S Lack of mechanical stability of mounting panel.
S Insecure attachment of RACC components to
mounting panel.
S Insecure attachment of hoses, shrouds and cables.
% S Leakage of hoses.
% 17. If the RACC system (OÄM 40-316) is installed: X* X X X
Check the condenser and evaporator for
contamination and remove any accumulation of dust
and dirt.
Page 14 Doc # 6.02.15
15 Apr 2013 05-28-50 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
4. Rear Fuselage
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 1. Examine the complete surface of the rear fuselage. X* X X X
Look specially for damage (dents, cracks, holes and
delamination).
Examine the paint coat.
% 2. Do a coin-tap test for delamination of the fuselage MSI
shell.
% 3. If the RACC system (OÄM 40-316) is installed: X
Check structure in the area of the RACC inlets and
outlets for cracks, delamination and disbonding.
% 4. Examine the push rod guides for the elevator push-rod. X* X X X
Look specially for:
S Incorrect attachment.
S Interference.
% 5. Examine the rudder-control cables and turnbuckles. X* X X X
Look specially for:
S Corrosion and wear.
S Incorrect lock devices.
% 6. Examine the rear fuselage structure. Look for X
% dis-bonding, delamination and damage specially to
% these components:
%
S The fuselage shells.
%
% S Ring frames 1, 2 and 3.
% 7. Check static source holes for blockage. X X X X
Doc # 6.02.15 Page 15
Rev. 2 05-28-50 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 8. Examine the ECU backup battery: X* X X X
S Check for leakage, damage, insecure mounting,
and loose connectors.
S Measure voltage (minimum: 24.5 Volts).
% 9. If the RACC system (OÄM 40-316) is installed: X* X X X
Examine the RACC air inlets and outlets:
S Check the air inlet filter for contamination.
% S Check the air inlets and outlets on the LH and RH
% side of the upper fuselage and at the bottom.
% S Check the RACC compartment ventilation filter on
% LH side fuselage for contamination (if installed).
% S Check evaporator drain on the bottom for blockage
% (if installed).
% Check the compartment fan for incorrect operation
% (if installed).
Page 16 Doc # 6.02.15
15 Apr 2013 05-28-50 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
5. Tail
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 1. Examine the complete surface of the aft part of the X* X X X
fuselage, vertical stabilizer, and horizontal stabilizer.
Look specially for damage (dents, cracks, holes and
delamination).
Examine the paint coat.
% 2. Examine the lower fin. Look specially for: X X X X
S Damage to the bottom of the fin.
S Incorrect attachment.
% 3. Remove the rudder. (Refer to Section 55-40). X* X X X
% 4. Examine the inside of the vertical stabilizer. X
% 5. Inspect the inner skin of the vertical stabilizer through MSI
all access holes with mirror and flashlight. Check for
damage, cracks and delamination.
(Refer to Section 53-10).
% 6. Inspect the interior structure of the vertical stabilizer MSI
through all access holes with mirror and flashlight.
Check for damage, cracks, delamination and
disbonding from the vertical stabilizer skin. Look
specially at these components:
S Front web.
S Rear web.
S Lower rib (front and rear).
S Structure next to holes for mounting brackets.
(Refer to Section 53-10).
% 7. Examine the rudder mounting and control cable X* X X X
connections.
% 8. Examine the rudder support bracket. X* X X X
Doc # 6.02.15 Page 17
Rev. 2 05-28-50 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 9. Examine the bottom edge of the rudder. Look specially X* X X X
for cracks and deformation.
% 10. Examine the rudder-stop reinforcement bars. Look X* X X X
specially for cracks and corrosion.
% 11. Examine the trim mechanism. Look specially for: X* X X X
S Incorrect attachment.
S Wear.
% 12. Examine the trim tab for damage. Look specially for X* X X X
incorrect attachment and loose or missing lock devices.
(Refer to Section 55-20).
% 13. Adjust the friction of the trim mechanism. X* X X X
% 14. Examine the horizontal stabilizer: X* X X X
S Remove the fairing for the horizontal stabilizer.
S Examine the mounting brackets. Look specially at
the attachment bolts for corrosion.
(Refer to Section 55-10).
% 15. Remove the tips from the horizontal stabilizer: X
S Examine the interior of the horizontal stabilizer.
Look specially for dis-bonding, delamination and
damage to the shells, spars and ribs.
S Install the horizontal stabilizer tips.
(Refer to Section 55-10).
% 16. Remove the horizontal stabilizer. MSI
(Refer to Section 55-10).
% 17. Inspect the inner skin of the horizontal stabilizer MSI
through all access holes with mirror and flashlight.
Check for damage, cracks, delamination.
(Refer to Section 55-10).
Page 18 Doc # 6.02.15
15 Apr 2013 05-28-50 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 18. Inspect the interior structure of the horizontal stabilizer MSI
through all access holes with mirror and flashlight.
Check for damage, cracks, delamination and
disbonding from the horizontal stabilizer skin. Look
specially at these components:
S Front spar.
S Rear spar.
S Trailing edge web.
S Root rib (front, middle and rear).
S All interior ribs and stiffeners.
S Structure next to holes for mounting brackets.
(Refer to Section 55-10).
% 19. Examine the elevator for damage. Look specially for X X X X
incorrect attachment and loose or missing lock devices.
(Refer to Section 55-20).
% 20. Examine the elevator hinges and control horn. Look X* X X X
specially for too much play.
Play allowed:
S Axial ± 1.00 mm (± 0.04 in).
S Radial ± 0.25 mm (± 0.01 in).
% 21. Examine the elevator push-rod: X
S Remove the elevator push-rod which goes through
the rear fuselage.
S Look specially for rub marks.
S Install the push-rod.
(Refer to Section 27-30).
% 22. Examine the structure of the vertical stabilizer. Look X
specially for dis-bonding, delamination and damage to
the shells, spars and ribs.
Doc # 6.02.15 Page 19
Rev. 2 05-28-50 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 23. Inspect the inner skin of the rear fuselage through all MSI
access holes with mirror and flashlight. Check for
damage, cracks, delamination and disbonding from the
sandwich foam. (Refer to Section 53-10).
% 24. Inspect the interior structure of the rear fuselage MSI
through all access holes with mirror and flashlight.
Check for damage, cracks, delamination and
disbonding from the fuselage skin. Look specially at
these components:
S Ring frames 1, 2 and 3.
% 25. Install the horizontal stabilizer. MSI
(Refer to Section 55-10).
% 26. Install the fairing for the horizontal stabilizer. X* X X X
(Refer to Section 55-10).
% 27. Install the rudder. (Refer to Section 55-40). X* X X X
Page 20 Doc # 6.02.15
15 Apr 2013 05-28-50 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
6. Wings
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 1. Examine the complete surface of the wings. Look X* X X X
specially for damage (dents, cracks, holes and
delamination).
Examine the paint coat.
% 2. Examine the ailerons. Look specially for damage X* X X X
(dents, cracks, holes and delamination).
% 3. Examine the aileron hinges and horn. Look specially for X* X X X
too much play.
Play allowed:
S Axial ± 1.00 mm (± 0.04 in).
S Radial ± 0.25 mm (± 0.01 in).
% 4. Examine the aileron mass balance. X* X X X
% 5. Examine the flaps. Look specially for damage (dents, X* X X X
cracks, holes and delamination).
% 6. Examine the flap hinges and horn. Look specially for X* X X X
too much play.
Play allowed:
S Axial ± 1.00 mm (± 0.04 in).
S Radial ± 0.25 mm (± 0.01 in).
% 7. Examine the flap mass balance. X* X X X
Doc # 6.02.15 Page 21
Rev. 2 05-28-50 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 8. Remove the flap and aileron bellcrank access panels in X* X X X
the wing (Refer to Section 52-40).
S Examine the aileron and flap control system. Look
specially for incorrect attachment and loose or
missing lock devices (Refer to Sections 27-10 and
27-50).
S Visually check fuel tank bonding system through
access panels for improper connections and
damaged strips.
S Install the access panels.
% 9. Examine the Pitot head. Look specially for: X X X X
S Incorrect attachment.
S Damage.
S Foreign objects.
% 10. Remove the winglets. (Refer to Section 57-10). X
% 11. Remove the wings. (Refer to Section 57-10): X
S Examine the main bolts.
S Grease the main bolts.
S Examine the A-bolts.
S Grease the A-bolts.
S Examine the B-bolts.
S Grease the B-bolts.
(Refer to Section 12-20).
% 12. Inspect the inner wing skin through all access holes MSI
with mirror and flashlight. Check for damage, cracks,
delamination and disbonding from the sandwich foam.
(Refer to Section 57-10).
Page 22 Doc # 6.02.15
15 Apr 2013 05-28-50 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 13. Inspect the interior structure of the wing through all MSI
access holes with mirror and flashlight. Check for
damage, cracks, delamination and disbonding from the
wing skin. Look specially at these components:
S Front spar.
S Rear spar.
S Rear web.
S Root rib (front, middle and rear).
S End rib.
S All interior ribs and stiffeners.
(Refer to Section 57-10).
% 14. Inspect the wing shells: X
S Look carefully for signs of damage.
S Look for dis-bonding between the shells and each
spar, rib and web.
S Do a coin-tap test for delamination of the shells.
(Refer to Section 51-10 and 57-10).
% 15. Examine the aileron push-rods: X
S Remove the aileron push-rods from the wings.
S Look specially for rub marks.
S Install the aileron push-rods.
(Refer to Section 27-10).
% 16. Examine the flap push-rods: X
S Remove the flap push-rods from the wings.
S Look specially for rub marks.
S Install the flap push-rods.
(Refer to Section 27-50).
Doc # 6.02.15 Page 23
Rev. 2 05-28-50 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE. DO
NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN CAUSE
INJURY TO PEOPLE AND DAMAGE TO EQUIPMENT.
% 17. Examine the fuel tank outlets: X
S Clean the finger filters.
S Look for foreign matter.
S Look for defective lock wire.
% 18. Remove the access covers. X X X
% 19. Check condition of tank interconnecting hoses. X X X
% 20. Check for leaks. X X X X
% 21. Collect a drain sample: X X X X
% S If sample is contaminated flush tank with removed
% drain valve.
%
% 22. Flush the tank: X X
% S Remove the drain valve.
% S Flush the fuel tank.
% S Check for debris and foreign objects.
% S Install the drain valve.
%
% 23. Install the access covers. X X X
% 24. Examine the fuel tank vents for blockage. X* X X X
% S Open fuel filler cap and carefully blow through the
% LH-forward and RH-aft vent lines from outside into
% the tank with compressed air.
Page 24 Doc # 6.02.15
15 Apr 2013 05-28-50 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 25. Examine the fuel tanks: X
S Remove the fuel tanks.
S Look specially for corrosion, leaks and other
damage.
S Look for foreign objects in the tanks.
S Look for material deterioration or damage of the
flexible fuel hoses connecting the fuel tank
chambers.
S Install the fuel tanks.
(Refer to Section 28-10).
% 26. Install the wings. (Refer to Section 57-10). X
% 27. Do a function test of the fuel low-level switch: X X
S Set the ELECTRIC MASTER key switch to ON.
S The FUEL LOW on the G1000 (if installed) or
LOW FUEL on the White Wire annunciator panel
(if installed) caution message must appear.
S Set the ELECTRIC MASTER key switch to OFF.
% 28. Examine the strobe and position lights for excessive X* X X X
% scratches, discoloration or cracking on the lens.
% 29. Install the winglets. (Refer to Section 57-10). X
Doc # 6.02.15 Page 25
Rev. 2 05-28-50 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
7. General
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 1. If necessary, inspect optional equipment. Refer to X X X X
Chapter 9 of the Airplane Flight Manual (Supplements).
% 2. If necessary, inspect additional equipment (equipment X X X X
which is installed but is not listed in Section 6.5 of the
Airplane Flight Manual).
% 3. Lubricate the airplane. (Refer to Section 12-20). X X X X
% 4. Measure the play in the aileron and elevator controls X* X X X
with the control surfaces locked. (Refer to Section
27-30).
Look specially for too much play. Do the test at the top
of the control stick.
S Maximum play allowed ± 2.5 mm (± 0.1 in).
(Refer to Section 27-10).
% 5. Check flight controls and engine controls for improper X* X X X
% operation and installation.
% 6. Do a function test of the aileron control system. X
(Refer to Section 27-10).
% 7. Do a function test of the rudder control system. X
(Refer to Section 27-20).
% 8. Do a function test of the elevator control system. X
(Refer to Section 27-30).
% 9. Do a function test of the trim-system. Look specially for X
incorrect operation and indication.
(Refer to Section 27-38).
Page 26 Doc # 6.02.15
15 Apr 2013 05-28-50 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 10. Do a function test of the flap system. X
(Refer to Section 27-50).
Look specially at the pre-load. With the flaps set to UP:
S Correct pre-load 3 - 5 daN (6.7 - 11.2 lbf).
% 11. Lower the airplane off jacks. X* X X X
(Refer to Section 07-10).
% 12. Do an operational test of the external lights. X* X X X
% 13. Do an operational test of the Pitot heat. X* X X X
% 14. Examine the airplane. Look specially for loose items X X X X
and tools. Close all access panels. Install these items:
S Engine cowling.
S The instrument panel cover.
S The seat shells.
S The control-stick boots.
WARNING: DO NOT LET PERSONS INTO THE DANGER AREA OF THE
PROPELLER. PROPELLERS CAN CAUSE INJURY OR DEATH.
WARNING: SET THE PARKING BRAKE TO ON. IF YOU DO NOT DO THIS THE
AIRPLANE CAN MOVE. THIS CAN CAUSE INJURY OR DEATH.
% 15. Put the chocks against the main airplane wheels. X X X X
% 16. Do the post maintenance engine test: X X X X
S For the engine run procedures refer to the Airplane
Flight Manual.
S Record the data. Refer to AE Maintenance Manual,
latest revision.
% 17. Examine the engine for leakage. X X X X
Doc # 6.02.15 Page 27
Rev. 2 05-28-50 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items 100 200 1000 2000 Time Initials
% 18. Make sure the engine oil filter is tight. X X X X
Refer to Section 79-00 or AE Maintenance Manual,
latest revision.
% 19. Do a test flight. Put the engine ground test and the flight X* X X X
test reports in the Airplane Maintenance Log.
% Note: If a Maintenance Check was done, complete the Maintenance Report. Refer to
Section 05-28-90.
% Note: If a Major Structural Inspection (MSI) was done, complete the Findings Report for
the Major Structural Inspection (MSI). Refer to Section 05-28-93.
Page 28 Doc # 6.02.15
15 Apr 2013 05-28-50 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Section 05-28-90
Maintenance Report
1. Maintenance Report
Complete a copy of the Maintenance Report after all of the applicable maintenance tasks in the
Maintenance Checklist have been initialed.
DA 40 NG
Airplane Serial Number: Registration Number:
Check: __________ (50 hr., 100 hr., 200 hr., 1000 hr., Annual)
REMARKS:
The airplane is airworthy with respect to its maintenance condition.
_________________ _________________ _________________
Place Date Authorized
Doc # 6.02.15 Page 1
Rev. 2 05-28-90 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 05-28-90 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Section 05-28-91
Engine Ground Test Report
1. Engine Ground Test Report
Do the engine test in accordance with Section 71-00 and record results and comments.
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
THE PROPELLER CAN CAUSE DEATH OR INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
TURN THE PROPELLER. MAKE SURE THAT:
- THE ELECTRIC MASTER KEY SWITCH IS SET TO "OFF".
- THE ENGINE MASTER SWITCH IS SET TO "OFF".
- THE POWER LEVER IS SET TO "IDLE".
WARNING: DO NOT GET OIL ON YOU. OIL CAN CAUSE SKIN DISEASE.
WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE. DO
NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN CAUSE
INJURY TO PEOPLE AND DAMAGE TO EQUIPMENT.
WARNING: WHEN YOU COMPLETE AN INSPECTION, MAKE SURE THAT YOU
REMOVE ALL LOOSE ITEMS/TOOLS FROM THAT AREA. LOOSE
ITEMS/TOOLS CAN PREVENT FULL MOVEMENT OF THE AIRPLANE
CONTROLS. THIS CAN CAUSE DEATH OR INJURY TO PERSONS.
CAUTION: YOU MUST ATTACH BLANKS/CAPS TO HOLES/PIPES WHEN YOU
REMOVE COMPONENTS. IF YOU DO NOT DO THIS, UNWANTED
DEBRIS CAN ENTER THE HOLES/PIPES. THIS CAN CAUSE
BLOCKAGE TO THE AIRPLANE SYSTEMS.
Doc # 6.02.15 Page 1
Rev. 2 05-28-91 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 05-28-91 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Section 05-28-92
Check Flight Report
1. Check Flight Report
CHECK FLIGHT DA 40 NG
AIRCRAFT
(See Maintenance Checklist for Applicability) Page 1 of 4
Registration: Pilot: Airdrome:
Date: Take-Off: Landing:
Findings
Functional Check, Flight Behavior
N/A NO YES
Fuel quantity indicators
Strobe lights (ACL), navigation lights
Warning, caution and status lights
Altimeter(s) (including G1000, if installed), QNH adjustment;
autopilot: QNH adjustment (if KAP 140 is installed)
Airspeed indicators (including G1000, if installed)
Vertical speed indicator (including G1000, if installed)
Attitude, Bank indicator (including G1000, if installed)
Compass (G1000, if installed: slaved directional gyro; magnetic compass)
Radio, radio check
Audio panel, intercom
Navigational instruments
G1000 reversionary mode (if installed)
Fuel transfer pump
Fuel pumps
Starter behavior
Engine starting behavior, cold
Oil pressure indicator
Fuel temperature indicator
Fuel flow indication
RPM indicator
Doc # 6.02.15 Page 1
Rev. 2 05-28-92 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
CHECK FLIGHT DA 40 NG
AIRCRAFT
(See Maintenance Checklist for Applicability) Page 2 of 4
Registration: Pilot: Airdrome:
Date: Take-Off: Landing:
Findings
Functional Check, Flight Behavior
N/A NO YES
Engine oil temperature indicator
Coolant temperature indicator
Gearbox temperature indicator
Instrument lighting
Flood light
Map light, overhead
G1000 manual dim (if installed)
Parking brake
Wing flaps
Power lever
Taxiing behavior, take-off behavior
Behavior during climb
Alternate static valve
Alternate air valve
OAT indicator
Chronometer (clock)
Transponder, modes A and C
VOR, CDI
ADF (if installed)
DME (if installed)
GPS, GPS annunciation control unit (if installed)
Page 2 Doc # 6.02.15
15 Apr 2013 05-28-92 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
CHECK FLIGHT DA 40 NG
AIRCRAFT
(See Maintenance Checklist for Applicability) Page 3 of 4
Registration: Pilot: Airdrome:
Date: Take-Off: Landing:
Findings
Functional Check, Flight Behavior
N/A NO YES
Autopilot (if GFC 700 is installed):
S HDG mode.
S FD.
S FLC mode.
S GA (go around) mode.
S NAV mode (if required).
S ALT / VS preselect and hold.
S CWS (control wheel steering) button.
S Disconnect (red button).
Autopilot (if KAP 140 is installed):
S HDG mode.
S Wings level mode.
S NAV mode (if required).
S ALT / VS preselect and hold.
S CWS (control wheel steering) button.
S Disconnect (red button).
Cabin heat / cabin air
Behavior during high-speed flight
Longitudinal trim / trim range
Directional trim
Lateral trim
Behavior during slow-speed flight
Doc # 6.02.15 Page 3
Rev. 2 05-28-92 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
CHECK FLIGHT DA 40 NG
AIRCRAFT
(See Maintenance Checklist for Applicability) Page 4 of 4
Registration: Pilot: Airdrome:
Date: Take-Off: Landing:
Findings
Functional Check, Flight Behavior
N/A NO YES
Pitot heat
Stall warning
Localizer, glideslope
Marker beacon receiver (if installed)
Landing behavior
Engine starting behavior, warm
Engine shut-down behavior
Remarks:
(Pilot)
Page 4 Doc # 6.02.15
15 Apr 2013 05-28-92 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Section 05-28-93
Major Structural Inspection Check Findings Report
1. General
Complete the Findings Report and report the following:
) Defects found during the Major Structural Inspection (MSI).
% ) Structural defects found during the associated 2000 hour inspection.
) All structural defects that were detected and repaired since new or since the last Major
Structural Inspection (MSI).
Send a copy of the completed Findings Report to the manufacturer:
Diamond Aircraft Industries
Office of Airworthiness
N.A.Otto-Str. 5
A-2700 Wr. Neustadt
Austria
by mail, fax (+43-2622-26780) or e-mail ([email protected]).
Note: The manufacturer will use the completed Findings Reports for the continuous
improvement of the checklist for the Major Structural Inspection (MSI).
Doc # 6.02.15 Page 1
Rev. 2 05-28-93 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Enter the applicable data in the blocks below:
FINDINGS REPORT DA 40 NG
AT MAJOR STRUCTURAL INSPECTION (MSI)
Registration : __________________ Date : _______________
Airplane
Airplane S/N : _________________
Operating Hours : _______________
AMM Rev.
Maintenance used for check : _______________
Organization:
Signature : _______________
no. defect/finding repair method, remarks at TSN
Page 2 Doc # 6.02.15
15 Apr 2013 05-28-93 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
no. defect/finding repair method, remarks at TSN
All defects have been repaired. The airplane is airworthy with respect to its maintenance condition.
Place: _____________________________________
Date: _____________________________________
Authorized: _____________________________________
Doc # 6.02.15 Page 3
Rev. 2 05-28-93 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 05-28-93 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Section 05-50
Unscheduled Maintenance Checks
1. General
Unscheduled maintenance checks are necessary after any incident that could cause damage to the
airplane.
2. Hard Landing Check
Figure 1 shows the hard landing check areas. You must do a hard landing check when the pilot makes
a report of a hard landing or when ground handling applies unusual loads.
A. Equipment
Item Quantity Part No.
Slide sheets. 4 Commercial.
B. Procedure
Detail Steps/Work Items Key Items
(1) Remove the access panels for the main and Refer to Section 52-40.
nose landing gear.
(2) Examine the landing gear fittings. Look specially Use a mirror and a flashlight.
for cracks.
(3) Examine the fuselage structure where the Refer to Section 32-10.
landing gear attaches. Look specially for:
S Delamination of the GFRP structure.
S Damage to the mounting brackets.
(4) Examine the landing gear struts. Look specially Refer to Section 32-10.
for:
S Bending.
S Cracks.
(5) Do a test of the wheel tracking. Refer to Section 32-10.
(6) Examine the tires. Look specially for cuts in the Refer to Section 32-40.
side walls.
Doc # 6.02.15 Page 1
Rev. 2 05-50-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Detail Steps/Work Items Key Items
(7) Examine the wheel rims. Look specially for
cracks and deformation of the flanges.
(8) Examine the brake discs. Look specially for
damage. Turn the wheel and make sure the disc
is not bent.
(9) Examine the nose-gear assembly. Look specially
for:
S Deformation of the upper cross bar of the
engine mount.
S Nose wheel strut axle area.
(10) Examine the elastomer pack center tube for Refer to Section 32-20.
bending:
S Remove elastomer pack.
S Remove elastomer elements.
S Check center tube. If center tube shows
signs of wear or deformation replace center
tube. No asymmetric wear allowed.
S Replace the elastomer elements in the event
that they are worn or cracks are found.
S Adjustment and installation of damper.
CAUTION: IF YOU THINK THE AIRPLANE HAS DAMAGE TO AN AREA THAT
TRANSMITS A LOAD, YOU MUST ASK THE AIRPLANE
MANUFACTURER FOR ADVICE.
(11) Examine the top hat profile and its closing rib in
the bottom of the fuselage for delamination and
disbonding. Look specially in the area of the
bearings for the nose-gear assembly.
(12) Remove the load from the nose-gear and
examine it. Look specially for more than the
usual play.
Page 2 Doc # 6.02.15
15 Apr 2013 05-50-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Detail Steps/Work Items Key Items
(13) Examine the control surfaces. Look specially for:
S Correct attachment of the hinges.
S Correct attachment of the mass balance to
the structure.
(14) Examine the leading edge of the wing for
damage.
(15) Examine the area of the spar attachments to the
wing shells. Look specially for cracks.
(16) Examine the leading edge of the horizontal and
vertical stabilizers for damage.
(17) Examine the engine mount.
(18) Examine the engine mount points on the firewall.
(19) Examine the propeller. Look specially to see if
the propeller has touched the ground.
Doc # 6.02.15 Page 3
Rev. 2 05-50-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
%
%
%
%
A
%
%
%
%
%
%
% B
%
A
Firewall
% Top Hat Profile
%
% Closing Rib
%
Bearings for Nose Gear Assembly
%
% Nose Gear Assembly
%
%
Rear Main Bulkhead
%
Front Closing Rib
% Main Landing
Gear Rib
%
% Reinforcement Rib
(if installed)
%
%
%
%
% B
% Inner Mounting
%
Outer Mounting Front Main
% Bulkhead
%
Main Landing Gear Leg
%
%
%
%
%
Figure 1: Hard Landing Check Areas
Page 4 Doc # 6.02.15
15 Apr 2013 05-50-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
3. Propeller Strike
A propeller strike can be a moving propeller (engine running) which has hit a solid object. Or it can be
a moving object that hits a propeller that is not moving.
A. Propeller Strike with the Engine Running
If the propeller has hit a solid object while the engine was running:
Detail Steps/Work Items Key Items
(1) Remove the propeller. Refer to Chapter 61.
(2) Remove engine.
Refer to Chapter 71-00 and contact AE.
(3) Do an inspection of the engine mount. Refer to Section 71-20.
(4) Do an inspection of the propeller. Refer to the mt-Propeller Owner's
Manual, latest revision.
B. Propeller Hit by a Moving Object
If a propeller which is not moving is hit by a moving object:
Detail Steps/Work Items Key Items
(1) Do an inspection of the propeller. Refer to the mt-Propeller Owner's
Manual, latest revision.
If the propeller must be removed to do a repair
other than minor dressing of the blades, you
must do the inspection procedure specified for a
moving propeller strike.
(2) Inspect the airplane for damage.
Doc # 6.02.15 Page 5
Rev. 2 05-50-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
4. Engine Fire
WARNING: BEFORE YOU DO WORK ON THE AIRPLANE MAKE SURE THE FIRE
HAS BEEN EXTINGUISHED. LET THE ENGINE COOL AND
DISCONNECT THE BATTERY.
WARNING: FIRE CAN SERIOUSLY WEAKEN CFRP. IF YOU FIND ANY DAMAGE TO
CFRP, DO NOT OPERATE THE AIRPLANE. ASK THE MANUFACTURER
FOR ADVICE.
Detail Steps/Work Items Key Items
(1) Remove the engine cowlings. Refer to Section 71-10.
(2) Disconnect the airplane batteries (main battery Refer to Section 24-31.
and ECU backup battery).
(3) Examine the engine cowlings. Look specially for
signs of fire damage.
(4) Examine the electrical cables. Look specially for Replace damaged cables.
signs of fire damage.
(5) Examine the fuel lines. Look specially for signs Replace damaged fuel lines.
of fire damage to the fire-protection sleeves.
(6) Examine the engine oil lines. Look specially for Replace damaged oil lines.
signs of fire damage to the fire-protection
sleeves.
(7) Examine the engine. Look specially for: Make a record of the damage you find
and ask the engine manufacturer for
S Damage to the engine air filter.
advice before you repair or operate the
S Damage to gaskets and seals. engine.
S Damage to the engine shock mounts.
S Damage to the engine mount.
S Damage to pipes/hoses.
Page 6 Doc # 6.02.15
15 Apr 2013 05-50-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Detail Steps/Work Items Key Items
(8) Examine the fuselage compartment. Look
specially for:
S Blisters on the paint or burn marks.
S Disbonding of the nacelle skin from the
firewall.
If you find any damage, ask the airplane
manufacturer for advice.
WARNING: DO NOT GET FIRE EXTINGUISHER PARTICLES ON YOU. THE
CHEMICALS USED TO EXTINGUISH A FIRE CAN BE
CAUSTIC/POISONOUS. WHEN YOU CLEAN THE ENGINE REFER TO
THE FIRE EXTINGUISHER MANUFACTURER'S SAFETY
INSTRUCTIONS. USE SAFETY MASKS AND GLOVES AS
RECOMMENDED.
(9) Clean the engine. Make sure you clean all the Refer to the manufacturer of the fire
fire extinguisher particles from the engine. extinguisher.
(10) Connect the airplane batteries (main battery and Refer to Section 24-31.
ECU backup battery).
(11) Trouble-shoot the engine. Find the cause of the Ask the engine manufacturer for advice
engine fire. Repair the defect if possible. before you repair or operate the engine.
(12) Install the engine cowlings. Refer to Section 71-10.
(13) Do an engine test. Refer to the AE Maintenance Manual,
latest revision.
Doc # 6.02.15 Page 7
Rev. 2 05-50-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
5. Lightning Strike
A lightning strike usually enters the airplane at one point and leaves the airplane at another point.
These points are called "attachment points". You usually find these points at the extremities of the
airplane. You will often find the most damage to the airplane occurs at the attachment points. There
can be more than two attachment points.
When a lightning strike is reported you must do the inspection procedure at Sub-paragraph D before
the next flight.
A. Group 1 Damage
Group 1 damage is the direct damage caused by the lightning strike. To find this damage you must
carefully examine all the external surface of the airplane. Look specially for burn marks, holes,
discoloration or other physical damage. If you find this damage you must remove panels or
equipment to look for damage on the inside of the airplane. Look specially around the area of the
external damage.
You must also examine the airplane lightning protection system. Look specially for signs of heat
damage or distortion to the conduction tubes and bonding strips. Also look for heat damage in the
structures around the conduction tubes and bonding strips. Refer to Section 51-80 for data about
the lightning protection system.
B. Group 2 Damage
Group 2 damage is the indirect damage caused by the lightning strike. It is mostly caused by the
electromagnetic fields associated with lightning strikes. The electromagnetic fields can induce
temporary voltages into the wiring system. These temporary voltages can cause damage to the
electrical and electronic components of the airplane. Refer to the Wiring Diagrams for data about
the electrical wiring.
Note: If you find any lightning damage you must make a record of the damage
and ask Diamond Aircraft for advice before you repair or operate the
airplane.
Page 8 Doc # 6.02.15
15 Apr 2013 05-50-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
C. Equipment
Item Quantity Part No.
Bonding tester. 1 Commercial.
D. Lightning Strike Inspection
Detail Steps/Work Items Key Items
(1) Examine the surface of the complete fuselage If you find any damage you must
assembly. Look specially in these areas: examine the airplane internally, specially
in the area of the external damage.
S Propeller and spinner.
Make a record of the damage you find
S Exhaust pipes. and ask Diamond Aircraft for advice
S Engine breather. before you repair or operate the
airplane.
S Canopy handles.
If you find any sign of a lightning strike
S Antennas.
on the propeller, spinner, exhaust pipe
S Static discharge wicks. or engine breather remove the engine
S Vertical fin tip. from the airplane and send it back to
Austro Engine GmbH.
S Rudder.
Refer to Section 71-00 for engine
S Lower fin. removal.
Doc # 6.02.15 Page 9
Rev. 2 05-50-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Detail Steps/Work Items Key Items
(2) Examine the surface of the left wing for lightning If you find any damage you must
damage. Look specially in these areas: examine the airplane internally, specially
in the area of the external damage.
S Pitot head.
Make a record of the damage you find
S Static discharge wicks. and ask Diamond Aircraft for advice
S Wing tip. before you repair or operate the
airplane.
S Strobe lights.
S Wing tip light assembly.
S Wing trailing edge.
S Aileron trailing edge.
S Flap trailing edge.
S Aileron horn.
S Flap horn.
(3) Examine the surface of the right wing for If you find any damage you must
lightning damage. Look specially in these areas: examine the airplane internally, specially
in the area of the external damage.
S Wing tip.
Make a record of the damage you find
S Static discharge wicks. and ask Diamond Aircraft for advice
S Strobe lights. before you repair or operate the
airplane.
S Wing tip light assembly.
S Wing trailing edge.
S Aileron trailing edge.
S Flap trailing edge.
S Aileron horn.
S Flap horn.
Page 10 Doc # 6.02.15
15 Apr 2013 05-50-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Detail Steps/Work Items Key Items
(4) Examine the surface of the horizontal stabilizer If you find any damage you must
for lightning damage. Look specially in these examine the airplane internally, specially
areas: in the area of the external damage.
Make a record of the damage you find
S Horizontal stabilizer tip.
and ask Diamond Aircraft for advice
S Static discharge wicks. before you repair or operate the
S Trailing edge. airplane.
S Elevator trailing edge.
S Trim tab.
(5) Examine the main landing gear. Look specially in Refer to Section 32-10.
these areas:
S Wheel fairings.
S Main gear leg attachment points.
(6) Examine the nose landing gear. Look specially in Refer to Section 32-20.
these areas:
S Wheel fairing.
S Nose gear attachment points.
(7) Operate the flight controls through their complete Refer Section 27-00.
range of movement. Look specially for:
S Stiff or unusual feel during movement.
S Restriction of movement.
S Noisy operation.
Doc # 6.02.15 Page 11
Rev. 2 05-50-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Detail Steps/Work Items Key Items
(8) Examine the metal conduction tubes and Make a record of any damage you find
bonding strips in the fuselage and in the wings. and ask Diamond Aircraft for advice
Look specially for: before you repair or operate the
airplane.
S Heat damage or discoloration.
S Fusion of bonding joints.
S Burn or scorch marks to the structure around
the conduction tubes. Refer to Section 51-80.
Use the bonding tester when you are not able to
see the whole length of a tube or bonding strip.
Follow the instructions of the tester
manufacturer. The resistance must be in
accordance with Section 51-80.
(9) Do a test of these lighting systems:
S External lights: Refer to Section 33-40.
S Navigation lights.
S Strobe lights.
S Landing light.
S Taxi light.
S Internal lights:
S Instrument panel lights. Refer to Section 33-10.
S Instrument flood lights.
S Dome lights.
(10) Do a test of the Pitot heat system. Refer to Section 34-10.
(11) Do a test of the Garmin G1000 system Refer to the Garmin G1000 Line
(if installed): Maintenance Manual, latest revision.
S Check all functions on the G1000 system.
Page 12 Doc # 6.02.15
15 Apr 2013 05-50-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
Detail Steps/Work Items Key Items
(12) Do a test of these communication systems:
S COM VHF.
S Intercom.
(13) Do a test of these attitude and direction systems:
S Magnetic compass.
S Directional gyro.
S Artificial horizon.
S Turn & bank indicator.
(14) Operate the engine power controls through their Refer to Section 76-10.
range of movement. Look specially for:
S Stiff or unusual feel during movement.
S Restriction of movement.
S Noisy operation.
(15) Do a visual check of engine bondings and
wirings.
(16) Operate the cockpit heating controls through Refer to Section 21-40.
their range of movement. Look specially for:
S Stiff or unusual feel during movement.
S Restriction of movement.
S Noisy operation.
(17) Operate the parking brake control through its Refer to Section 32-40.
range of movement. Look specially for:
S Stiff or unusual feel during movement.
S Restriction of movement.
S Noisy operation.
Doc # 6.02.15 Page 13
Rev. 2 05-50-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Detail Steps/Work Items Key Items
(18) Do an engine run-up. Look specially for Refer to Section 71-00.
abnormal operation of the following systems:
S Engine indicating systems.
Refer to Section 31-00.
S DC generation.
Refer to Section 24-30.
(19) Do an ECU test. Refer to Section 71-00.
(20) Do an ECU VOTER test. Refer to Section 71-00.
(21) Contact the engine manufacturer.
(22) Do a compass check swing.
6. Over Temperature
Detail Steps/Work Items Key Items
(1) Check the fluid level and leakage.
(2) Check data and oil sample and send it to Austro
Engine GmbH.
7. High Oil Consumption
Detail Steps/Work Items Key Items
(1) Check engine for oil leakage.
(2) Check the compression.
Page 14 Doc # 6.02.15
15 Apr 2013 05-50-00 Rev. 2
Time Limits and
DA 40 NG AMM
AIRCRAFT Maintenance Checks
8. Oil Pressure Loss
Detail Steps/Work Items Key Items
(1) Check the oil quantity.
(2) Check the indication.
(3) Check the wiring.
(4) Check if negative g-load flights have been
conducted. (Visual inspection of the breather
outlet for oil contamination).
9. Hang Start
Detail Steps/Work Items Key Items
(1) Check voltage.
(2) Check battery condition.
(3) Read out data and send to Austro Engine
GmbH.
Doc # 6.02.15 Page 15
Rev. 2 05-50-00 15 Apr 2013
Time Limits and
DA 40 NG AMM
Maintenance Checks AIRCRAFT
Intentionally left blank
Page 16 Doc # 6.02.15
15 Apr 2013 05-50-00 Rev. 2
DA 40 NG AMM Dimensions and Areas
AIRCRAFT
CHAPTER 06
DIMENSIONS AND AREAS
Doc # 6.02.15 Page 1
Rev. 2 06-TITLE 15 Apr 2013
Dimensions and Areas DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 06-TITLE Rev. 2
DA 40 NG AMM Dimensions and Areas
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 06
DIMENSIONS AND AREAS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Adjustment Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Weight and Static Moments of Control Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Doc # 6.02.15 Page 1
Rev. 2 06-CONTENTS 15 Apr 2013
Dimensions and Areas DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 06-CONTENTS Rev. 2
DA 40 NG AMM Dimensions and Areas
AIRCRAFT
CHAPTER 06
DIMENSIONS AND AREAS
1. General
The DA 40 NG uses the System Internationale (SI) for dimensions and areas. Imperial dimensions are
also given in brackets. For example: Wing span 11.63 m (38.16 ft).
Conversions between SI units and imperial units are given in Chapter 02.
Doc # 6.02.15 Page 1
Rev. 2 06-00-00 15 Apr 2013
Dimensions and Areas DA 40 NG AMM
AIRCRAFT
2. Dimensions
%
Propeller:
% Ø 1.90 m (74.8 in)
%
%
%
%
%
2.97 m (9.7 ft)
%
% 11.63 m (38.15 ft)
%
% 8.06 m (26.4 ft)
%
1.97 m (6.5 ft)
%
%
%
% Ground Line, Static
%
3.29 m (10.8 ft)
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
Figure 1: DA 40 NG, Overall Dimensions (Approximate Values)
Page 2 Doc # 6.02.15
15 Apr 2013 06-00-00 Rev. 2
DA 40 NG AMM Dimensions and Areas
AIRCRAFT
DA 40 NG
Overall Dimensions
Wing span 11.63 m (38.16 ft)
Length 8.06 m (26.44 ft)
Height (nominal) 1.97 m (6.46 ft)
Wing
Airfoil Wortmann FX 63-137/20-W4
Wing area 13.244 m² (142.6 ft²)
Dihedral (nominal) 5°
Angle of incidence (nominal) 0°
Horizontal Tail Surfaces
Span 3.29 m (10.79 ft)
Angle of incidence -3.0° relative to longitudinal axis of airplane
Landing Gear (Typical Static, Normal Load)
Wheel track 2.97 m (9.74 ft)
% Wheel base 1.72 m (5.64 ft)
% Wheel base (if MÄM 40-631 is installed) 1.88 m (6.17 ft)
% Wheel base (if OÄM 40-334 or MÄM 40-574 1.79 m (5.87 ft)
% are installed)
% Nose wheel tire 5.00-5; 6 PR, TT, 120 mph
% Nose wheel tire (if OÄM 40-334 is installed) Goodyear 6.00-6; 6 PR, TT
% Main wheel tire 15x6.0-6; 6 PR, TT, 160 mph
% Main wheel tire (if OÄM 40-334 is installed) Goodyear 8.50-6; 6 PR, TT
3. Adjustment Values
The measurements of the DA 40 NG are recorded on an Adjustment Report at the factory when the
% airplane is built. See Figure 2 and 3. These Reports become part of the airplane records.
When you measure the dimensions, use the Adjustment Report as a reference for deviations.
Doc # 6.02.15 Page 3
Rev. 2 06-00-00 15 Apr 2013
Dimensions and Areas DA 40 NG AMM
AIRCRAFT
Right
Left
-1 )
(26° +1
-1 )
Values according to DA4-2738-00-PL
) -8 +1 °
+8
(215 (24
-8 )
+8 8
( 19
RUDDER
Dow n (+)
N os e 77
R4
Up
(-) N os e
l
N utra
e
ELEVATOR TRIM
5
R9
477
°
90
+2
(20 ° -2 ) +0 )
) -2 (21° -1
-0
+7 ) (1 3° +2 (17° +1)
(6 9 -7
+0 )
-7
(8 8 -4
(71 -0 )
(45 +7) +4
AILERON
ELEVATOR
00
0
R 24
R2
ding
Lan -1 ) f
° ke Of
( 2 +1 Ta -2 )
4
(20° +2
FLAPS
-8 )
(81 +8 -4 )
+4 7
Pre-Load (16
3
R23
Figure 2: Control Surface Adjustment Report
Page 4 Doc # 6.02.15
15 Apr 2013 06-00-00 Rev. 2
DA 40 NG AMM Dimensions and Areas
AIRCRAFT
%
%
%
% Adjustment Report Registration
%
% Date
%
% Horizontal Main Landing Gear (at Empty Rudder
Wings
Stabilizer Weight, on Glide Sheets) Controls
%
Leading Edge Dihedral Angle of Camber Toe Cable
% (Wing Supported) Incidence Tension
Sweep Back
%
Left Right Left Right Left Right Left Right Differ-
ence
%
1.0° 1.0° 5.0 ° 5.0° 3.0° 1° to 1° to 0° to 0° to max. 15 daN (33.7 lb)
% Nominal
± 0.2° ± 0.2° ± 0.25° ± 0.25° + 0.0° / - 0.2° 4° 4° ±1° ±1° 1° ± 2 daN (± 4.5 lb)
%
Actual
%
%
% Angle of
% Incidence
%
%
%
%
%
Wing Dihedral
% (Wings supported with no load on the wing mounting bolts).
%
%
%
%
%
%
%
%
%
%
Figure 3: Adjustment Report, General Items
Doc # 6.02.15 Page 5
Rev. 2 06-00-00 15 Apr 2013
Dimensions and Areas DA 40 NG AMM
AIRCRAFT
4. Weight and Static Moments of Control Surfaces
WARNING: IF YOU REPAINT (OR DO REPAIRS TO) THE CONTROL SURFACES,
YOU MUST MAKE SURE THAT THE WEIGHTS AND STATIC MOMENTS
OF THE CONTROL SURFACES ARE IN THE LIMITS IN THE CONTROL
SURFACE BALANCING REPORT. THIS WILL PREVENT CONTROL
SURFACE FLUTTER.
To measure the static moments you must remove the control surface from the airplane. Refer to
Section 51-60 for the measuring procedures.
If the values are not within the limits in the Control Surface Balancing Report, you must ask the
manufacturer for advice before you adjust the balancing weight.
Page 6 Doc # 6.02.15
15 Apr 2013 06-00-00 Rev. 2
DA 40 NG AMM Lifting and Shoring
AIRCRAFT
CHAPTER 07
LIFTING AND SHORING
Doc # 6.02.15 Page 1
Rev. 2 07-TITLE 15 Apr 2013
Lifting and Shoring DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 07-TITLE Rev. 2
DA 40 NG AMM Lifting and Shoring
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 07
LIFTING AND SHORING
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 07-10
Jacking
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Lifting the Airplane on Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Doc # 6.02.15 Page 1
Rev. 2 07-CONTENTS 15 Apr 2013
Lifting and Shoring DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 07-CONTENTS Rev. 2
DA 40 NG AMM Lifting and Shoring
AIRCRAFT
CHAPTER 07
LIFTING AND SHORING
1. General
The DA 40 NG has no hoisting points. Use straps to lift the airplane.
You can use your hands to lift the wings and the horizontal stabilizer.
Section 07-10 tells you how to lift the airplane with jacks.
Doc # 6.02.15 Page 1
Rev. 2 07-00-00 15 Apr 2013
Lifting and Shoring DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 07-00-00 Rev. 2
DA 40 NG AMM Lifting and Shoring
AIRCRAFT
Section 07-10
Jacking
1. General
The DA 40 NG has three jacking points. There are main jacking points under each stub-wing. The
tie-down hole in the lower fin makes the tail jacking point. For maintenance lift the fuselage with the
three hydraulic jacks. Use a trestle with a special former to hold the front of the fuselage. Use standard
trestles under the wings at the position where the tips connect to the wing. Refer to Figure 1.
WARNING: IF THE WIND SPEED IS MORE THAN 10 KM/H (6 KNOTS), DO NOT LIFT
THE AIRPLANE ON JACKS OUTDOORS.
2. Lifting the Airplane on Jacks
A. Equipment
Item Quantity Part Number
Airplane jacks (800 kg / 1764 lb minimum lifting capacity). 3 Commercial.
Nose trestle. 1 Commercial.
Wing trestles. 2 Commercial.
Doc # 6.02.15 Page 1
Rev. 2 07-10-00 15 Apr 2013
Lifting and Shoring DA 40 NG AMM
AIRCRAFT
Nose
Wing Trestle Wing Trestle
Main Jack Trestle Main Jack
Tail Jacking
Main Jacking Point Point
LH & RH
Nose Tail Jack
Trestle
Figure 1: Lifting the Airplane on Jacks
Page 2 Doc # 6.02.15
15 Apr 2013 07-10-00 Rev. 2
DA 40 NG AMM Lifting and Shoring
AIRCRAFT
B. Lifting the Airplane
Detail Steps/Work Items Key Items/References
CAUTION: IF THE AIRPLANE IS IN THE OPEN THEN ALIGN IT INTO THE
WIND. MAXIMUM WIND SPEED: 10 KM/H (6 KTS).
(1) Apply the parking brake. Put chocks under
the main wheels.
(2) Put two jacks in position under the main Refer to Figure 1.
jacking points. Extend the jacks to engage The jacking plates are bonded to the
with the jacking plates. bottom surface of the stub wing,
forward of the front main spar.
(3) Put a jack in position under the tail jacking
point. Extend the jack to engage with the
lower fin skid plate.
(4) Extend the jacks until the wheels are clear of Operate the jacks together to keep the
the ground. airplane level.
(5) If necessary, level the airplane. Refer to Section 08-20.
CAUTION: DO NOT PUT TRESTLES UNDER THE MIDDLE OF THE WING.
YOU MUST ONLY PUT TRESTLES UNDER THE OUTBOARD RIB
OF THE WINGS.
(6) Put the wing trestles in position under each Refer to Figure 1.
wing at the tip.
(7) Put the nose trestle in position under the front Just aft of the access panel for the nose
fuselage. gear leg.
Doc # 6.02.15 Page 3
Rev. 2 07-10-00 15 Apr 2013
Lifting and Shoring DA 40 NG AMM
AIRCRAFT
C. Lowering the Airplane
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE AREA UNDER THE AIRPLANE IS CLEAR
BEFORE YOU LOWER THE AIRPLANE.
(1) Remove the nose trestle from under the
fuselage.
(2) Remove the wing trestles from under the
wings.
(3) Retract the jacks until the wheels are on the Retract the three jacks equally to keep
ground. the airplane level.
(4) Apply the parking brake. Put chocks under
the wheels.
(5) Retract the three jacks fully. Move the jacks
clear of the airplane.
Page 4 Doc # 6.02.15
15 Apr 2013 07-10-00 Rev. 2
DA 40 NG AMM Weighing and Levelling
AIRCRAFT
CHAPTER 08
WEIGHING AND LEVELLING
Doc # 6.02.15 Page 1
Rev. 2 08-TITLE 15 Apr 2013
Weighing and Levelling DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 08-TITLE Rev. 2
DA 40 NG AMM Weighing and Levelling
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 08
WEIGHING AND LEVELLING
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 08-10
Weighing
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Weighing with Electronic Weighing Units at the Jacking Points . . . . . . . . . . . . . . . 3
3. Weighing with Mechanical Scales Under the Wheels . . . . . . . . . . . . . . . . . . . . . . . 9
Section 08-20
Levelling
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Make the Airplane Level with Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Doc # 6.02.15 Page 1
Rev. 2 08-CONTENTS 15 Apr 2013
Weighing and Levelling DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 08-CONTENTS Rev. 2
DA 40 NG AMM Weighing and Levelling
AIRCRAFT
CHAPTER 08
WEIGHING AND LEVELLING
1. General
This Chapter tells you how to weigh the airplane. It also tells you how to level the airplane. Use the
procedures in Section 08-10 to weigh the airplane and to calculate the airplane moment. Use the
procedures in Section 08-20 to level the airplane.
Note: In this Airplane Maintenance Manual masses are referred to as weights. The
authors accept that this is technically incorrect but have used the expression for
simplicity and convenience.
Doc # 6.02.15 Page 1
Rev. 2 08-00-00 15 Apr 2013
Weighing and Levelling DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 08-00-00 Rev. 2
DA 40 NG AMM Weighing and Levelling
AIRCRAFT
Section 08-10
Weighing
1. General
Only operate the airplane within the permitted range of weight and center of gravity limits. This will give
good flight performance and good handling qualities. It is also necessary for safety.
If you make any changes to the airplane that will alter the weight (or the center of gravity), then you
must calculate the new weight of the airplane. You must also calculate its center of gravity.
Only an approved person can weigh the airplane. The national Airworthiness Authority of the country
where the airplane is registered gives approval for persons to weigh the airplane. It also gives the time
limits.
Use the Weighing Report when you do the weight and balance calculations (Refer to Figure 4 or
Figure 6).
The reference plane for the DA 40 NG is a transverse, vertical plane in front of the airplane. It is at right
angles to the horizontal reference line. The reference plane lies 2,194 mm (86.38 in) in front of the
stub-wing leading edge at the wing joint on each side.
Doc # 6.02.15 Page 1
Rev. 2 08-10-00 15 Apr 2013
Weighing and Levelling DA 40 NG AMM
AIRCRAFT
Spirit Level
Horizontal Part of
Baggage Compartment Frame
Figure 1: Level the Airplane Laterally for Weighing
600 mm (23.62 in.)
Sprit Level
31 mm (1.22 in.)
Wedge
2910
mm (114.
57 in
.)
Figure 2: Level the Airplane Longitudinally for Weighing
Page 2 Doc # 6.02.15
15 Apr 2013 08-10-00 Rev. 2
DA 40 NG AMM Weighing and Levelling
AIRCRAFT
2. Weighing with Electronic Weighing Units at the Jacking Points
If you can use electronic weighing units to weigh the airplane, you can use the jacks to make the
airplane level. You must obey the manufacturers' instructions on the weighing units.
A. Equipment
Items Quantity Part Number
Airplane jacks (800 kg / 1764 lb minimum lifting 3 Commercial.
capacity).
Electronic weighing units. 3 Commercial.
Spirit level. 1 Commercial.
Wedge, slope 600:31. 1 Local Manufacture.
Before you weigh the airplane do these items:
) Make sure the airplane has all its equipment. The equipment must be in the location shown in
the Equipment Inventory. The Equipment Inventory is included in Section 6.5 of the Airplane
Flight Manual.
) Defuel the airplane to the unusable fuel level. The unusable fuel level is 1 US gal (approx.
3.8 liter) per wing tank. Refer to Section 12-10.
) Add engine oil and operating fluids up to the maximum level. Refer to Section 12-10.
) Clean the airplane and dry it.
) Remove all objects which are not part of the Equipment Inventory (for example tools, baggage,
etc.). The Equipment Inventory is included in Section 6.5 of the Airplane Flight Manual.
Doc # 6.02.15 Page 3
Rev. 2 08-10-00 15 Apr 2013
Weighing and Levelling DA 40 NG AMM
AIRCRAFT
Reference Plane
Arm - Empty Weight XCG
2194 mm
(86.38 in.)
X1 2394 mm
(94.25 in.) G1
X2 7312 mm
(287.87 in.)
G2
Legend:
X1 = Arm, Reference Plane to Center Line of Main Jacking Points.
X2 = Arm, Reference Plane to Center Line of Tail Jacking Point.
G1 = G1LH + G1RH = Net Weight, main jacks LH and RH.
G2 = Net Weight, Tail Jack.
G = G1LH + G1RH + G2 = Empty Weight.
XCG = Arm - Empty Weight Center-of-Gravity (calculated).
Figure 3: Weighing Dimensions for Electronic Weighing Units at the Jacking Points
Page 4 Doc # 6.02.15
15 Apr 2013 08-10-00 Rev. 2
DA 40 NG AMM Weighing and Levelling
AIRCRAFT
B. Weighing Procedure with Electronic Weighing Units at the Jacking Points
Detail Steps/Work Items Key Items/References
Note: Weigh the airplane in a closed room. This will avoid any wind causing weighing
errors.
(1) Make a copy of the Weighing Report form. Refer to Figure 4.
(2) Put the electrical weighing units in position on the Refer to the weighing unit
jacks. manufacturer‘s instructions.
(3) Zero the electrical weighing units. Refer to the weighing unit
manufacturer‘s instructions.
(4) Lift the airplane on jacks. Refer to Section 07-10.
(5) Make the airplane level laterally: Refer to Figure 1.
Behind the back seats. Make sure that
S Put a spirit level on the horizontal surface of
you do not touch the airplane when you
the baggage compartment frame.
read the spirit level.
S Adjust the main jacks to bring the sprit level
horizontal.
(6) Make the airplane level longitudinally: Refer to Figure 2.
S Place a wedge on the rear fuselage with the
thin end forward.
S Place a spirit level on the wedge.
S Adjust the tail jack to bring the spirit level
horizontal.
(7) Remove the levelling equipment from the
airplane.
(8) Put the rear passenger seats in the upright
position.
(9) Close the canopy and the passenger door.
(10) Read the value from the left main jack weighing
unit. Enter the value on the Weighing Report
under MAIN G1LH Gross.
Doc # 6.02.15 Page 5
Rev. 2 08-10-00 15 Apr 2013
Weighing and Levelling DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(11) Read the value from the right main jack weighing
unit. Enter the value on the Weighing Report
under MAIN G1RH Gross.
(12) Read the value from the tail jack weighing unit.
Enter the value on the Weighing Report under
TAIL G2 Gross.
(13) Refer to the calibration records for the electrical
weighing units. If necessary, correct the Gross
values of MAIN G1LH, MAIN G1RH, and TAIL G2.
(14) Lower the airplane with the jacks. Refer to Section 07-10.
(15) If you have used adaptors between the weighing
units and the jacking points, and these adaptors
were not placed on the weighing units during
zeroing (step 3), then record the weight of them
under Tare in the related column.
(16) Subtract each Tare value from the related Gross
value. Record the result under Net in the
Weighing Report.
(17) Calculate the Empty Weight, G. G = Net G1LH + Net G1RH + Net G2
(18) Calculate the Empty Weight Moment, M. M = ((G1LH + G1RH) * X1) + (G2 * X2)
(19) Calculate the position of the Empty Weight XCG = M/G
Center-of-Gravity, XCG.
(20) Record the Empty Weight (G) and the Empty
Weight Moment (M) in the Airplane Flight Manual.
Page 6 Doc # 6.02.15
15 Apr 2013 08-10-00 Rev. 2
DA 40 NG AMM Weighing and Levelling
AIRCRAFT
WEIGHING REPORT
Model: DA 40 NG Serial Number:___________ Registration:_____________
Data with reference to the Type Certificate Data Sheet and the Airplane Flight Manual.
Reference Plane: Vertical plane 2194 mm (86.38 in) in front of the leading edge of wing at
the root rib.
Horizontal reference line: Wedge 600:31 (2.96°), 2910 mm (114.57 in) aft of the step in the cockpit
rim.
Equipment Inventory - dated:_______ Cause for Weighing:_______________________________
Weight and Balance Calculations (Weighing at the jacking points)
Weight Condition: Including brake fluid, engine oil (MAX level), coolant, and unusable fuel
(2 x 1 US gal / 2 x 3.8 liters).
Support Gross Tare Net Lever Arm
MAIN G1LH X1 = 2394 mm
(94.25 in)
MAIN G1RH X2 = 7312 mm
(287.87 in)
TAIL G2
Empty Weight
Calculate the Empty Weight, G = MAIN G1LH + MAIN G1RH + TAIL G2. G=
Calculate the Empty Weight Moment, M = ((G1LH + G1RH) * X1) + (G2 * X2). M=
Calculate the Empty Weight Center-of-Gravity position, XCG = M/G. XCG =
Maximum permitted all-up-weight: Max AUW (see AFM)
Maximum useful load = Max AUW - G.
Record the Empty Weight (G) and the Empty-Weight Moment (M) in the Airplane Flight Manual.
Place/Date Authorizing Stamp Authorizing Signature
Figure 4: Weighing Report for Electronic Weighing Units at the Jacking Points
Doc # 6.02.15 Page 7
Rev. 2 08-10-00 15 Apr 2013
Weighing and Levelling DA 40 NG AMM
AIRCRAFT
Reference Plane
Arm - Empty Weight XCG
2194 mm
(86.38 in.)
X2
G2 X
1LH
X1RH G1
If necessary, use blocks under wheels
Ramp same Height as Nose Scale to ensure horizontal alignment
Legend:
X1 = Arm, Reference Plane to center line of main wheels.
X2 = Arm, Reference Plane to center line of nose wheel.
G1 = G1LH + G1RH = Net weight, main wheel scales LH and RH.
G2 = Net weight, Nose wheel scale.
G = G1LH + G1RH + G2 = Empty Weight.
XCG = Arm - Empty Weight center-of-gravity (calculated).
Figure 5: Weighing Dimensions for Mechanical Scales under the Wheels
Page 8 Doc # 6.02.15
15 Apr 2013 08-10-00 Rev. 2
DA 40 NG AMM Weighing and Levelling
AIRCRAFT
3. Weighing with Mechanical Scales Under the Wheels
If you use mechanical scales to weigh the airplane, you must also use wooden blocks under the
wheels to level the airplane. You must obey the manufacturers' instructions on the scales.
A. Equipment
Items Quantity Part Number
Mechanical scales (the scales used for the main 3 Commercial.
wheels must be the same).
Spirit level. 1 Commercial.
Plumb line. 1 Commercial.
Wedge, slope 600:31 (2.96°). 1 Local Manufacture.
Wooden blocks (various thicknesses). A/R Local Manufacture.
Ramps. 3 Local Manufacture.
Optional: Airplane jacks (800 kg / 1764 lb minimum 3 Commercial.
lifting capacity).
Note: If you use airplane jacks to lift the airplane onto the ramps, you must move the
airplane a small distance back and forward to allow the landing gear to spread.
This will prevent side loads on the scales causing errors.
This procedure uses jacks because the main wheel scales need approximately
% 52 mm (2 in) of blocks to bring the airplane level. If OÄM 40-334 is installed, the
% blocks must be approximately 100 mm (4 in) high to bring the airplane level.
Before you weigh the airplane do these items:
) Make sure the airplane has all its equipment. The equipment must be in the location shown in
the Equipment Inventory. The Equipment Inventory is included in Section 6.5 of the Airplane
Flight Manual.
Defuel the airplane to the unusable fuel level. The unusable fuel level is 1 US gal (approx. 3.8 liter)
per wing tank. Refer to Section 12-10.
) Add engine oil and operating fluids up to the maximum level. Refer to Section 12-10.
) Clean the airplane and dry it.
) Remove all objects which are not part of the Equipment Inventory (for example tools, baggage,
etc.). The Equipment Inventory is included in Section 6.5 of the Airplane Flight Manual.
Doc # 6.02.15 Page 9
Rev. 2 08-10-00 15 Apr 2013
Weighing and Levelling DA 40 NG AMM
AIRCRAFT
B. Weighing Procedure with Mechanical Scales Under the Wheels
Detail Steps/Work Items Key Items/References
Note: Weigh the airplane in a closed room. This will avoid any wind causing weighing
errors.
(1) Make a copy of the Weighing Report form. Figure 6.
(2) Put the weighing scales in position on the floor in
front of each wheel.
(3) Zero the scales. Refer to the scale manufacturer‘s
instructions.
(4) Close the canopy.
(5) Lift the airplane on jacks. Refer to Section 07-10.
(6) Put the flat part of the ramps under each wheel.
(7) Lower the airplane onto the ramps with the jacks. Refer to Section 07-10.
Remove the jacks.
(8) Move the airplane a small distance backwards To allow the landing gear legs to spread.
and forwards on the flat top of the ramps.
(9) If necessary, put a wooden on the scale in front To ensure horizontal alignment of the
of each main wheel. airplane.
CAUTION: DO NOT ALLOW THE AIRPLANE TO RUN OFF THE SCALES. THIS
WILL CAUSE DAMAGE TO THE WHEEL FAIRINGS.
(10) Push the airplane forward onto the scales. Make sure that the wheels are above
the center of the scales.
(11) Engage parking brake or use wheel chocks.
(12) Make the airplane level laterally: Refer to Figure 1.
S Put a spirit level on the horizontal surface of Behind the back seats.
the baggage compartment frame.
S If necessary, use additional thin blocks Push the airplane on and off the scales
between the scale and the main wheel on the as necessary.
low side to bring the sprit level horizontal.
Make sure that you do not touch the
airplane when you read the spirit level.
Page 10 Doc # 6.02.15
15 Apr 2013 08-10-00 Rev. 2
DA 40 NG AMM Weighing and Levelling
AIRCRAFT
Detail Steps/Work Items Key Items/References
(13) Make the airplane level longitudinally: Refer to Figure 2.
S Place a wedge on the rear fuselage with the
thin end forward.
S Place a spirit level on the wedge.
S Put thin blocks between the nose wheel and
the scale to bring the spirit level horizontal.
S Or, if necessary, reduce the air pressure in
the nose wheel tire to bring the spirit level
horizontal.
(14) Remove the levelling equipment from the
airplane.
(15) Put the rear passenger seats in the upright
position.
(16) Close the passenger door.
(17) Read the value from the left main wheel scale.
Enter the value on the weighing form under MAIN
G1LH Gross.
(18) Read the value from the right main wheel scale.
Enter the value on the weighing form under MAIN
G1RH Gross.
(19) Read the value from the nose wheel scale. Enter
the value on the weighing form under NOSE G2
Gross.
Doc # 6.02.15 Page 11
Rev. 2 08-10-00 15 Apr 2013
Weighing and Levelling DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(20) Use the plumb line to mark the position of the
reference plane on the floor:
S Hold the plumb line against the leading edge Do this on each side.
of the wing where the wing joins the stub-
wing.
S Mark this position on the floor.
S Draw a straight line between the 2 points you
marked on the floor.
S Draw a second line 2194 mm (86.38 in)
forward of the first line.
(21) Use the plumb line to mark the position of the
nose wheel center line on the floor.
(22) Use the plumb line to mark the position of each
main wheel center line on the floor.
(23) Lift the airplane off the scales with the jacks. Refer to Section 07-10.
(24) Read the weight of the wooden blocks on each of
the scales. Record the values in the column
headed TARE in the Weighing Report.
(25) Remove the scales and the ramps.
(26) Measure the distance X1LH. Record the value in
the Weighing Report.
(27) Measure the distance X1RH. Record the value in
the Weighing Report.
(28) Measure the distance X2. Record the value in the
Weighing Report.
(29) Refer to the calibration records for the weighing
scales. If necessary, correct the Gross and Tare
values of MAIN G1LH, MAIN G1RH, and NOSE G2.
(30) Subtract each Tare value from the related Gross
value. Record the result under Net in the
Weighing Report.
(31) Lower the airplane with the jacks.
Page 12 Doc # 6.02.15
15 Apr 2013 08-10-00 Rev. 2
DA 40 NG AMM Weighing and Levelling
AIRCRAFT
Detail Steps/Work Items Key Items/References
(32) Calculate the Empty Weight, G, from the Net G=
values.
Net G1LH + Net G1RH + Net G2
(33) Calculate the Empty Weight Moment, M. M=
(G1LH * X1LH)+( G1RH * X1RH) + (G2 * X2)
(34) Calculate the position of the Empty Weight XCG = M/G
Center-of-Gravity, XCG.
(35) Record the Empty Weight (G) and the Empty
Weight Moment (M) in the Airplane Flight Manual.
Doc # 6.02.15 Page 13
Rev. 2 08-10-00 15 Apr 2013
Weighing and Levelling DA 40 NG AMM
AIRCRAFT
WEIGHING REPORT
Model: DA 40 NG Serial Number:___________ Registration:_____________
Data with reference to the Type Certificate Data Sheet and the Airplane Flight Manual.
Reference Plane: Vertical plane 2194 mm (86.38 in) in front of the leading edge of wing at
the root rib.
Horizontal reference line: Wedge 600:31 (2.96°), 2910 mm (114.57 in) aft of the step in the cockpit
rim.
Equipment Inventory - dated:_______ Cause for Weighing:______________________________
Weight and Balance Calculations (Weighing at the wheels)
Weight Condition: Including brake fluid, engine oil (MAX level), coolant and unusable fuel
(2 x 1 US gal / 2 x 3.8 liters).
Support Gross Tare Net Lever Arm
MAIN G1LH X1LH =
MAIN G1RH X1RH =
NOSE G2 X2 =
Empty Weight
Calculate the Empty Weight, G = MAIN G1LH + MAIN G1RH + NOSE G2. G=
Calculate the Empty Weight Moment, M=
M = (G1LH * X1LH)+( G1RH * X1RH) + (G2 * X2).
Calculate the Empty Weight Center-of-Gravity position, XCG = M/G. XCG =
Maximum permitted all-up-weight: Max AUW (see AFM).
Maximum useful load = Max AUW - G.
Record the Empty Weight (G) and the Empty-Weight Moment (M) in the Airplane Flight Manual.
Place/Date Authorizing Stamp Authorizing Signature
Figure 6: Weighing Report for Mechanical Scales under the Wheels
Page 14 Doc # 6.02.15
15 Apr 2013 08-10-00 Rev. 2
DA 40 NG AMM Weighing and Levelling
AIRCRAFT
Section 08-20
Levelling
1. General
These procedures tell you how to make the airplane level. See Section 07-10 for lifting the airplane
with jacks.
Make the airplane level with jacks unless you are weighing the airplane. If you weigh the airplane,
change the airplane tire pressures or use blocks to make the airplane level (see Section 08-10).
2. Make the Airplane Level with Jacks
A. Equipment
Items Quantity Part Number
Airplane jacks (600 kg / 1320 lb minimum lifting 3 Commercial.
capacity).
Wing trestle. 2 Commercial.
Nose trestle. 1 Commercial.
Spirit level. 1 Commercial.
Wedge, slope 600:31 (2.96°). 1 Local Manufacture.
Doc # 6.02.15 Page 1
Rev. 2 08-20-00 15 Apr 2013
Weighing and Levelling DA 40 NG AMM
AIRCRAFT
Spirit Level
Horizontal Part of
Baggage Compartment Frame
Figure 1: Level the Airplane Laterally
600 mm (23.62 in.)
Sprit Level
31 mm (1.22 in.)
Wedge
2910
mm (114.
57 in
.)
Figure 2: Level the Airplane Longitudinally
Page 2 Doc # 6.02.15
15 Apr 2013 08-20-00 Rev. 2
DA 40 NG AMM Weighing and Levelling
AIRCRAFT
B. Level the Airplane with Jacks Procedure
Detail Steps/Work Items Key Items/References
Note: Level the airplane in a closed room. This will avoid any wind causing levelling
errors.
(1) Lift the airplane on jacks. Refer to Section 07-10.
(2) Make the airplane level laterally: Refer to Figure 1.
S Put a spirit level on the horizontal surface of Behind the back seats.
the baggage compartment frame.
S Adjust the main jacks to bring the sprit level
horizontal.
(3) Make the airplane level longitudinally: Refer to Figure 2.
S Place a wedge on the rear fuselage with the
thin end forward.
S Place a spirit level on the wedge.
S Adjust the tail jack to bring the spirit level
horizontal.
(4) Put trestles under each wing and the front Refer to Section 07-10.
fuselage.
(5) Remove the levelling equipment from the
airplane.
Doc # 6.02.15 Page 3
Rev. 2 08-20-00 15 Apr 2013
Weighing and Levelling DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 08-20-00 Rev. 2
DA 40 NG AMM Towing and Taxiing
AIRCRAFT
CHAPTER 09
TOWING AND TAXIING
Doc # 6.02.15 Page 1
Rev. 2 09-TITLE 15 Apr 2013
Towing and Taxiing DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 09-TITLE Rev. 2
DA 40 NG AMM Towing and Taxiing
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 09
TOWING AND TAXIING
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 09-10
Towing
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Towing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 09-20
Taxiing
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Doc # 6.02.15 Page 1
Rev. 2 09-CONTENTS 15 Apr 2013
Towing and Taxiing DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 09-CONTENTS Rev. 2
DA 40 NG AMM Towing and Taxiing
AIRCRAFT
CHAPTER 09
TOWING AND TAXIING
1. General
You can move the airplane on the ground by hand or by taxiing it. Use the procedures in Section 09-10
and Section 09-20 to move the airplane safely. Section 09-10 tells you how to tow the airplane. Section
09-20 tells you how to taxi the airplane.
WARNING: YOU MUST NOT TAXI THE AIRPLANE UNLESS YOU HAVE BEEN
TRAINED TO TAXI AND HAVE BEEN AUTHORIZED BY YOUR
AIRWORTHINESS AUTHORITY.
Doc # 6.02.15 Page 1
Rev. 2 09-00-00 15 Apr 2013
Towing and Taxiing DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 09-00-00 Rev. 2
DA 40 NG AMM Towing and Taxiing
AIRCRAFT
Section 09-10
Towing
1. General
You can move the airplane without using a tow bar. You can push or pull the DA 40 NG at the wing
tip, at the wing nose, and at the propeller blades near the spinner.
2. Towing Procedure
WARNING: DO NOT PUSH ON THE SPINNER. IF YOU PUSH ON THE SPINNER
YOU CAN DAMAGE THE SPINNER WHICH CAN CAUSE VIBRATION.
CAUTION: NEVER USE FORCE ON THE PROPELLER TIPS OR ON THE
CONTROL SURFACES. YOU CAN DAMAGE THE PROPELLER AND
THE CONTROL SURFACES.
CAUTION: NEVER APPLY WEIGHTS TO THE TAILPLANE TO LIFT THE NOSE
WHEEL. YOU CAN DAMAGE THE TAILPLANE.
CAUTION: NEVER TOW THE AIRPLANE IF THE WHEELS ARE BLOCKED BY
SNOW OR MUD. YOU CAN DAMAGE THE LANDING GEAR.
CAUTION: THE NOSE WHEEL STEERING ANGLE IS 30º TO THE LEFT AND
RIGHT. IF YOU TURN THE WHEEL MORE THAN 30º YOU WILL CAUSE
DAMAGE TO THE NOSE GEAR.
A. Forward Movement
Pull the airplane forward on the propeller blades near the spinner. The nose wheel will follow the
movement of the airplane. You can change direction by pulling on the appropriate propeller blade
near the spinner.
B. Rearward Movement
Push down the fuselage in front of the vertical stabilizer until the nose wheel is clear of the ground
while pushing the airplane in rearward direction.
C. Turn the Airplane on the Ground
If you have a limited area to maneuver the airplane, two persons can turn the airplane around the
main wheels. One person must push down in front of the vertical stabilizer until the nose wheel is
clear of the ground. The other person must push on the wing tip.
Doc # 6.02.15 Page 1
Rev. 2 09-10-00 15 Apr 2013
Towing and Taxiing DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 09-10-00 Rev. 2
DA 40 NG AMM Towing and Taxiing
AIRCRAFT
Section 09-20
Taxiing
1. General
When you taxi the DA 40 NG you use the toe operated brakes to steer the airplane. To make the
airplane turn operate the left or the right toe brake.
WARNING: YOU MUST NOT TAXI THE AIRPLANE UNLESS YOU HAVE BEEN
TRAINED TO TAXI AND HAVE BEEN AUTHORIZED BY YOUR
AIRWORTHINESS AUTHORITY.
CAUTION: THIS SECTION GIVES GENERAL DATA ON TAXIING ONLY. YOU
MUST USE THE DA 40 NG AIRPLANE FLIGHT MANUAL WHEN YOU
TAXI THE AIRPLANE.
Key Items/References Detail Steps/Work Items
(1) Make sure the area around the airplane is clear For example: ground equipment and
of objects. tools.
(2) Operate the parking brake.
(3) If necessary remove:
S Wheel chocks.
S Tow bar.
S Mooring ropes.
WARNING: MAKE SURE THAT THERE ARE NO PERSONS OR OBJECTS NEAR
THE AIRPLANE. THE AIRPLANE CAN INJURE PERSONS. OBJECTS
CAN DAMAGE THE AIRPLANE.
(4) Start the engine. Refer to the Airplane Flight Manual.
(5) Release the parking brake.
Doc # 6.02.15 Page 1
Rev. 2 09-20-00 15 Apr 2013
Towing and Taxiing DA 40 NG AMM
AIRCRAFT
Key Items/References Detail Steps/Work Items
WARNING: MAKE SURE THE BRAKES OPERATE CORRECTLY WHEN YOU
TAXI THE AIRPLANE. IF THE BRAKES SHOULD FAIL, YOU MUST
BE ABLE TO STOP THE AIRPLANE BEFORE YOU HIT PERSONS OR
EQUIPMENT.
CAUTION: OBEY THE SAFETY RANGE FOR TAXIING SHOWN IN FIGURE 1.
CAUTION: TAKE CARE IF YOU TAXI ON UNEVEN GROUND. THE PROPELLER
MUST NOT TOUCH THE GROUND. LOOSE STONES AND GRAVEL
CAN DAMAGE THE PROPELLER.
(6) Taxi the airplane to its new position.
(7) Shut down the engine. Refer to the Airplane Flight Manual.
(8) Park the airplane. If necessary, moor the Refer to Chapter 10.
airplane.
Page 2 Doc # 6.02.15
15 Apr 2013 09-20-00 Rev. 2
DA 40 NG AMM Towing and Taxiing
AIRCRAFT
m )
1 0 0 ft
(3
(1 m
ft)
3
0
Figure 1: The Safety Range for Taxiing the DA 40 NG Airplane
Doc # 6.02.15 Page 3
Rev. 2 09-20-00 15 Apr 2013
Towing and Taxiing DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 09-20-00 Rev. 2
DA 40 NG AMM Parking, Mooring, etc.
AIRCRAFT
CHAPTER 10
PARKING, MOORING, STORAGE AND
RETURN TO SERVICE
Doc # 6.02.15 Page 1
Rev. 2 10-TITLE 15 Apr 2013
Parking, Mooring, etc. DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 10-TITLE Rev. 2
DA 40 NG AMM Parking, Mooring, etc.
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 10
PARKING, MOORING, STORAGE AND RETURN TO SERVICE
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 10-10
Parking and Storage
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section 10-20
Mooring
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 10-30
Return to Service
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Return to Service Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Doc # 6.02.15 Page 1
Rev. 2 10-CONTENTS 15 Apr 2013
Parking, Mooring, etc. DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 10-CONTENTS Rev. 2
DA 40 NG AMM Parking, Mooring, etc.
AIRCRAFT
CHAPTER 10
PARKING, MOORING, STORAGE AND RETURN TO SERVICE
1. General
Always park or moor the DA 40 NG when it is not in use. Use the procedures in Section 10-10 for
parking the airplane. Use the procedure in Section 10-20 to moor the airplane. If the airplane is parked
over-night, we recommend that you moor the airplane. If strong winds are forecast, you must always
moor the airplane.
Refer to the AE Operation Manual, latest revision for detailed information about engine storage.
Doc # 6.02.15 Page 1
Rev. 2 10-00-00 15 Apr 2013
Parking, Mooring, etc. DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 10-00-00 Rev. 2
DA 40 NG AMM Parking, Mooring, etc.
AIRCRAFT
Section 10-10
Parking and Storage
1. General
Use these procedures to protect the airplane when it is parked. Use the short-term parking procedure
when the airplane will be parked for less than 5 days. Use the long term parking procedure when the
airplane will be parked for 5 to 30 days. Use the storage procedure if the airplane will be parked for
more than 30 days.
All pilots and all maintenance staff for the DA 40 NG must know the procedures in this Section.
CAUTION: MAKE SURE THAT THE AIRPLANE IS CORRECTLY MOORED AND
PROTECTED IF STRONG WINDS ARE FORECAST. STRONG WINDS
CAN CAUSE DAMAGE TO AN UNPROTECTED AIRPLANE.
A. Equipment
Items Quantity Part Number
Wheel chocks. 4 Commercial.
Gust lock. 1 Commercial.
B. Short-Term Parking
Detail Steps/Work Items Key Items/References
(1) Taxi or tow the airplane to the parking position. Refer to Chapter 09.
(2) Align the airplane into wind.
CAUTION: MAKE SURE THAT THE NOSE WHEEL IS ALIGNED STRAIGHT
AHEAD WHEN THE AIRPLANE STOPS. THIS WILL PREVENT SIDE
LOADS WHICH CAN DAMAGE THE NOSE LANDING GEAR.
(3) If the wind is gusty (or the weather is stormy) Refer to Section 10-20.
moor the airplane.
(4) If there is packed snow or ice on the parking
area, spread about 5 mm (0.2 in) of sand under
the wheels.
Doc # 6.02.15 Page 1
Rev. 2 10-10-00 15 Apr 2013
Parking, Mooring, etc. DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
% CAUTION: DO NOT SET THE PARKING BRAKE WHEN THE BRAKES ARE
OVER-HEATED. THE BRAKES CAN SEIZE ON.
(5) Set the parking brake ON. Pull the lever fully aft,
and push both brake pedals at least two times.
(6) Put chocks in front of and behind the main
wheels.
(7) RELEASE the parking brake. Lever fully forward.
(8) Install the gust lock:
S Move the rudder pedals fully rearward.
S Engage the control surfaces gust lock with
the pedals.
S Engage the sticks; wrap straps around stick
once.
S Attach the locks and tighten the straps.
(9) Set the flaps to UP. Fully up.
(10) Make sure that the passenger door and canopy is
closed and locked.
Page 2 Doc # 6.02.15
15 Apr 2013 10-10-00 Rev. 2
DA 40 NG AMM Parking, Mooring, etc.
AIRCRAFT
C. Long-Term Parking
CAUTION: MAKE SURE TO PERFORM THE LONG TERM PARKING PROCEDURE
WHEN THE AIRPLANE IS PARKED FOR A LONG TIME. IF THE
PROCEDURE IS NOT FOLLOWED CORRECTLY, DAMAGE TO THE
AIRPLANE CAN OCCUR.
Key Items/References Detail Steps/Work Items
(1) Do the procedure for short-term parking. Refer to Paragraph 1.B.
(2) If the airplane can be moved, remove the chocks. You can push or tow the airplane.
Move the airplane to turn the wheels 3 or 4
Make sure that a different part of the
revolutions. Put the chocks back.
tire touches the ground when you stop.
If the airplane is on jacks, turn each wheel 3 or 4
revolutions by hand.
Note: Do step 2 every day in cold weather every 7 days in warm weather.
(3) Do the procedure for corrosion prevention on the Refer to AE Operation Manual, latest
engine installed in an inactive airplane. revision.
(4) Install Pitot cover. Located on the lower side of the
LH wing.
(5) Do a test for water contamination of the fuel. Refer to Section 12-10.
Doc # 6.02.15 Page 3
Rev. 2 10-10-00 15 Apr 2013
Parking, Mooring, etc. DA 40 NG AMM
AIRCRAFT
2. Storage
If the airplane is parked (or not operated) for more than 30 days, you have to do this storage
procedure.
A. Equipment and Material
Item Quantity Part Number
Wheel chocks. 4 Commercial.
Tire protector spray. A/R Commercial.
B. Preparation
Detail Steps/Work Items Key Items/References
(1) If possible, ventilate the airplane in a dry
atmosphere.
(2) Do the procedure for the long-term parking. Refer to Paragraph 1.
(3) Remove the engine oil. Refer to AE Operation Manual, latest
(4) Change the oil filter. revision.
(5) Fill the engine with preservation oil Fuchs Titan
EM530 DC or Shell Helix Ultra DC225.10.
(6) Check the coolant level - if necessary correct
the coolant level.
(7) Warm up the engine according to the
AE Operation Manual, latest revision.
(8) Set 100% load until the oil temperature is
100 °C (212 °F).
(9) Continue 100% load for one minute.
(10) Set IDLE power for one minute.
(11) Shut down the engine.
CAUTION: The engine must not be started after v-ribbed belt tension relieve.
(12) Relieve v-ribbed belt tension. Refer to AE Maintenance Manual, latest
revision.
(13) Close all engine openings airproof.
(14) Disconnect the airplane main battery. Refer to Section 24-31.
Page 4 Doc # 6.02.15
15 Apr 2013 10-10-00 Rev. 2
DA 40 NG AMM Parking, Mooring, etc.
AIRCRAFT
Detail Steps/Work Items Key Items/References
(15) Completely fill the fuel tanks with fuel. Refer to Section 12-10.
(16) Wipe the tires with a dry cloth. Apply tire Obey the tire protector manufacturers
protector spray. instructions.
(17) Lubricate the airplane. Refer to Section 12-20.
(18) Deactivate the ELT.
(19) Remove loose equipment from the airplane.
C. Monthly Routine Check
Do these steps each month while the airplane is stored.
Detail Steps/Work Items Key Items/References
(1) Remove all plugs from the engine openings.
(2) Tighten the v-ribbed belt. Refer to AE Maintenance Manual, latest
revision.
(3) Engine ground run:
S Connect the main battery or connect the
airplane to ground power.
S Start up the engine for at least 20 minutes. Refer to AFM Chapter 4A.
S Disconnect the main battery or disconnect
the airplane from ground power.
CAUTION: The engine must not be started after v-ribbed belt tension relieve.
(4) Relieve v-ribbed belt tension. Refer to AE Maintenance Manual, latest
revision.
(5) Close all engine openings airproof.
Doc # 6.02.15 Page 5
Rev. 2 10-10-00 15 Apr 2013
Parking, Mooring, etc. DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 6 Doc # 6.02.15
15 Apr 2013 10-10-00 Rev. 2
DA 40 NG AMM Parking, Mooring, etc.
AIRCRAFT
Section 10-20
Mooring
1. General
CAUTION: IF THE AIRPLANE MUST BE STORED OUTSIDE FOR A LONG TIME,
THEN YOU MUST MOOR IT. STRONG WINDS OR GUSTS CAN CAUSE
DAMAGE TO AN AIRPLANE WHICH IS NOT MOORED.
2. Mooring
Figure 1 shows the location of the mooring points on the airplane. There are three mooring points: One
below each wing and one on the skid plate at the tail.
A. Equipment
Item Quantity Part Number
Wheel chocks. 4 Commercial.
Rope (nylon preferred, or hemp). A/R Commercial.
B. Mooring Procedure
Key Items/References Detail Steps/Work Items
(1) Park the airplane. Refer to Section 10-10.
(2) Make sure that the flaps are set to UP. Fully up.
CAUTION: MOOR THE AIRPLANE AT THE MOORING POINTS ONLY.
CAUTION: WHEN USING HEMP ROPES, DO NOT MAKE THEM TIGHT. IF THE
ROPES GET WET THEY WILL TIGHTEN AND DAMAGE THE
AIRPLANE. THIS IS MOST IMPORTANT WHEN YOU USE SECURE
GROUND ANCHOR-POINTS.
(3) Attach a rope to each mooring point and to the
ground anchor point.
Do not make the ropes tight.
(4) Remove all items from the area that may damage
the airplane.
(5) If snow is forecast you must put a trestle under
the lower fin.
Doc # 6.02.15 Page 1
Rev. 2 10-20-00 15 Apr 2013
Parking, Mooring, etc. DA 40 NG AMM
AIRCRAFT
Wing Tie-Down Point Wing Tie-Down Point
Mooring Ring Mooring Ring
Rear Tie-Down Point
Figure 1: Location of Mooring Points on the Airplane
Page 2 Doc # 6.02.15
15 Apr 2013 10-20-00 Rev. 2
DA 40 NG AMM Parking, Mooring, etc.
AIRCRAFT
Section 10-30
Return to Service
1. General
Do this procedure when the airplane has been parked (or stored) for more than 5 days.
2. Return to Service Procedure
A. Storage Time Less Than One Year
Detail Steps/Work Items Key Items/References
(1) If necessary, install loose equipment which was
removed for storage.
(2) If the battery has been removed: Refer to Section 24-31.
S Install the airplane main battery.
(3) Do the test for water contamination of the fuel. Refer to Section 12-10.
(4) Do the test for correct air pressure in each tire. Refer to Section 12-10.
If necessary, inflate the tires.
(5) Check Pitot system and canopy for
contamination/dirt.
(6) Open all engine openings.
(7) Install the v-ribbed belt according to the AE
Maintenance Manual, latest revision.
(8) Change the engine oil to approved engine oil. Refer to Airplane Flight Manual, latest
revision.
(9) Check oil and coolant level. Refer to Section 12-10.
(10) Perform an engine ground run according to the
AE Operation Manual, latest revision.
(11) Reactivate the ELT.
(12) Remove the gust lock:
S Loosen the straps and detach the locks.
S Disengage the stick from the straps.
S Disengage the pedals from the gust lock.
S Move the rudder pedals into position.
Doc # 6.02.15 Page 1
Rev. 2 10-30-00 15 Apr 2013
Parking, Mooring, etc. DA 40 NG AMM
AIRCRAFT
B. Storage Time One Year and More
Detail Steps/Work Items Key Items/References
(1) Contact the engine manufacturer Austro Engine
GmbH.
(2) If necessary, install loose equipment which was
removed for storage.
(3) If the battery has been removed: Refer to Section 24-31.
S Install the airplane main battery.
(4) Remove the gust lock:
S Loosen the straps and detach the locks.
S Disengage the stick from the straps.
S Disengage the pedals from the gust lock.
S Move the rudder pedals into position.
(5) Do a 200 hour maintenance check. Refer to Section 05-10.
Page 2 Doc # 6.02.15
15 Apr 2013 10-30-00 Rev. 2
DA 40 NG AMM Placards and Markings
AIRCRAFT
CHAPTER 11
PLACARDS AND MARKINGS
Doc # 6.02.15 Page 1
Rev. 2 11-TITLE 15 Apr 2013
Placards and Markings DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 11-TITLE Rev. 2
DA 40 NG AMM Placards and Markings
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 11
PLACARDS AND MARKINGS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 11-20
Exterior Placards and Markings
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Replace the Safety Walk Adhesive Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 11-30
Interior Placards and Markings
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Doc # 6.02.15 Page 1
Rev. 2 11-CONTENTS 15 Apr 2013
Placards and Markings DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 11-CONTENTS Rev. 2
DA 40 NG AMM Placards and Markings
AIRCRAFT
CHAPTER 11
PLACARDS AND MARKINGS
1. General
Placards are used for identification and indication. They show the function, operation and operating
limitations of systems and equipment.
Note: Placards must not be removed, exchanged or altered unless approved by the
national Airworthiness Authority.
This Chapter shows you the location of these placards and markings:
) Exterior placards.
) Exterior markings.
) Interior placards.
Self-adhesive plastic foil is used for all placards except for the manufacturer's placard. Metal makes
the manufacturer's placard which is located on the vertical stabilizer, lower left side.
Replace damaged placards.
2. Replace Plastic Foil Placards
A. Material
Item Quantity Part Number
Solvent. A/R Commercial.
Doc # 6.02.15 Page 1
Rev. 2 11-00-00 15 Apr 2013
Placards and Markings DA 40 NG AMM
AIRCRAFT
B. Replace a Placard
Use this procedure for both internal and external foil placards.
Detail Steps/Work Items Key Items/References
(1) Remove the old placard:
S Heat the placard with a hot air blower.
S Lift one corner of the placard.
S Pull the placard off.
WARNING: DO NOT GET SOLVENT ON YOUR SKIN. DO NOT BREATH
SOLVENT VAPOR. SOLVENT CAN CAUSE DISEASE OR ILLNESS.
(2) Clean the surface where the new placard will go. Use a commercial solvent. There must
be no dirt or grease on the surface.
Obey the solvent manufacturer's
instructions.
(3) Remove the protective backing from the new
placard.
(4) Put the new placard in the correct position. Make
the placard smooth with a clean cloth.
Page 2 Doc # 6.02.15
15 Apr 2013 11-00-00 Rev. 2
DA 40 NG AMM Placards and Markings
AIRCRAFT
Section 11-20
Exterior Placards and Markings
1. General
% Figure 1 and 2 show the exterior markings and placards for the DA 40 NG.
For the safety walk adhesive strips are installed. Refer to the Maintenance Practices for more details
about the positioning of the safety walk adhesive strips.
If OÄM 40-317 is installed the safety walk is a coated safety walk instead of safety walk with adhesive
strips. Refer to Section 51-20 for coated safety walk repair procedures.
% If OÄM 40-339 is installed the foot steps are mounted aft of the wing’s trailing edge.
%
% WARNING If OÄM 40-339 is left side and
APPROVED FUEL:
NOT installed right side
%
JET-A1
% or see Airplane Flight Manual
% If OÄM 40-339 is
installed
%
%
%
%
%
%
If OÄM 40-339 is
NOT installed
% External Power Connector
+ +
% If OÄM 40-339 is WARNING
%
Before connecting external power
installed ENGINE MASTERS..................OFF
PROPELLER........................CLEAR
%
% Coolant
%
%
% OIL
%
3 off between Shell Helix Ultra If OÄM 40-339 is
the Blades 5W-30
NOT installed
% or see Airplane Flight Manual
WARNING
% APPROVED FUEL:
If OÄM 40-339 is JET-A1
% installed or see Airplane Flight Manual
%
%
If OÄM 40-339 is
NOT installed
%
% Figure 1: Exterior Placards 1
Doc # 6.02.15 Page 1
Rev. 2 11-20-00 15 Apr 2013
Placards and Markings DA 40 NG AMM
AIRCRAFT
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
3.3 bar / 48 psi Basic
%
1.2 bar / 17 psi If OÄM 40-334 is installed
%
% 3.1 bar / 45 psi Basic
% 1.2 bar / 17 psi If OÄM 40-334 is installed
% 2.4 bar / 35 psi If MÄM 40-574 & MÄM 40-631 are installed
%
%
%
%
%
%
%
% Figure 2: Exterior Placards 2
Page 2 Doc # 6.02.15
15 Apr 2013 11-20-00 Rev. 2
DA 40 NG AMM Placards and Markings
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to replace safety walk adhesive strips.
2. Replace the Safety Walk Adhesive Strips
A. Equipment
Item Quantity Part Number
Safety walk template. 1 D44-1127-10-52.
Roller. 1 Commercial.
Heat gun. 1 Commercial.
B. Material
Item Quantity Part Number
Socomore Dienstone DLS Satwipes as required 29003-C86-C10.
Acetone as required N000 148.
C. Replacement Procedure
Detail Steps/Work Items Key Items/References
(1) Remove the safety walk adhesive strips:
S Use a heat gun to warm up the safety Do not exceed 60° C (140°F).
walk adhesive strips.
S Start removing the safety walk adhesive
strips by lifting one corner.
S Carefully pull the safety walk adhesive
strips off.
WARNING: WHEN HANDLING CHEMICALS ALWAYS OBSERVE HEALTH AND
SAFETY REGULATIONS GIVEN BY THE MANUFACTURER OF THE
CHEMICALS.
Doc # 6.02.15 Page 201
Rev. 2 11-20-00 15 Apr 2013
Placards and Markings DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(2) Remove the adhesives layer of the safety
walk adhesive strips from surface:
S Use fresh acetone or Socomore®
cleaning cloth (P/N: 29003-C86-C10) to
remove the adhesive layer. Do not use
cleaning or polishing agents which
contain silicon.
(3) Use water to remove dirt from the surface. If Refer to Section 12-30.
necessary, add a mild cleaning agent.
(4) Use a commercial solvent to remove grease
from the surface. The surface must be
totally clean from grease or dirt.
(5) Place the safety walk template on the LH Refer to Figure 3.
side of center wing.
(6) Make sure that the template orientation is
parallel to flight direction.
(7) Remove the protective layer from the safety Note LH side - long strips.
walk adhesive strips.
(8) Place the safety walk adhesive strips into
the slots of the safety walk template.
(9) Use a roller to flatten and paste on the
safety walk adhesive strips.
% (10) Place the ‘No Step’ placard (front) and the Refer to Figures 1, 2 and 3.
‘Foot Step’ placard (rear) according to the
safety walk template.
(11) Use a clean cloth to flatten the ‘No Step’
placard and the ‘Foot Step’ placard.
(12) Remove the safety walk template.
(13) Place the safety walk template on the RH Refer to Figure 3.
side of center wing.
(14) Make sure that the template orientation is
parallel to flight direction.
Page 202 Doc # 6.02.15
15 Apr 2013 11-20-00 Rev. 2
DA 40 NG AMM Placards and Markings
AIRCRAFT
Detail Steps/Work Items Key Items/References
(15) Remove the protective layer from the safety Note RH side - short strips.
walk adhesive strips.
(16) Place the safety walk adhesive strips into Start from the most forward end of template.
the slots of the safety walk template . Refer to Figure 3.
(17) Use a roller to flatten and paste on the
safety walk adhesive strips.
% (18) Place the ‘No Step’ placard (front) and the Refer to Figures 1, 2 and 3.
‘Foot Step’ placard (rear) according to the
safety walk template.
(19) Use a clean cloth to flatten the ‘No Step’
placard and the ‘Foot Step’ placard.
(20) Remove the safety walk template.
Doc # 6.02.15 Page 203
Rev. 2 11-20-00 15 Apr 2013
Placards and Markings DA 40 NG AMM
AIRCRAFT
Prefabricated Strips
Root Rib
10mm
Place Safety
Template Walk Cover
to Trailing Edge
Template Place Safety
Walk Cover
to Trailing Edge
10mm
Root Rib
Prefabricated Strips
Figure 3: Safety Walk Template Positioning
Page 204 Doc # 6.02.15
15 Apr 2013 11-20-00 Rev. 2
DA 40 NG AMM Placards and Markings
AIRCRAFT
Section 11-30
Interior Placards and Markings
1. General
Figure 1 shows the interior placards and markings.
Figures 2 thru 4 show the instrument panel placards, if the G1000 system is installed.
Figures 5 shows the instrument panel placards, if the conventional cockpit is installed.
Doc # 6.02.15 Page 1
Rev. 2 11-30-00 15 Apr 2013
Placards and Markings DA 40 NG AMM
AIRCRAFT
Rear Wall of Baggage Side Wall of Baggage
Compartment Compartment
C OCKPIT B AGGAGE BAG GAGE STAN D ARD BAGG AGE SHO RT BAG GAGE
C O MPAR TM ENT EXTEN SION C OMPA R TM ENT EXTEN SION
M AX. 45 kg [100 lb] M AX. 18 kg [40 lb] M AX. 30 kg [66 lb] M AX. 15 kg [33 lb]
ARM : 3.89 M [153.1”] ARM : 4.54 M [178.7”] ARM : 3.65 m [143.7 in] ARM : 3.97 m [156.3 in]
ELT
LOCATED
HERE M AX BAGG AGE T O TAL (CO CKPIT BAGGAGE
C O MPAR TM ENT & EXT EN SION) : 45 kg [100 lb]
C AU TION : OBS ERVE W EIG HT AND BALAN CE LIMITATION S C AU TION : OBSERVE W E IG HT AND BALAN CE LIMITATIO N S
SEE AIR PLAN E FLIGHT MAN UA L C H APT ER 6 SEE AIR PLAN E FLIGHT MAN UAL C H APT ER 6
Optional Optional
NOTE
Inside Top of Contains flourinated greenhouse gas
covered by the Kyoto Protocol.
Passenger Door 1,1,1,2 - Tetraflouroethane
Optional
MAP LIGHT
Optional
Inside Passenger Door
Rear Face of
Center Console
Alternate Static
OPEN
CLOSED
If Alternate Static is open
Emergency Window and
Cockpit Vent must be closed
Inside Cockpit Door
Below LH Canopy Frame
Figure 1: Interior Placards and Markings
Page 2 Doc # 6.02.15
15 Apr 2013 11-30-00 Rev. 2
DA 40 NG AMM Placards and Markings
AIRCRAFT
Optional, if GFC 700 is installed
Limitations for GFC 700 Autopilot System:
Do not use AP if “Alternate Static” is open.
Conduct AP and trim check prior to each flight (see AFM).
Autopilot OFF during take-off and landing.
Maximum speed for autopilot operation is 165 KIAS.
Minimum speed for autopilot operation is 70 KIAS.
Minimum altitude for autopilot operation:
Cruise, Climb, Descent and Maneuvering: 800 feet AGL
Approach: 200 feet AGL
Optional, if KAP 140 is installed
Limitations for KAP 140 Autopilot System:
Optional H
O
OFF ENG INE POWE R IS LIM ITED TO M AX. 80& LO AD INDICATION
DURING A UTO PILO T OPE RATION.
R For N 30 60 E 120 150 DO NOT USE A P IF “ALTE RNATE STATIC” IS OP EN.
GPS NOT APPROVED I
Z
Steer CO NDUCT A P A ND TRIM CHECK PRIOR T O EACH FLIGHT (SEE AF M).
AUTO PILOT OFF DURING TAKE-OFF AND LA NDING.
FOR WAAS OPERATIONS O For S 210 240 W 300 330 MA XIMUM SP EED FO R A UTOP ILOT OPERATION IS 160 KIA S.
MINIMUM SP EED F OR AUT OP ILOT OPERATIO N IS 75 KIA S.
N ON Steer MINIMUM A LTITUDE FO R A UTO PILO T O PE RATION:
CRUISE , CLIMB, DES CE NT AND M ANEUVERING: 800 FEET AG L
EMERGENCY APP ROACH: 200 FEET AGL
H
OF F
O
R
I
Fo r N 3 0 60 E 12 015 0
Z Steer
O Fo r S 2 1024 0 W 30 033 0
N ON Steer
G PS NO T AP PROVED
FOR WAAS OPERATIONS
EMERGENCY
OE-XXX
Manouvering speed:
L imitatio ns for GFC 700 Au topi lot Sys te m:
VA =11
1 KIAS (above 1036 up to 1200 kg / above 2284 up to 2646 lb)
THEAUX PO WER SWITC H MUST BE Do not use AP if “Alternate St atic” is open.
VA=94 KIAS (780 to 1036 kg / 1720 to 2284lb) Ess Bus SWITCHED OFF IN ALL EMERGENCIES,
This airplane may only be oper ated in acco rdance with theAirplane Flight max . us ab le fue l: 2 x 19. 5 U S gal Conduct AP an d tr imc heck pr ior to e ach flight (s ee AFM) .
not for DURIN G TAKE-O FF, LANDING , GO- Auto pilot OFF dur ing take -off and landing.
Manual. It can be operated in the "Normal" and "Utility" ca tegories in * M a x indi cated f ue l q ua ntit y: 2 x 14 U S g al AROUND OR ABNORMAL OPERATIN G
non-icing conditions. Provided that national operational requirements
normal Maximum speed for au top ilot oper ation is 165 KIAS.
* R e fer t o AFM to u se en t ire ta nk ca paci ty PROCEDURES, AT OUTSI DEAI R
are me t and the appropr iate equipment is insta led, this airplane is ap- operation * M a x di ffe re nce LH /R H t an k : 9 U S gal TEMPERATURES BELOW 10 °C (50 °F) , Minimum speed f or aut opilot oper ation is 70 KIAS.
proved for the following kinds of opera tion: day VFR, night VFRand SeeAFM ABOVE 10,00 0ft MSL AND I F ADF IS IN U SE. Minimum altitude for autopilo t oper ation:
IFR. All aeroba tics maneuvers including spinnin g are prohibited. For Cr uise, Climb, Descen t an d Man euv erin g: 8 00 fee t AGL
further operational limitations refer to the Airplane Flight Manual.
No smoking Approach: 2 00 fee t AGL
Optional Optional ALTER NATE A IR
P
R
max. usable fuel: 2 x 19.5 US gal THE AUX POWER SWITCH MUST BE A
R E
D
E
ON
L
* Max indicated fuel quantity: 2 x 14 US gal SWITCHED OFF IN ALL EMERGENCIES, K
I E
F
R
C
A
A
* Refer to AFM to use entire tank capacity DURING TAKE-OFF, LANDING, GO- ALTER NATE A IR
ON
N
G S
O B
ALTERNATE AIR
S I
* Max difference LH/RH tank: 9 US gal AROUND OR ABNORMAL O PERATING E
T N P
PROCEDURES, AT OUTSIDE AIR B A R
R F H
D ON
TEMPERATURES BELOW 10 °C (50 °F), A
L L E
R E
ABOVE 10,000ft MSL AND IF ADF IS IN USE. K
O
C
O
O
A
T L E
E K R K F C
OFF
I E
R A
N A
O B
G S
E S I
T N
B
F H
R
L L E
A
100% O O A
K T
C O
E
K R
OFF
GO-
ARO UND
0%
FUEL VALVE
N OR M AL EM ER GE NC Y
CAUTION intermittent use
only (seeAFM)
100%
EL
FU
OFF
0%
FUEL VALVE
NORMAL EMERGENCY
CA U TION interm ittent use
onl y (s ee AFM )
OFF
Figure 2: Instrument Panel Placards and Markings
Doc # 6.02.15 Page 3
Rev. 2 11-30-00 15 Apr 2013
Placards and Markings DA 40 NG AMM
AIRCRAFT
EECU BUS
FUEL FUEL
EECU A EECU B EECU A EECU B PUMP A PUMP B
20 20 20
ESSENTIAL BUS
HORIZON AHRS ADC COM1 GPS/NAV1
3 5 5 5 5
5 5 5 10 3
MASTER
CONTROL
5 5 2 30 30
MAIN BUS
ENGINE AVIONICS BUS
VOTER ECU MA STER
ECU A TEST
ON
AUTO 60 5 5 5 25 5 5 5 2
O FF
ECU B
FUEL
PUM PS
ON
O FF
3 10 5 3 5 5 3
ESS AVIONIC
BUS MASTER Limita tio ns for GFC 7 00 Au topi lot Sys te m:
Do not use APif “Alternate St atic” is o pen.
Ess Bus ON Condu ct AP and tr im c heck pr ior to e ach flight (s ee AFM) .
not for Autopilot OFF dur ing take-off and landin g.
normal Maximum speed for au top ilot o per atio n is 165 KIAS.
operation Minimum speed f or aut opilot oper ation is 70 KIAS.
See AFM OFF Minimum altitude for au topilot oper ation:
Cr uise, Climb , Descent an d Maneuv erin g: 8 00 feet AGL
Approach: 2 00 feet AG L
ESS AVIONIC
BUS MASTER
Ess Bus ON
not for
normal
operation
See AFM OFF
ELECTRIC MASTER FUEL TRANS PITOT FLAPS Limitations for GFC 700 Autopilot System:
ON S Do not use AP if “Alternate Static” is open.
T UP
F Conduct AP and trim check prior to each fli ght (see AFM ).
AR
OF
ON Autopilot OFF dur ing take-off and landing.
T
T/O Maxim um speed for autopilot oper ation is 165 KIAS.
108 KIAS Mi ni mum speed for autopilot operation is 70 KIAS .
OFF Mi ni mum al titude for autopil ot operation:
LDG Cr ui se, Climb, D escent and Maneuver ing: 800 feet AGL
91 KIAS Approach: 200 feet A GL 28V GROUND OPS. ONLY 2A MAX
Figure 3: Placard Panels - Sheet 1
Page 4 Doc # 6.02.15
15 Apr 2013 11-30-00 Rev. 2
DA 40 NG AMM Placards and Markings
AIRCRAFT
Manouvering speed: L imitations fo r G FC 700 Auto pi lot Sys tem:
VA =11
1 KIAS (above 1036 up to 1200 kg / above 2284 up to 2646 lb)
Do not use AP fi “Alte rnate St atic” is open.
VA =94 KIAS (780 to 1036 kg / 1720 to 2284lb) Ess Bus Con duct AP an d tr imc heck pr ior to each flight (s ee AFM) .
This airplane may only be oper ated in acco rdance with t heAirplane Flight not for
Manual. It can be operated in the "Normal" and "Utility" ca tegories in Auto pilot OFF dur ing take -off an d la nding.
non-icing conditions. Provided that national operational requirements normal Maximum speed for autop ilo t oper ation is 165 KIAS.
are me t and the appropr iate equipment is insta led, this airplane is ap- operation Minimum spee d f or aut opilot oper ation is 7 0 KIAS.
proved for the following kinds of opera tion: day VFR, night VFRand
IFR. All aerobatics maneuvers including spinnin g are prohibited. For
SeeAFM Minimum altitu de for autopilo t oper ation:
Cr uise, Climb, De scen t an d Man euv erin g: 800 fee t AGL
further operational limitations refer to the Airplane Flight Manual.
No smoking App roach: 200 fee t AGL
Figure 4: Placard Panels - Sheet 2
Doc # 6.02.15 Page 5
Rev. 2 11-30-00 15 Apr 2013
Placards and Markings DA 40 NG AMM
AIRCRAFT
OPERATING MANEUVERING SPEED:
INSTRUMENT vo = 113 KIAS (ABOVE 1180 KG / ABOVE 2601 LB)
ON vo = 108 KIAS (ABOVE 1080 KG TO 1180 KG / ABOVE 2381 LB TO 2601 LB)
ELECTRIC ESS. AVIONIC FUEL TRANS
PITOT LANDING TAXI POSITION STROBE MASTER BUS MASTER vo = 101 KIAS (ABOVE 1080 KG / ABOVE 2381 LB)
ENGINE
ON ST THIS AIRPLANE MAY ONLY BE OPERATED IN ACCORDANCE WITH THE AIRPLANE FLIGHT
ON MASTER
OFF
AR
F
MANUAL. IT CAN BE OPERATED IN THE “NORMAL” CATEGORY IN NON-ICING
OF
T
FLOOD CONDITIONS. PROVIDED THAT NATIONAL OPERATIONAL REQUIREMENTS ARE MET AND
ON OFF THE APPROPRIATE EQUIPMENT IS INSTALLED AND OPERATIONAL, THIS AIRPLANE IS
APPROVED FOR THE FOLLOWING KINDS OF OPERATION: DAY VFR, NIGHT VFR AND IFR.
FUEL
ALL AEROBATIC MANEUVERS INCLUDING SPINNING ARE PROHIBITED. FOR FURTHER
PUMPS
ON OFF OPERATIONAL LIMITATIONS REFER TO THE AIRPLANE FLIGHT MANUAL.
OFF NO SMOKING
VOTER ECU
ECU TEST
AUTO
ECU B
P W R/ XM T PM1000II
PILOT CO-PI LOT
IS O
O P E R A T I N G M A NE U V E RI N G S P E E D :
AL L v o = 11 3 K I A S ( A B O V E 1 1 80 K G / A B O V E 26 0 1 LB )
v o = 10 8 K I A S ( A B O V E 1 0 8 0 K G T O 11 8 0 K G / A B O V E 2 38 1 L B T O 2 6 0 1 L B )
OFF v o = 10 1 K I A S ( A B O V E 1 0 8 0 K G / A B O V E 2 3 81 L B )
0
T H I S A I R P L A N E M A Y O N LY B E OP E R A T E D I N A C CO R DA N CE W I T H T H E A I RP L A N E F LI G HT
VO LUME SQ UEL CH VO LUME SQ UELCH
M A NU A L . I T C A N B E O P E R A T E D I N T HE “N O R MA L ” C AT E GO RY I N N O N- C I I NG
CO ND IT I O NS . P R O V I D E D T HA T N AT I O N A L O P E RA T I O NA L RE Q U I RE ME N T S A RE M E T A ND
9 1 T H E A P P R O P R I A T E E Q UI P M E N T I S I N S TA LL E D A ND O P E R AT I O N A L , T HI S A I R P L A NE I S
A P P R OV E D F O R T HE F O LL O W I NG K I ND S O F O P E RA T I O N: D A Y V F R A N D NI G HT V F R .
20 A L L A E RO B A T I C M A NE U V E RS I N CL UD IN G S P I N NI NG A R E P R OH I B I T E D. F O R F UR T H E R
160 O P E R A T I O NA L L IM I T A T I ON S RE F E R T O T HE A I R P LA NE F L I GH T M A N U A L .
INSTRUMENT AIRSPEED 40 10 20 8 ALT 2 NO S M OK I N G
140 10 CALIBRATED
TO
ON 10 20 ,000 FEET
120 20 10
KNOTS 60 20
7 3
100
OFF 80 6 4 OP
FLOOD 5 LH RH
OT 0 ,9 ba r 6 ,5 CT 14
F U ELP RE SS
14 0
ON FLOW-GAL/hr
9 1 O.A.T. VOLTS
FT FT
- 30 °C 1 40 GT - 30 °C 1 05
FUEL 8 ALT
PUMPS 2 30 0
l/ min %
1 00
10
60 60
10
2
DC VOLTAGE/V CALIBRATED
ON OFF EL E C RPM - 30 °C 1 20 UT LT
24 10
L R TO
20,000 FEET
21 27 2 4 ,1 32
OFF 5
UP
15 -2 5 CURRENT/A - 2 5
7 3 FT ET
5 °C °C 5
15 18
VOTER ECU
30 33 0
VE RT IC AL S PEE D SELECT CONTROL
ECU TEST 100 FE ET P ER M IN UT E
20
LOAD
W ATER L E V
70
6 4
% 0 0 5
AUTO TU R N CO OR D IN ATO R 20 GAL
ma x . us a ble fu el: 2 x 19 . 5 U S ga l
12
ECU B L R DOWN * M ax indi ca ted f u el qua ntit y: 2 x 14 U S g al
* R efe r t o AFM to use e nt ire tan k ca pa c ity
9 3 5 15 * M ax di ffere nce L H /R H t ank : 9 U S ga l
2 M IN 6 10
N O P ITC H
IN FO R MATI ON
P U L L S QU E L CH TX
Ess. Bus not for normal operation. See AFM VOL
ELECTRIC ESS. AVIONIC FUEL TRANS OFF
PIT OT LANDING TAXI POSIT IO N STROBE MASTER BUS MASTER
ENGINE ON
G TX 32 8
MAX
ON ST MASTER ID E N T FUNC CR SR 110 KIAS
ON FLIGHT TIME
7000
AR
F
OF
ALT ALT
T
S TB
01:23:20 STAR T MIN
O FF
V FR STOP CL R 98 KIAS
Y
OFF
0 1 2 3 4 5 6 7 8 9
A R TEX
E LT
EM ER GE NC Y US E ON LY
ON
A RM
MIC EECU A EECU B FUEL FUEL PWR MAIN FAN/O AT T&B DG INST. LT TAXI/MAP POSIT IO N STROBE START XFER AUDIO COM1 NAV1 XPDR AV. BUS FLAPS HORIZO N ANNUN INST. 1 PIT OT LANDING FLOO D ESS MASTER
T E S T /R E S E T
PUMP A PUMP B TIE PUMP PR E SS O N
TIE CONTRO L
W A IT 1 S E C O N D 28 VDC AC CESSO RY PWR .
ECU BUS MAIN BUS P R ES S A RM
G RO UND O PS. ON LY 2A MAX AVIONIC BUS ESSENTIAL BUS
Ess. Bus not for normal operation. See AFM max. usable fuel: 2 x 19.5 US gal
* Max indicated fuel quantity: 2 x 14 US gal
* Refer to AFM to use entire tank capacity
* Max difference LH/RH tank: 9 US gal
(Optional) MAX
110 KIAS
MIN
98 KIAS
MIC EECU A EECU B FUEL FUEL PWR MAIN FAN/OAT T& B DG INST. LT TAXI/MAP POSITION STROBE START XFER
PUMP A PUMP B TIE PUMP
ECU BUS MAIN BUS
AUDIO COM1 NAV1 XPDR AV. BUS FLAPS HORIZON ANNUN INST. 1 PITOT LANDING FLOOD ESS MASTER
28 VDC ACCESSORY PWR. TIE CONTROL
GROUND OPS. ONLY 2A MAX AVIONIC BUS ESSENTIAL BUS
Figure 5: Instrument Panel Placards and Markings - Conventional Cockpit (OÄM 40-321)
Page 6 Doc # 6.02.15
15 Apr 2013 11-30-00 Rev. 2
DA 40 NG AMM Servicing
AIRCRAFT
CHAPTER 12
SERVICING
Doc # 6.02.15 Page 1
Rev. 2 12-TITLE 15 Apr 2013
Servicing DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 12-TITLE Rev. 2
DA 40 NG AMM Servicing
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 12
SERVICING
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 12-10
Replenishing
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Refueling/Defueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Fuel Contamination Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Engine Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7. Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8. Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9. Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Section 12-20
Scheduled Servicing
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Section 12-30
Unscheduled Servicing
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Exterior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Canopy Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Interior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. Engine Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6. Snow and Ice Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Doc # 6.02.15 Page 1
Rev. 2 12-CONTENTS 15 Apr 2013
Servicing DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 12-CONTENTS Rev. 2
DA 40 NG AMM Servicing
AIRCRAFT
CHAPTER 12
SERVICING
1. General
This Chapter gives these servicing tasks which apply to the whole airplane:
) Section 12-10. Replenishing procedures for fluid systems.
) Section 12-20. Lubrication data.
) Section 12-30. Cleaning and snow and ice removal.
The procedures for preventive and corrective maintenance of systems are given in the related Chapter
of this manual. Refer to Chapter 05 for time limits and schedules.
Note: The designation of "left" and "right" as well as "forward" and "aft" is based on the
airplanes direction of flight.
Doc # 6.02.15 Page 1
Rev. 2 12-00-00 15 Apr 2013
Servicing DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 12-00-00 Rev. 2
DA 40 NG AMM Servicing
AIRCRAFT
Section 12-10
Replenishing
1. General
Use the procedures in this Section to replenish the fluid systems on the airplane. Figures 1 thru 2 show
the location of the servicing points.
2. Fuel System
The fuel tanks are located in each wing between the two main spars. They consist of one (Standard
Tank configuration) or two (Long Range Tank configuration) interconnected chambers. Number of
chambers and usable fuel capacity are shown in the following table:
Chambers Usable Capacity per Tank
Fuel Tank Version
per Tank [US gal] [liter]
Standard Tank
1 14 53
Configuration
Long Range Tank
Configuration 2 19.5 74
(OÄM 40-130)
Each wing has a fuel filler cap located at the top wing side about midway between the wing root and
the tip. The filler cap connects to the outboard end of the fuel tanks. A fuel tank drain is located below
each wing just outboard of the wing root. A third drain is located below the front fuselage and is
connected to the gascolator.
WARNING: DO NOT ALLOW FIRE, SPARKS OR HEAT NEAR FUEL. FUEL BURNS
VIOLENTLY AND CAN CAUSE INJURY TO PERSONS AND DAMAGE
TO THE AIRPLANE.
WARNING: DO NOT GET FUEL ON YOUR SKIN. FUEL CAN CAUSE SKIN DISEASE.
WARNING: CONNECT THE AIRPLANE AND THE FUEL SUPPLY VEHICLE TO
ELECTRICAL GROUND BEFORE REFUELING. IF YOU DO NOT
GROUND THE AIRPLANE, STATIC ELECTRICITY CAN CAUSE FIRE
DURING REFUELING.
Doc # 6.02.15 Page 1
Rev. 2 12-10-00 15 Apr 2013
Servicing DA 40 NG AMM
AIRCRAFT
WARNING: MAKE SURE THAT A FIRE EXTINGUISHER IS AVAILABLE.
WARNING: TURN OFF ALL GROUND EQUIPMENT IN THE REFUELING AREA.
WARNING: DO NOT OPERATE ELECTRICAL SWITCHES IN THE AIRPLANE.
CAUTION: USE ONLY FUEL TYPES GIVEN IN CHAPTER 2 OF THE AIRPLANE
FLIGHT MANUAL.
Page 2 Doc # 6.02.15
15 Apr 2013 12-10-00 Rev. 2
DA 40 NG AMM Servicing
AIRCRAFT
%
%
%
%
%
%
%
%
%
%
%
% Fuel
% Brake Fluid
(on Co-Pilot’s
%
Brake Pedals)
%
%
%
%
%
%
% Fuel
%
%
Tire Air
% Tire Air (LH & RH)
%
%
%
%
%
%
%
%
%
%
%
%
Figure 1: Replenishment Points
Doc # 6.02.15 Page 3
Rev. 2 12-10-00 15 Apr 2013
Servicing DA 40 NG AMM
AIRCRAFT
3. Refueling/Defueling
A. Refueling
Detail Steps/Work Items Key Items/References
(1) Shut down the engine.
(2) Set ENGINE MASTER OFF.
(3) All occupants leave the airplane.
(4) Ground the airplane electrically. At the refueling connection.
(5) Ground the refueling vehicle electrically.
(6) Remove the fuel filler cap.
(7) Refuel the airplane.
(8) Install the fuel filler cap. Make sure that the filler cap is locked.
(9) Do steps 6 thru 8 for the other wing.
(10) Remove the ground cable from the airplane.
(11) Remove the ground cable from the refueling
vehicle.
B. Defueling
Detail Items/Work Steps Key Items/References
(1) Ground the airplane electrically. At the refueling connection.
(2) Put a suitable container below the drain valve Make sure that you have enough
for the wing that you will defuel. containers to hold all the fuel. Each wing
can hold approximately 20 US gal
(75 liter) fuel.
(3) Open the drain valve.
(4) When the fuel stops draining, close the drain Make sure that the drain valve is seated
valve. correctly.
(5) If necessary, do steps 2 thru 4 for the other
wing.
(6) Remove the ground cable from the airplane. At the refueling ground connection.
Page 4 Doc # 6.02.15
15 Apr 2013 12-10-00 Rev. 2
DA 40 NG AMM Servicing
AIRCRAFT
4. Fuel Contamination Test
A. Equipment
Item Quantity Part Number
Glass container. 1 Commercial.
B. Fuel Contamination Test Procedure
Detail Steps/Work Items Key Items/References
(1) Put the glass container under the fuel tank drain
valve that you will take the fuel from.
(2) Open the drain valve.
(3) When the fuel container is half full, close the Make sure that the drain valve is seated
drain valve. correctly.
(4) Let the fuel in the glass container stand for
1 minute.
(5) Examine the fuel sample: If you find any contamination you must
do the test again. If you still find
S It must be clear (JET A1).
contamination after 3 tests, you must
S Look specifically for small water droplets at drain the related fuel tank. Flush the
the bottom of the glass container. tank (use fuel) and fill it with clean fuel.
S Look for small contamination particles.
(6) Perform steps 1 thru 5 for the other wing.
(7) Perform steps 1 thru 5 for the drain valve at the Gascolator drain is located below the
gascolator. front fuselage.
Doc # 6.02.15 Page 5
Rev. 2 12-10-00 15 Apr 2013
Servicing DA 40 NG AMM
AIRCRAFT
5. Engine Oil System
WARNING: ENGINE OPERATION WITH NO ENGINE OIL (OR VERY LOW OIL
LEVEL) WILL CAUSE ENGINE MALFUNCTION OR FAILURE.
The engine installed on the DA 40 NG has a wet-sump oil system. The oil capacities are given in the
following table:
Oil Sump Capacity Minimum Safe Quantity
[liters] [US qts] [liters] [US qts]
7.0 7.4 5.0 5.3
Use only oil specified by the engine manufacturer.
The oil filler is located on the left side of the engine (Figure 2). There is an access hole implemented
in the top engine cowling LH side. The oil filler has a dip-stick attached.
A marginal oil consumption of 0.1 liter/h is normal. Measure the oil quantity before each flight (or
engine ground run-up). If necessary, replenish the oil system.
Page 6 Doc # 6.02.15
15 Apr 2013 12-10-00 Rev. 2
DA 40 NG AMM Servicing
AIRCRAFT
A. Replenish the Engine Oil System
Detail Steps/Work Items Key Items/References
(1) Open the access panel on the LH side of the top
cowling.
% CAUTION: USE ONLY APPROVED ENGINE OIL. REFER TO CHAPTER 2 OF
% THE AIRPLANE FLIGHT MANUAL FOR APPROVED ENGINE OIL
% SPECIFICATIONS. IF YOU DO NOT USE APPROVED ENGINE OIL,
THE ENGINE CAN BE DAMAGED.
% (2) Replenish the oil system to the correct level. Refer to AE Maintenance Manual, latest
% revision.
(3) Close the access panel of the top cowling.
Doc # 6.02.15 Page 7
Rev. 2 12-10-00 15 Apr 2013
Servicing DA 40 NG AMM
AIRCRAFT
%
%
%
%
%
%
%
%
%
% Coolant
%
%
%
%
%
%
%
%
%
Gearbox Oil
%
%
%
%
% Engine Oil
%
%
%
%
%
%
%
%
%
%
%
% Figure 2: Replenishment Points 2
Page 8 Doc # 6.02.15
15 Apr 2013 12-10-00 Rev. 2
DA 40 NG AMM Servicing
AIRCRAFT
6. Gearbox Oil
WARNING: ENGINE OPERATION WITH NO GEARBOX OIL (OR VERY LOW OIL
LEVEL) WILL CAUSE ENGINE MALFUNCTION OR FAILURE.
% The gearbox oil level can be checked through an oil level window at the front side of the engine.
A. Replenish the Gearbox Oil System
CAUTION: IF THE GEARBOX OIL LEVEL IS LOW THE REASON MUST BE
DETERMINED AND THE PROBLEM MUST BE CORRECTED BY
AUTHORIZED PERSONNEL.
Detail Steps/Work Items Key Items/References
(1) Remove the engine top cowling. Refer to Section 71-10.
% CAUTION: USE ONLY APPROVED GEARBOX OIL. REFER TO CHAPTER 2 OF
% THE AIRPLANE FLIGHT MANUAL FOR APPROVED GEARBOX OIL
% SPECIFICATIONS. IF YOU DO NOT USE APPROVED GEARBOX OIL,
THE ENGINE CAN BE DAMAGED.
% (2) Replenish gearbox oil. Refer to AE Maintenance Manual, latest
% revision.
(3) Install the engine top cowling. Refer to Section 71-10.
Doc # 6.02.15 Page 9
Rev. 2 12-10-00 15 Apr 2013
Servicing DA 40 NG AMM
AIRCRAFT
7. Engine Coolant
WARNING: DO NOT REMOVE THE EXPANSION TANK FILLER CAP WHEN THE
ENGINE IS HOT. THE TANK IS PRESSURIZED WITH HOT COOLANT.
HOT COOLANT CAN CAUSE INJURY TO PERSONS.
WARNING: DURING NORMAL OPERATION THE AE E4 ENGINE SHOULD NOT
CONSUME COOLANT. ANY COOLANT LOSS MUST BE INVESTIGATED
BEFORE FURTHER OPERATION OF THE ENGINE. OPERATING THE
ENGINE WITH A FAULTY COOLING SYSTEM CAN DAMAGE THE
ENGINE.
The DA 40 NG engine uses liquid coolant to cool the engine and supply heating to the cabin. The
coolant is circulated around the engine in an integral water jacket. When the coolant is at normal
engine operating temperature a thermostatic valve directs the coolant to flow through a heat
exchanger. The thermostatic valve controls the flow of coolant through the coolant radiator in order to
control the temperature of the coolant.
% A coolant expansion tank is located on the left side of the engine (Figure 3). The expansion tank has
a filler cap and a pressure regulating valve to protect the system from over pressure. Use the
procedures in this Paragraph to replenish the coolant system when the system has been drained for
maintenance or system repair.
A. Replenish the Coolant System
CAUTION: IF THE COOLANT LEVEL IS LOW THE REASON MUST BE
DETERMINED AND THE PROBLEM MUST BE CORRECTED BY
AUTHORIZED PERSONNEL.
Detail Steps/Work Items Key Items/References
(1) Remove the engine top cowling. Refer to Section 71-10.
WARNING: DO NOT REMOVE THE PRESSURE CAP FROM THE COOLANT
TANK IF THE ENGINE IS HOT. THE PRESSURE IN THE SYSTEM
CAN FORCE HOT COOLANT TO COME OUT AND CAUSE INJURY
TO PERSONS.
Page 10 Doc # 6.02.15
15 Apr 2013 12-10-00 Rev. 2
DA 40 NG AMM Servicing
AIRCRAFT
Detail Steps/Work Items Key Items/References
(2) Remove the pressure cap from the coolant tank:
S Turn the cap counter-clockwise a small
distance to release the pressure.
S When the pressure has fully released, turn
the cap fully counter-clockwise.
% CAUTION: USE ONLY APPROVED COOLANT. REFER TO CHAPTER 2 OF THE
% AIRPLANE FLIGHT MANUAL FOR APPROVED COOLANT
% SPECIFICATIONS. IF YOU DO NOT USE APPROVED COOLANT,
THE ENGINE CAN BE DAMAGED.
(3) Add coolant until the level is at the bottom of the Allow time for the coolant to move
tank filler tap. through the system.
(4) Install the filler cap.
(5) Do an engine ground run-up until the engine Refer to Section 71-00
reaches normal operating temperature. Then
Inspect for leaks.
shut down the engine.
(6) Let the engine cool down.
WARNING: DO NOT REMOVE THE PRESSURE CAP FROM THE COOLANT
TANK IF THE ENGINE IS HOT. THE PRESSURE IN THE SYSTEM
CAN FORCE HOT COOLANT TO COME OUT AND CAUSE INJURY
TO PERSONS.
Note: When the coolant system has been drained for maintenance / repair air may get
trapped in the system. The following steps are to remove any air trapped in the
system and give a correct fluid level in the expansion tank.
(7) Repeat steps 2 thru 6 until the coolant level
remains constant and is at the correct level.
(8) Install the engine top cowling.
Doc # 6.02.15 Page 11
Rev. 2 12-10-00 15 Apr 2013
Servicing DA 40 NG AMM
AIRCRAFT
8. Brake System
The brake fluid reservoirs are located on the brake master cylinders on the co-pilot’s side. You get
access in the cockpit below the instrument panel.
WARNING: DO NOT GET BRAKE FLUID ON YOUR SKIN OR IN YOUR MOUTH.
BRAKE FLUID IS TOXIC AND CAN CAUSE INTERNAL INJURY.
CAUTION: REMOVE SPILLED BRAKE FLUID IMMEDIATELY. BRAKE FLUID CAN
CAUSE DAMAGE TO PAINT AND OTHER MATERIALS.
A. Fill the Brake System Reservoirs
Detail Steps/Work Items Key Items/References
(1) Clean the top of the brake fluid reservoir and filler
cap.
(2) Remove the filler cap.
(3) Fill the reservoir to the correct level. Use only MIL-H-5606A hydraulic fluid.
12 to 25 mm (0.5 to 1 in) below the top
of the filler hole.
(4) Install the filler cap.
Page 12 Doc # 6.02.15
15 Apr 2013 12-10-00 Rev. 2
DA 40 NG AMM Servicing
AIRCRAFT
9. Tires
The DA 40 NG has these tires:
% Main tires: 15x 6.0 - 6, 6PR, TT, 160 mph, TSO C62; pressure (loaded): 3.3 bar (48 PSI).
% Nose tire: 5.00 - 5, 6PR, TT, 120 mph; TSO C62; pressure (loaded): 3.1 bar (45 PSI).
% If MÄM 40-631 is installed:
% Main tires: 15x 6.0 - 6, 6PR, TT, 160 mph, TSO C62; pressure (loaded): 3.3 bar (48 PSI).
% Nose tire: 5.00 - 5, 6PR, TT, 120 mph; TSO C62; pressure (loaded): 2.4 bar (35 PSI).
% If OÄM 40-334 is installed:
% Main tires: 8.50 - 6, 6PR, TT, 120 mph, TSO C62; pressure (loaded): 1.2 bar (17 PSI).
% Goodyear, P/N 856C61-3
% Nose tire: 6.00 - 6, 6PR, TT, TSO C62; pressure (loaded): 1.2 bar (17 PSI)
% Goodyear, P/N 606C66-8
% Goodyear, P/N 606C61-6
% Goodyear, P/N 606C61B1
Doc # 6.02.15 Page 13
Rev. 2 12-10-00 15 Apr 2013
Servicing DA 40 NG AMM
AIRCRAFT
A. Examine the Tires and Measure the Pressure
Detail Steps/Work Items Key Items/References
(1) Examine the tires. Look specially for: Move the airplane as necessary so that
each part of each tire can be seen.
S Cuts and friction damage.
If the slippage markers do not align,
S Correct alignment of the slippage markers.
remove the wheel for shop
maintenance.
% (2) Measure the tire pressure (loaded). If necessary,
inflate the tires to the correct pressure:
Main tire: 3.3 bar (48 PSI).
Nose tire: 3.1 bar (45 PSI).
% If MÄM 40-631 is installed:
% Nose tire: 2.4 bar (35 PSI).
% If OÄM 40-334 is installed:
% Main tire: 1.2 bar (17 PSI) -1.5 bar
% (22PSI).
% Nose tire: 1.2 bar (17 PSI) -1.5 bar
% (22PSI).
% For operation on paved surface or hard
% unpaved surfaces it is recommended to
% operate the airplane at the upper limit of
% the inflation pressure.
Page 14 Doc # 6.02.15
15 Apr 2013 12-10-00 Rev. 2
DA 40 NG AMM Servicing
AIRCRAFT
Section 12-20
Scheduled Servicing
1. General
This Section gives lubrication data. It tells you where components are located. It gives a list of
approved lubricants. It also gives the components which MUST NOT be lubricated.
Most systems and components have maintenance-free bearings. These can be sealed ball/roller
bearings or Teflon bushes. These bearings MUST NOT be lubricated. Table 1 shows the bearings
which MUST NOT be lubricated.
Table 1 - Items which MUST NOT be Lubricated
Rudder pedal sled. DO NOT LUBRICATE.
Flap rod-end bearings. DO NOT LUBRICATE.
Aileron rod-end bearings. DO NOT LUBRICATE.
Elevator rod-end bearings. DO NOT LUBRICATE.
Elastomeric spring. (See Note 7). DO NOT LUBRICATE.
Doc # 6.02.15 Page 1
Rev. 2 12-20-00 15 Apr 2013
Servicing DA 40 NG AMM
AIRCRAFT
2. Lubrication Schedule
Table 2 shows the lubrication schedule. Clean each lubrication point before lubrication.
See Figures 1 thru 3 for the location of lubrication points listed on the left side of the table. The center
columns show the type of lubricant. The right column shows the lubrication interval.
Table 2 - Lubrication Schedule
Location Type of Lubricant Interval
No. See Figures 1 thru 3 1 2 3 4 5 6 (Hours)
see Notes (1), (2)
(1) Brake pedal pivot. 200
(2) Rudder cable S-tubes. 200
(3) Flap actuator extension rod. 200
(4) Passenger door safety hook (red). 100
(5) Upper rudder pivot bearing. 200
(6) Nose wheel bearing (see notes 3, 5 and 6). 200
(7) Wing main bolts. 1000
(8) Elastomer pack eye-end 200
(9) Battery terminals. 1000
(10) B-bolts. 1000
(11) B-bolt spherical bearings. 1000
(12) A-bolts. 1000
(13) A-bolt spherical bearings. 1000
(14) Brake pedal pivot shaft interior. 1000
(15) Flap actuator universal pivot block. 1000
(16) Brake caliper locating pins. 1000
(17) Stick support pivot pins. 1000
(18) Main wheel bearings (see notes 3, 5 and 6). 200
(19) Cable eyes on rudder. 200
Page 2 Doc # 6.02.15
15 Apr 2013 12-20-00 Rev. 2
DA 40 NG AMM Servicing
AIRCRAFT
Notes:
(1) Lubricate at the time shown or at every disassembly/assembly.
(2) Lubricate more frequently in severe climates or operating conditions.
(3) Lubricate at the time shown and at Annual Inspection.
(4) Do not get grease on the threads. It will reduce the friction of the lock-nut.
% CAUTION: DO NOT MIX AVIATION WHEEL BEARING GREASES WITH EACH OTHER. IF
% USING OTHER APPROVED GREASES, COMPLETE REMOVAL OF CONTAINED
% GREASE AND BEARING CLEANING IS REQUIRED. REPLACEMENT OF
% PREVIOUSLY LUBRICATED FELT GREASE SEALS IS ALSO REQUIRED.
% (5) The wheel manufacturer lubricates the main wheel bearings with Mobil Aviation Grease SHC
% 100.
(6) On airplanes registered in the USA, lubricate the wheel bearings at every annual/100 hour
inspection (see FAR 43, Appendix D).
(7) The elastomeric spring is maintenance free.
Doc # 6.02.15 Page 3
Rev. 2 12-20-00 15 Apr 2013
Servicing DA 40 NG AMM
AIRCRAFT
Table 3 - Lubricant Specifications
Specification Product Manufacturer
TYPE 1
MIL-G-3545 (obsolete) AeroShell Grease 5 Shell Oil Company
% (Warm climates only)
% GOST 6267-74 Grease CIATIM 201 RUSMA LLC Company
% GOST 9433-80 Grease CIATIM 221 RUSMA LLC Company
% Mobil Aviation Grease Exxon Mobil Company
% SHC 100
% MIL-PRF-81322F Grade 2 AeroShell Grease 22 Shell Oil Company
TYPE 2
MIL-L-7870 Royco 363 Royal Lubricants Co. Inc.
Brayco 363 Bray Oil Co.
LPS 2 LPS
% (Warm climates only)
TYPE 3
Greaseless Lubricant LPS 1
TYPE 4
VV-P-236 (petrolatum) Royco 1 Royal Lubricants Co. Inc.
DC 4 Dow Corning
TYPE 5
MIL-C-16173 (grade 2) LPS 3 LPS
TYPE 6
MIL-A-907 Loctite Antiseize 767 Loctite
Page 4 Doc # 6.02.15
15 Apr 2013 12-20-00 Rev. 2
DA 40 NG AMM Servicing
AIRCRAFT
1
1
2 5
2
15
14
17
16
18
Figure 1: Lubrication Points Sheet 1
Doc # 6.02.15 Page 5
Rev. 2 12-20-00 15 Apr 2013
Servicing DA 40 NG AMM
AIRCRAFT
19
10 & 12
11 & 13
Figure 2: Lubrication Points Sheet 2
Page 6 Doc # 6.02.15
15 Apr 2013 12-20-00 Rev. 2
DA 40 NG AMM Servicing
AIRCRAFT
Section 12-30
Unscheduled Servicing
1. General
This Section tells you how to clean the airplane. It also tells you how to remove snow and ice from the
airplane.
2. Exterior Cleaning
The outer surfaces of the DA 40 NG must be kept clean to keep the good performance characteristics
of the airplane. The leading edges of the wings are specially important.
Protect all control surface bearings and other lubricated components before cleaning the airplane.
Use large quantities of water to clean the airplane. If necessary, add a mild cleaning agent to the
water. Remove excess dirt or dead insects immediately after flight. Dried-on dirt or dead insects are
very difficult to remove.
CAUTION: DO NOT USE CLEANING OR POLISHING AGENTS WHICH CONTAIN
SILICONE. IF THE AIRPLANE NEEDS REPAIR, SILICONE CAN
PREVENT REPAIR MATERIALS FROM BONDING CORRECTLY.
Approximately once a year, apply a silicone-free automotive polish to the outer surface.
3. Canopy Cleaning
CAUTION: DO NOT RUB THE CANOPY WHILE IT IS DRY. DO NOT USE DIRTY
CLOTHS OR SPONGES. THE ACRYLIC CANOPY SCRATCHES VERY
EASILY WITH EVEN THE SMALLEST PARTICLES OF DUST.
Clean the canopy with large quantities of water. Use clean sponges and a good chamois leather which
is not used for any other purpose.
Polish dull or scratched areas using a special acrylic cleaner. Remove scratches with special polishing
emery cloth (e.g. Micro-mesh).
Doc # 6.02.15 Page 1
Rev. 2 12-30-00 15 Apr 2013
Servicing DA 40 NG AMM
AIRCRAFT
4. Interior Cleaning
Clean the interior with a flame-proof vacuum cleaner.
All plastic surfaces should be wiped clean using a damp cloth without any cleaning agents.
CAUTION: IF INSTALLED, THE PFD AND MFD DISPLAYS OF THE GARMIN G1000
USE A LENS COATED WITH A SPECIAL ANTI-REFLECTIVE COATING
THAT IS VERY SENSITIVE TO SKIN OILS, WAXES, AND ABRASIVE
CLEANERS. CLEANERS CONTAINING AMMONIA WILL HARM THE
ANTI-REFLECTIVE COATING. IT IS VERY IMPORTANT TO CLEAN THE
LENS USING A CLEAN, LINT-FREE CLOTH AND AN EYEGLASS LENS
CLEANER THAT IS SPECIFIED AS SAFE FOR ANTI-REFLECTIVE
COATINGS.
5. Engine Cleaning
Use a cold cleaning agent to clean the engine (e.g. Berner Cold Cleaner No.13618.0 or refer to the
AE Maintenance Manual, latest revision).
CAUTION: DO NOT CLEAN THE ENGINE WHILE THE ENGINE IS HOT.
CAUTION: DO NOT USE HIGHLY FLAMMABLE OR CORROSIVE CLEANING
AGENTS TO CLEAN THE ENGINE.
CAUTION: DO NOT LET THE CLEANING AGENT GET INTO ELECTRICAL
COMPONENTS AND ENGINE INTAKES.
CAUTION: DO NOT START THE ENGINE UNTIL ALL OF THE CLEANING AGENT
HAS EVAPORATED.
Protect all electrical components and engine intakes with polythene bags or other means. Obey the
cleaning agent manufacturer's instructions. Refer to the engine manufacturer's Maintenance Instruction
Manual for more data.
Page 2 Doc # 6.02.15
15 Apr 2013 12-30-00 Rev. 2
DA 40 NG AMM Servicing
AIRCRAFT
6. Snow and Ice Removal
Remove snow and ice as soon as possible to prevent melted water from freezing later and causing
damage.
CAUTION: DO NOT USE SHARP OBJECTS TO REMOVE SNOW OR ICE. YOU
CAN DAMAGE THE AIRPLANE STRUCTURE.
% Use soft brushes to remove snow from the surfaces.
% Put the airplane in a heated hangar to remove ice or spray de-icing fluid onto ice-covered surfaces
% using a suitable spray bottle. For approved de-icing fluids refer to the AFM, Section 8.6.
% Use a soft piece of cloth to wipe the airplane dry.
Doc # 6.02.15 Page 3
Rev. 2 12-30-00 15 Apr 2013
Servicing DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 12-30-00 Rev. 2
DA 40 NG AMM Standard Practices
AIRCRAFT
CHAPTER 20
' STANDARD PRACTICES
Doc # 6.02.15 Page 1
Rev. 2 20-TITLE 15 Apr 2013
Standard Practices DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 20-TITLE Rev. 2
DA 40 NG AMM Standard Practices
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 20
STANDARD PRACTICES - AIRFRAME
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
' Section 20-10
' Standard Practices - Airframe
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Bolt and Nut Types Used in the Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Standard Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Special Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Torque Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
' Section 20-30
' Standard Practices - Electrical
' 1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
' 2. Thread Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
' 3. Repair and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
' Section 20-70
' Standard Practices - Engine
' 1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
' 2. Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
' 3. Special Torque Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
' 4. Installation and Tightening Torques of Worm Drive Clamps . . . . . . . . . . . . . . . . . 4
Doc # 6.02.15 Page 1
Rev. 2 20-CONTENTS 15 Apr 2013
Standard Practices DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 20-CONTENTS Rev. 2
DA 40 NG AMM Standard Practices
AIRCRAFT
CHAPTER 20
STANDARD PRACTICES - AIRFRAME
1. General
' This Chapter gives you the standard practices for the DA 40 NG airplane. Use industry standard
' practice where no specific practice is given.
' This Chapter has the following Sections:
' ) Section 20-10. Standard Practices - Airframe.
' ) Section 20-30. Standard Practices - Electrical.
' ) Section 20-70. Standard Practices - Engine.
Doc # 6.02.15 Page 1
Rev. 2 20-00-00 15 Apr 2013
Standard Practices DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 20-00-00 Rev. 2
DA 40 NG AMM Standard Practices
AIRCRAFT
' Section 20-10
' Standard Practices - Airframe
1. General
There are no Maintenance Practices which apply to the DA 40 NG airframe and its systems in general.
This Chapter only has data about standard threaded fasteners.
Always tighten the nut or bolt to the torque shown in the tables below. Always use the correct locking
device with the nut or bolt.
CAUTION: DISCARD SELF-LOCKING NUTS AFTER REMOVAL. THE FRICTION
TORQUE REDUCES WITH USE.
2. Bolt and Nut Types Used in the Airplane
The DA 40 NG uses three types of standard bolts: DIN 931 and LN9037 metric specifications and AN3
through AN20 American specifications. You can identify the bolt type by the marking on the head and
the surface treatment.
Bolt Type Marking on Head Surface Treatment
AN-Bolt
Corrosion resistant Non-corrosion
steel bolts have a dash resistant steel Cadmium
bolts have an X
DIN-Bolt
OEV Manufacturer
Zink coated
8.8 Property class
The DA 40 NG uses these types of standard nuts: DIN 934, DIN 985, AN364, AN365, MS21042,
MS21044.
Doc # 6.02.15 Page 1
Rev. 2 20-10-00 15 Apr 2013
Standard Practices DA 40 NG AMM
AIRCRAFT
3. Standard Torque Values
These tables show the correct torque values for bolts and nuts to AN and DIN specifications. Use the
following torque values for all bolts, nuts and screws which meet the specifications unless they are in
the list of special torque values below.
A. AN Fine Thread Series
Bolt Size Torque (Nm) Torque (lbf.ft.)
10 - 32 1.6 1.2
1/4 - 28 6.2 4.6
5/16 - 24 13.6 10
3/8 - 24 20.7 15.3
7/16 - 20 37.7 27.8
1/2 - 20 54.2 40
9/16 - 18 90.4 66.7
5/8 - 18 124.3 91.7
B. AN Coarse Thread Series
Bolt Size Torque (Nm) Torque (lbf.ft.)
10 - 24 1.6 1.2
1/4 - 20 5.7 4.2
5/16 - 18 10.2 7.5
3/8 - 16 20.9 15.4
7/16 - 14 28.9 21.3
1/2 - 13 54.2 40
9/16 - 12 79 58.3
5/8 - 11 101.6 75
Page 2 Doc # 6.02.15
15 Apr 2013 20-10-00 Rev. 2
DA 40 NG AMM Standard Practices
AIRCRAFT
C. DIN and LN Specifications
Metric Thread Torque (Nm) Torque (lbf.ft.)
M4 1.8 1.3
M5 3.6 2.7
M6 6.4 4.7
M8 16 11.8
M10 32 23.6
M12 60 44.3
4. Special Torque Values
Part Torque (Nm) Torque (lbf.ft.)
Bolts attaching the engine corners 40 29.5
mount to the firewall. center 60 44.3
Bolts attaching the engine mounting arms to
85 ± 8 62.7 ± 5.9
shock mounts (forward).
Nose wheel fork pivot nut. Refer to the procedure given in Section 32-40.
' Main landing gear outer unloaded 25 18.4
attaching bolts
'
' (2x M10 per side). at static load 23 17.0
' If OÄM 40-334 or
' unloaded 30 22.1
' MÄM 40-574 is installed:
'
' Main landing gear outer
' attaching bolts
' at static load 28 20.7
' (2x M12 per side).
' Main landing gear inner fitting attachment bolts
' 15 11.1
' (6x M8 per side).
Main landing gear inner height of spring 4 mm 0.16 in
attaching bolt. washers (+0.5 mm / -0 mm) (+0.02 in / -0 in)
' Bolts attaching the MLG axle to the MLG strut. 6.5 4.8
' If OÄM 40-334 is installed:
' 12 8.9
' Bolts attaching the MLG axle to the MLG strut.
Doc # 6.02.15 Page 3
Rev. 2 20-10-00 15 Apr 2013
Standard Practices DA 40 NG AMM
AIRCRAFT
Part Torque (Nm) Torque (lbf.ft.)
' MLG wheel rim bolts.
'
' Refer to Cleveland/Parker Maintenance Manual,
' NLG wheel rim bolts.
' latest revision or placard on part.
'
' Brake back plate tie bolts.
Main wheel. Refer to the procedure given in Section 32-10.
Nose wheel. Refer to the procedure given in Section 32-40.
Bolts attaching the MLG axle to the MLG strut 6.5 4.8
MLG wheel rim bolts. 16.9 12.5
NLG wheel rim bolts. 10.0 7.4
Brake back plate tie bolts. 8.75 ± 0.25 6.5 ± 0.15
Horizontal stabilizer attaching bolts. 45 33.2
' Fuel drain valve. 1-3 0.7 - 2.2
5. Torque Measurement
For self-locking nuts, add the torque value of the locking device (friction or brake torque) to the value
in the table. Read the friction value from the torque wrench before the nut seats.
Where a bolt is tightened from the bolt-head, add the value of the shaft friction (the friction of the bolt
in the attached part) to the value in the table. Read the friction value from the torque wrench before
the bolt seats.
Page 4 Doc # 6.02.15
15 Apr 2013 20-10-00 Rev. 2
DA 40 NG AMM Standard Practices
AIRCRAFT
' Section 20-30
' Standard Practices - Electrical
' 1. General
' This Section gives you the standard practices for the electrical system. Modern airplanes reliability
' depends on proper function of the electric and electronic systems to a greater extent than previous
' certified airplanes. Maintenance carried out must be of good workmanship strictly considering the
' guidelines of AC 43-13.1B. Any time you work on the engine harness refer to AE Maintenance Manual,
' Doc. No. E4.08.04, latest revision.
' The satisfactory performance of a modern airplane, like the DA 40 NG, depends to a great extent, on
' reliability of its electrical systems. Improperly or carelessly maintained wiring can be a source of
' potential danger, and many malfunctions and failures of an electrical system can be traced to this
' cause. The continued proper performance of the electrical systems depends on the knowledge of the
' personal who do the inspection and repair.
' It is therefore important that maintenance is carried out in accordance with the best available
' techniques and properly trained maintenance personal, in order to eliminate possible failures.
' 2. Thread Locking
' Many electrical terminals are locked with electrical varnish or lacquer. If you release a terminal that has
' been thread locked with lacquer or varnish then use Loctite 222 or equivalent to lock the thread when
' you re-assemble the terminal.
' 3. Repair and Maintenance
' Repair and maintenance of the electrical system wiring, not covered in a separate document (e.g.
' Service Bulletin, Work Instruction) is limited to the extent of:
' ) Replacement of wires and cables.
' ) Replacement of ring terminals.
Doc # 6.02.15 Page 1
Rev. 2 20-30-00 15 Apr 2013
Standard Practices DA 40 NG AMM
AIRCRAFT
' A. Crimp Tools
' Following crimp tools are commonly used for crimp contacts in the DA 40 NG. Refer to the
' equipment manufacturer for more details of the tools and their use.
' ) Tyco, P/N 69478-1
' ) Tyco CERTI-LOK, P/N 169400
' ) Tyco SUPER CHAMP FT, P/N 720781-3
' ) Tyco CERTI-CRIMP, P/N 91523-1
' ) Tyco CERTI-CRIMP, P/N 91512-1
' ) Commercial, M22520/1-01
' ) Commercial, M22520/2-01
' ) Commercial, M22520/37-01
' B. Wires and Cables
' (1) Wires
' For the purpose of electric and electronic installation, an insulated wire consists of a metal
' conductor covered with a dielectric or insulating material. Wires used in the airplane contain
' stranded conductors for flexibility. The insulation may consist of several materials and layers to
' provide:
' ) Dielectric insulation
' ) Thermal protection
' ) Abrasion resistance
' ) Moisture resistance
' ) Fluid resistance
' Approved wires for the DA 40 NG:
' ) M22759/16
' ) M22759/34
Page 2 Doc # 6.02.15
15 Apr 2013 20-10-00 Rev. 2
DA 40 NG AMM Standard Practices
AIRCRAFT
' (2) Cables
' The term “cable”, may refer to any of the following:
' ) Two conductors twisted together (twisted pair).
' ) A single center conductor with a metallic braided outer conductor (coaxial cable).
' ) Two or more insulated conductors contained in a common covering (multi conductor
' cable).
' ) One or more insulated conductors with an overall shield (shielded cable).
' Approved cables for the DA 40 NG are:
' ) M27500
' ) M17/60-RG142
' ) M17/128-RG400
' (3) Wire Marking
' Locating a specific wire within a large wiring loom would be extremely difficult without individual
' identification of each wire, or cable. To simplify maintenance, each interconnecting wire and
' cable installed in the airplane is marked with a combination of numbers and letters. If a wire or
' cable must be replaced, the wire must be marked according to the wiring diagrams in
' Chapter 92.
' C. Testing
' After a wire, cable or ring terminal has been replaced, testing must be done as listed below:
' ) Visual inspection of the crimp connection (all leads within the crimp, insulation not crimped
' etc.).
' ) Check for continuity between the two ends of the conductor.
' ) Check for NO continuity between the conductor and aircraft electrical ground.
' ) The crimp contact is not damaged of bend.
'
Doc # 6.02.15 Page 3
Rev. 2 20-30-00 15 Apr 2013
Standard Practices DA 40 NG AMM
AIRCRAFT
' Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 20-30-00 Rev. 2
DA 40 NG AMM Standard Practices
AIRCRAFT
' Section 20-70
' Standard Practices - Engine
' 1. General
' This Section gives you data about the fasteners used on the AE E4-B engine installed in the DA 40 NG
' airplane. It also gives you the procedures for tightening the fasteners.
' Refer to the AE Maintenance Manual, latest revision for more data.
' 2. Torque Values
' Use the torque values given in tables 1 thru 4 for standard fasteners on the engine and use the torque
' values given in table 5 for the components listed.
' 3. Special Torque Procedures
' When you use self-locking nuts, add the safety torque (friction torque or braking torque) to the table
' values. Set this value on the dial of the torque meter before you tighten the nut.
' If a bolt has an additional torque due to shaft friction, add this torque value to the table value. Set this
' calculated value on the dial of the torque meter before you tighten the bolt.
' Lubricate threads unless shown differently.
' CAUTION: YOU MUST ADD THE SAFETY TORQUE (OR THE FRICTION TORQUE)
' TO THE FOLLOWING VALUES FOR SELF-LOCKING NUTS (OR BOLTS
' WITH SHAFT FRICTION).
'
Page 1
Doc # 6.02.15
Rev. 2 20-70-00 15 Apr 2013
Standard Practices DA 40 NG AMM
AIRCRAFT
' Table 1 - Standard Torque Values for Engine Bolts and Nuts
' INCH THREAD TORQUE (Nm) TORQUE (lbf.ft.)
' 1/4 11 8
' 5/16 23 17
' 3/8 41 30
' 7/16 68 50
' 1/2 102 75
' 9/16 149 110
' 5/8 203 150
' 3/4 366 270
' Table 2 - Standard Torque Values for Engine Pipe Plugs
' TAPER THREAD TORQUE (Nm) TORQUE (lbf.ft.)
' 1/16 - 27 NPT 4.5 3.3
' 1/8 - 27 NPT 4.5 3.3
' 1/4 - 18 NPT 9.5 7
' 3/8 - 18 NPT 12.3 9
' 1/2 - 14 NPT 18 13.3
' 3/4 - 14 NPT 26 19
Page 2 Doc # 6.02.15
15 Apr 2013 20-70-00 Rev. 2
DA 40 NG AMM Standard Practices
AIRCRAFT
' Table 3 - Standard Torque Values for Engine Crush-Type Asbestos Gaskets
' THREAD PITCH ANGLE OF TURN
' THREADS PER INCH ALUMINUM ASBESTOS COPPER ASBESTOS
' 8 135° 67°
' 10 135° 67°
' 12 180° 90°
' 14 180° 90°
' 16 270° 135°
' 18 270° 135°
' 20 270° 135°
' 24 360° 180°
' 28 360° 180°
' Note: Install all crush type gaskets (except the self-centering type) with the continuous
' surface against the flange of the plug or against the part which you will tighten
' against the gasket. Turn the part until the surfaces which you must seal, touch the
' gasket. Then tighten to the angle of turn shown for the thread size as given in
' Table 3.
' Table 4 - Standard Torque Values for Engine Flexible Hose (or Tube) Connections
' TUBE SIZE THREAD TORQUE (Nm) TORQUE (lbf.ft.)
' (-4) 1/4 7/16 - 20 11 - 16 7 -11
' (-6) 3/8 9/16 - 18 17 - 22 11 - 16
' (-10) 5/8 7/8 - 14 41 - 48 30 - 36
' Table 5 - Special Torque Values for the Engine
' ITEM THREAD TORQUE (Nm) TORQUE (lbf.ft.)
' Engine oil filter - 25 18.5
Page 3
Doc # 6.02.15
Rev. 2 20-70-00 15 Apr 2013
Standard Practices DA 40 NG AMM
AIRCRAFT
' 4. Installation and Tightening Torques of Worm Drive Clamps
' The Figures and tables show the proper installation and the tightening torques of worm drive clamps.
' A. Single Worm Drive Clamp
' CAUTION: DO NOT PLACE A WORM DRIVE CLAMP ON A TUBE BEAD. THIS CAN
' DAMAGE THE HOSE AND MAY (IN CASE OF ENGINE CHARGE AIR
' INSTALLATION) CAUSE LOSS OF ENGINE POWER.
'
' Worm Drive Clamp
'
'
'
'
'
'
'
' Aluminium
' Tube Bead
'
'
'
' Silicon Hose Aluminium Tube
'
'
' Figure 1: Installation with Single Worm Drive Clamp
Page 4 Doc # 6.02.15
15 Apr 2013 20-70-00 Rev. 2
DA 40 NG AMM Standard Practices
AIRCRAFT
' B. Two Worm Drive Clamps
' (1) Axial Placement
' CAUTION: DO NOT PLACE A WORM DRIVE CLAMP ON A TUBE BEAD. THIS CAN DAMAGE
' THE HOSE AND MAY (IN CASE OF ENGINE CHARGE AIR INSTALLATION)
' CAUSE LOSS OF ENGINE POWER.
'
Worm Drive Clamps
'
'
'
'
'
'
'
'
Aluminium
'
Tube Bead
'
'
' Silicon Hose Aluminium Tube
'
' Figure 2: Installation with Two Worm Drive Clamps and Single Bead (Axial Placement)
'
Worm Drive Clamps
'
'
'
'
'
'
' Aluminium
' Tube Beads
'
'
'
' Silicon Hose Aluminium Tube
'
' Figure 3: Installation with Two Worm Drive Clamps Two Beads (Axial Placement)
Page 5
Doc # 6.02.15
Rev. 2 20-70-00 15 Apr 2013
Standard Practices DA 40 NG AMM
AIRCRAFT
' (2) Radial Placement
'
'
'
'
' Minimum 4 mm
' Minimum 2 mm
'
'
'
' Minimum 90°
'
'
'
'
Connection Tube Silicon Tube
'
'
Hose Clamps
'
' Figure 4: Installation with Two Worm Drive Clamps (Radial Placement)
Page 6 Doc # 6.02.15
15 Apr 2013 20-70-00 Rev. 2
DA 40 NG AMM Standard Practices
AIRCRAFT
' C. Tightening Torques for Worm Drive Clamps
' CAUTION: WORM DRIVE CLAMPS MUST BE TIGHTENED ACCORDING TO THE TABLE
' BELOW. OVER-TIGHTENING A WORM DRIVE CLAMP CAN DAMAGE THE HOSE
' AND MAY (IN CASE OF ENGINE INSTALLATIONS) CAUSE LOSS OF ENGINE
' POWER.
'
' CAUTION: FOR WORM DRIVE CLAMP INSTALLATION THE ENGINE MUST BE COLD.
' INSTALLATION ON A HOT ENGINE CAN CAUSE DAMAGE TO THE HOSE AND
' MAY (IN CASE OF ENGINE INSTALLATIONS) CAUSE LOSS OF ENGINE POWER.
'
' CAUTION: DO NOT RE-TIGHTEN A WORM DRIVE CLAMP ON A SILICONE HOSE
' PERFORMING AN AIRPLANE INSPECTION UNLESS IT IS LOOSE. REFER TO
' THE TABLE BELOW FOR THE CORRECT TIGHTENING TORQUES OF WORM
' DRIVE CLAMPS.
'
' (1) Tightening Torques for Clamp Widths Below 12 mm (0.47 in)
' Clamp Diameter Torque (Nm) Torque (lbf.ft.)
' 8-12 2.5 ± 0.5 1.8 ± 0.4
' 10-160 3.0 ± 0.5 2.2 ± 0.4
' (2) Tightening Torques for Clamp Widths of 12 mm (0.47 in) and Higher
' Clamp Diameter Torque (Nm) Torque (lbf.ft.)
' 8-160 5.0 ± 0.5 3.7 ± 0.4
Page 7
Doc # 6.02.15
Rev. 2 20-70-00 15 Apr 2013
Standard Practices DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 8 Doc # 6.02.15
15 Apr 2013 20-70-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
CHAPTER 21
AIR CONDITIONING,
HEATING AND VENTILATION
Doc # 6.02.15 Page 1
Rev. 2 21-TITLE 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 21-TITLE Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 21
HEATING AND VENTILATION
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Heat Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Test/Adjust the Heat Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Remove/Install the Distributor Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5. Test/Adjust the Distributor Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Section 21-50
Cooling
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Trouble Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. Remove/ Install the Central Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
3. RACC System Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
4. Remove/Install Parts of the Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 209
Doc # 6.02.15 Page 1
Rev. 2 21-CONTENTS 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
% Section 21-51
% Cooling (OÄM 40-316/i or later installed)
% 1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
% 2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
% 3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
% Trouble Shooting
% 1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
% Maintenance Practices
% 1. Remove/ Install the Central Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
% 2. Remove/Install the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
% 3. RACC - System Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
% 4. Remove/Install Parts of the Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 208
Page 2 Doc # 6.02.15
15 Apr 2013 21-CONTENTS Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
CHAPTER 21
HEATING AND VENTILATION
1. General
This Chapter describes the heating and ventilation system of the DA 40 NG. It provides information
about the operation and trouble-shooting of the heating and ventilation system. Refer to Section 75-00
for more maintenance data of the coolant heat-exchanger.
If OÄM 40-316 is installed, a recirculating air - cabin cooling (RACC) system is installed. Refer to
% Section 21-50 (if OÄM 40-316/h or earlier is installed) or Section 21-51 (if OÄM 40-316/i or later is
% installed) for more details about the RACC system.
2. Description and Operation
The DA 40 NG has two separate systems, one for heating and one for cooling/ventilating the cabin.
Figure 1 shows the heating system and Figure 2 shows the cooling and ventilation system.
A. Cabin Heating
A heat exchanger is attached to the engine mount and provides the warm air for heating. Hot
cooling liquid from the engine's cooling system flows through the matrix of the heat exchanger.
Ambient air flows from an air inlet in the engine nacelle through the heat exchanger. The
temperature of the air raises and flows from the heat exchanger through a control valve to the
airplane cabin. The heated air is then used for cabin heating and windscreen defrosting. Levers in
the center control console of the cockpit connect to the control valve with Bowden cable and control
the flow of heated air.
A flap inside the heat valve has an opening either to the atmosphere or to a distributor valve on the
rear face of the firewall. A lever in the cockpit controls the flap. The lever is marked ‘CABIN HEAT,
ON OFF’.
The distributor valve has also a flap. The flap connects to the pilot and passenger floor areas or the
front of the canopy. A lever in the cockpit controls the flap. The lever is marked ‘DEFROST -
FLOOR'.
Doc # 6.02.15 Page 1
Rev. 2 21-00-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
Canopy
Defrost Hot Air
Instrument Panel Cover
Firewall CABIN HEAT
ON Control Levers
Air
Intake CABIN HEAT DEFROST
Cabin Heat OFF
Exchanger
FLOOR
Passengers Floor Hot Air
Pilots Floor Hot Air
Floor Heat/Defrost
Distributor Valve
Bowden Cables Bowden Cables
STATUS:
Cabin Heat ON. STATUS:
Distributor Control Valve Cabin Heat OFF.
in Mid Position. Distribution Control
(Between and ) Lever in Defrost
( ) Position
Heat Control Flap Distribution Hot Air out
in Heat Valve (Defrost/Floor) To Atmosphere
Control Flap
in Distributor Valve
Figure 1: Cabin Heat Schematic Diagram
Page 2 Doc # 6.02.15
15 Apr 2013 21-00-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
If the heat valve is set to OFF, the hot air is released into the bottom of the engine cowling. If it is
set to ON, the hot air is guided through the firewall to the distributor valve. The valve can be set to
any position between OFF and ON. If the valve is set to a middle position, only part of the airflow
will reach the distributor valve.
If the distributor valve is set to FLOOR, air flows to the pilots' and passengers' footwells. If it is set
to DEFROST, the air flows to the front of the canopy. This prevents mist or frost from forming at the
canopy. The valve can be set to any position between FLOOR and DEFROST. If the valve is set
to a middle position, part of the airflow goes to the footwells and part to the canopy.
B. Cooling and Ventilation
Figure 2 shows the cooling and ventilation system.
% Refer to Section 21-50 for more details about the RACC system (if OÄM 40-316/h or earlier is
% installed).
% Refer to Section 21-51 for more details about the RACC system (if OÄM 40-316/i or later is
% installed).
(1) Pilots' Cabin Air
Air enters the system through two NACA air inlets in the front fuselage on the left and right side.
Hoses connect the air inlets to two adjustable outlets in the instrument panel.
(2) Passengers' Cabin Air
Air enters the system through a NACA air inlet below the leading edge of the left stub-wing. The
front main spar and the inner and outer closing ribs make a collector box. Air can only leave the
area through an opening in the closing rib.
The front of the rib connects to a hose across the fuselage to the front closing rib of the right
stub-wing.
The top part of the inner closing rib on each side connects to the fuselage side ducts. The side
ducts connect to the roll bar.
Air from both front closing ribs can flow up through the fuselage side ducts. Four adjustable
outlets in the roll bar give cool air to the passengers.
C. Air Exit
Both hot and cold air leave the cockpit through slots in the baggage compartment frame. The air
flows through the rear fuselage and leaves the airplane through the gap between the fuselage and
the rudder.
Doc # 6.02.15 Page 3
Rev. 2 21-00-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
Cabin Air Control
Cabin Air
Exhaust
NACA Air Inlet
NACA Air Inlet
Sealed
Cabin Air Control RH
Rear Cabin Air Control
Rear Cabin Air Control
Sealed Cabin Air
Exhaust
Cabin Air Control LH
Rear Cabin Air Control
NACA Air Inlet
Figure 2: Cabin Ventilation System Schematic Diagram
Page 4 Doc # 6.02.15
15 Apr 2013 21-00-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the air conditioning system. If you have the
trouble detailed in the Trouble column read across to the Possible Cause column. Then do the repair
given in the Repair column.
Trouble Possible Cause Repair
No hot air flows to the system Heat valve control cable out of Adjust the heat valve control
at any setting. adjustment. cable.
Heat valve control cable Replace the heat valve control
broken. cable.
Defective heat exchanger. Trouble-shoot in accordance
with Section 75-00.
Defective engine cooling Trouble-shoot in accordance
system. with Section 75-00.
Heating system supplies warm Heat valve control cable out of Adjust the heat valve control
air when set to OFF. adjustment. cable.
Heat valve control cable Replace the heat valve control
broken. cable.
No hot air flows to the canopy. Distributor valve control cable Adjust the distributor valve
out of adjustment. control cable.
Distributor valve control cable Replace the distributor valve
broken. control cable.
Canopy defrost hose Re-connect hose.
disconnected.
No hot air flows to the Distributor valve control cable Adjust the distributor valve
footwells. out of adjustment. control cable.
Distributor valve control cable Replace the distributor valve
broken. control cable.
Air hose to footwell Re-connect hose.
disconnected.
No cool air from one outlet. Outlet defective. Replace the cool air outlet.
Other outlet operates correctly. Air duct blocked. Remove blockage.
Doc # 6.02.15 Page 101
Rev. 2 21-00-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 21-00-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
Maintenance Practices
1. General
This Section gives you the Maintenance Practices for the cabin heating system and tells you how to
replace outlets for the cooling system. Refer to Section 75-00 for maintenance data on the
heat-exchanger.
2. Remove/Install the Heat Valve
Refer to Figure 3.
A. Remove the Heat Valve
Detail Steps/Work Items Key Items/References
(1) Remove the engine cowlings. Refer to Section 71-10.
WARNING: IF THE ENGINE HAS BEEN RUNNING, TAKE CARE WHEN
TOUCHING THE HEAT VALVE. THE HEAT VALVE GETS HOT.
(2) Release the worm drive clamp which holds the
flexible hose to the heat valve. Then disconnect
the hose from the valve.
(3) Set the CABIN HEAT control lever to ON.
(4) Loosen the screw which holds the control cable Access through the front of the valve.
to the swivel fitting in the heat valve.
(5) Remove 4 nuts and washers which attach the
heat valve to the firewall.
(6) Remove the heat valve from the firewall.
Doc # 6.02.15 Page 201
Rev. 2 21-00-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
Instrument Panel Cover Distributor Valve
Control Cable
Defrost Hose
Heat Valve Control Cable Swivel
Fitting Defrost
Heat Valve Control Hose
Cable Lock-Nut
Firewall
Hot Air Hose
Swivel Fitting to Passenger
Foot Wells
Cable Binder
Heat Valve Washer
Attaching Bolt
Distribution
Valve Floor Panel
Heat Valve Attaching
Nut and Washer Heat Valve
Attaching Bolt
(Bonded In)
Hot Air Hose from
Heat Exchanger
Heat Exchanger
To/From Engine Cooling System
Figure 3: Heat Valve and Distributor Valve Installation.
Page 202 Doc # 6.02.15
15 Apr 2013 21-00-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
B. Install the Heat Valve
Detail Steps/Work Items Key Items/References
(1) Examine the copper seal between the distributor Replace defective seal. Use self-
valve and the firewall. adhesive copper tape.
(2) Put the heat valve in position on the firewall. Apply fire resistant sealant. Use PR 812
or equivalent.
(3) Install the 4 washers and nuts which attach the
heat valve to the firewall.
(4) Set the CABIN HEAT control lever to ON. Then
move the cabin heat flap 3 mm (1/8 in) before full
open.
(5) Attach the control cable:
S Put the control cable through the hole in the
swivel fitting.
S Make sure that the flap is 3 mm (1/8 in)
before full open.
S Tighten the screw in the swivel fitting.
(6) Do a test for correct operation of the heat valve. Refer to Paragraph 3.
(7) Connect the flexible hose to the heat valve.
Tighten the worm drive clamp.
(8) Install the engine cowlings. Refer to Section 71-10.
Doc # 6.02.15 Page 203
Rev. 2 21-00-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
3. Test/Adjust the Heat Valve
WARNING: MAKE SURE THAT THE FLAP ON THE HEAT VALVE FULLY CLOSES
THE FIREWALL OUTLET WHEN YOU SET THE CABIN HEAT CONTROL
LEVER TO 'OFF'. THIS IS TO STOP FIRE OR EXHAUST FUMES FROM
ENTERING THE COCKPIT IN AN EMERGENCY.
Detail Steps/Work Items Key Items/References
(1) Remove the engine cowlings. Refer to Section 71-10.
WARNING: IF THE ENGINE HAS BEEN RUNNING, TAKE CARE WHEN
TOUCHING THE HEAT VALVE. THE HEAT VALVE GETS HOT.
(2) Release the worm-drive-clamp which holds the Refer to Figure 3.
flexible hose to the heat valve and then
disconnect the hose from the heat valve.
(3) Set the CABIN HEAT control lever in the cockpit The flap should stop 3 mm prior to the
to ON. right wall valve limit.
(4) Set the CABIN HEAT control lever in the cockpit The flap must be completely against the
to OFF. closed valve limit.
(5) Make sure that the flap fully closes the outlet to Access through the front of the valve.
the distributor valve.
(6) If necessary, adjust the control cable in the Access through the front of the valve.
swivel fitting to assure complete closure of the
valve during "OFF" position.
(7) Connect the flexible hose to the heat valve and
tighten the worm-drive-clamps.
(8) Install the engine cowlings. Refer to Section 71-10.
Page 204 Doc # 6.02.15
15 Apr 2013 21-00-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
4. Remove/Install the Distributor Valve
Refer to Figure 3.
A. Remove the Distributor Valve
Detail Steps/Work Items Key Items/References
(1) Remove the engine cowlings. Refer to Section 71-10.
(2) Disconnect the battery. Refer to Section 24-31.
(3) Remove the instrument panel cover. Refer to Section 25-10.
(4) Remove the pilots' seats. Refer to Section 25-10.
(5) Disconnect the 2 hot air hoses from the Cut the cable binders.
passengers' footwells.
(6) Remove the heat valve. Refer to Paragraph 2.
(7) Remove the 2 screws which attach the distributor In the cockpit.
valve to the side walls of the floor panel.
(8) Remove the copper seal between the distributor
valve and the firewall.
(9) Move the valve forward through the firewall. To give access to the rear of the valve.
(10) Remove the bottom locknut from the control Where the cable outer sheath attaches
cable for the heat valve. to the distributor valve.
(11) Move the heat valve control cable clear of the
distributor valve.
(12) Loosen the screw which holds the control cable
to the swivel fitting in the distributor valve.
(13) Remove the front locknut from the control cable
for the distributor valve.
(14) Move the control cable clear of the valve.
(15) Disconnect the 2 canopy defrost hoses from the
valve.
(16) Disconnect the 2 hot air hoses to the passengers'
footwells from the valve.
(17) Remove the valve from the airplane.
Doc # 6.02.15 Page 205
Rev. 2 21-00-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
B. Install the Distributor Valve
Detail Steps/Work Items Key Items/References
(1) Hold the distributor valve in front of the firewall.
(2) Attach the 2 hot air hoses which go from the Use cable binders.
passengers' footwells to the bottom outlets.
(3) Attach the 2 defrost hoses which go to the Use cable binders.
instrument panel cover to the top outlets.
(4) Attach the outer sheath of the distributor valve
control cable to the bracket at the top rear of the
distributor valve:
S Put the cable through the hole.
S Attach the locknut.
(5) Set the distribution control lever to DEFROST.
Then move it down about 3 mm (1/8 in).
(6) Attach the distributor valve control cable:
S Put the control cable through the hole in the
swivel fitting.
S Make sure that the flap is hard against the
bottom of the valve.
S Tighten the screw in the swivel fitting.
(7) Do a test for correct operation of the flap in the Refer to Paragraph 5.
distributor valve.
(8) Attach the outer sheath of the heat valve control Where the cable outer sheath attaches
cable to the top front of the distributor valve: to the distributor valve.
S Put the cable through the hole. Turn the threaded adjuster into the
hole.
S Attach the locknut.
(9) Move the distributor valve aft through the hole in Make sure that the control cables and
the firewall. hoses do not catch.
(10) Move the valve into position on the cockpit side of The hole in the firewall holds the front of
the firewall. the valve.
Page 206 Doc # 6.02.15
15 Apr 2013 21-00-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
Detail Steps/Work Items Key Items/References
(11) Install the 2 attaching bolts and washers. In the side walls of the floor panel in the
cockpit. Torque: 6.4 Nm (4.7 lbf.ft.).
(12) Install a new copper seal between the distributor Use self-adhesive copper tape.
valve and the firewall.
(13) Install the heat valve. Refer to Paragraph 2.
(14) Connect the 2 flexible hot air hoses to the Use cable binders.
passengers' footwells.
(15) Install the pilots' seats. Refer to Section 25-10.
(16) Install the instrument panel cover. Refer to Section 25-10.
(17) Connect the battery. Refer to Section 24-31.
(18) Install the engine cowlings. Refer to Section 71-10.
Doc # 6.02.15 Page 207
Rev. 2 21-00-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
5. Test/Adjust the Distributor Valve
Detail Steps/Work Items Key Items/References
(1) Set the distribution control lever in the cockpit There should be a gap of about 3 mm
to DEFROST. (1/8 in) between the back of the lever
and the cockpit stop.
WARNING: IF THE ENGINE HAS BEEN RUNNING, TAKE CARE WHEN
TOUCHING THE DISTRIBUTOR VALVE. THE DISTRIBUTOR VALVE
GETS HOT.
(2) Make sure that the flap is hard against the bottom Reach through the outlet hole for the
of the of the distributor valve. pilots' footwells in the floor panel. Push
against the bottom of the flap. Then let
it return.
(3) Set the distribution control lever in the cockpit There should be a gap of about 3 mm
to FLOOR. (1/8 in) between the back of the lever
and the cockpit stop.
(4) Make sure that the flap is hard against the top of Reach through the outlet hole for the
the of the distributor valve. pilots' footwells in the floor panel.
(5) If the valve is not correctly adjusted, do the
following items.
(6) Remove the top cover plate from the engine Refer to Section 31-10.
control assembly.
(7) Adjust the control cable in the swivel fitting to give
the correct bounce:
S Set the distribution control lever close to
DEFROST.
S Loosen the screw in the swivel fitting. At the cockpit end of the control cable.
S Move the flap a small distance. If there was no gap in the DEFROST
position, then move the flap down. If
S Tighten the screw in the swivel fitting.
there was too much gap in the
DEFROST position, then move the flap
up.
(8) Set the distribution control lever in the cockpit There should be a gap of about 3 mm
to DEFROST. (1/8 in) between the back of the lever
and the cockpit stop.
Page 208 Doc # 6.02.15
15 Apr 2013 21-00-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
Detail Steps/Work Items Key Items/References
Note: If you cannot get bounce at both ends of the range of movement, adjust the
cable to give bounce at the DEFROST end.
(9) Do steps 8 and 9 as necessary to get the correct
adjustment.
(10) Install the top cover plate to the engine control Refer to Section 31-10.
assembly.
Doc # 6.02.15 Page 209
Rev. 2 21-00-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 210 Doc # 6.02.15
15 Apr 2013 21-00-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
Section 21-50
Cooling
1. General
If OÄM 40-316 is installed, a recirculating air - cabin cooling (RACC) system is installed. The RACC
system is an independent subsystem of the airplane and is electrically powered. It consists of the
central unit (installed aft of baggage compartment) and a control panel (in the cabin, center console).
2. Description
A. Central Unit
The central unit operates with a refrigerant R134a vapor cycle cooling circuit. The system requires
electrical power (28 V DC, max. 65 A) for operation, which is provided by an additional alternator.
The central unit is subdivided into the following components:
) Compressor assembly (part of refrigerant circuit).
) Condenser assembly (part of refrigerant circuit).
) Evaporator assembly (part of refrigerant circuit).
) Condenser fan.
) Evaporator radial fan.
) Cabin radial fan.
) Electrical control system.
Refer to Figure 1 for a system schematic of the RACC system.
Note: The refrigerant vapor cooling system is a hermetically sealed and
pressurized circuit and contains the refrigerant R134a.
WARNING: ALL MAINTENANCE AND REPLENISHMENT WHICH REQUIRES TO
OPEN AND DEPRESSURIZE THE REFRIGERANT CIRCUIT MUST BE
DONE BY AUTHORIZED PERSONNEL ACCORDING TO NATIONAL
AND INTERNATIONAL REGULATIONS FOR REFRIGERANT SYSTEMS.
Doc # 6.02.15 Page 1
Rev. 2 21-50-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
Airplane Compartment Fan
Central Unit
Cabin
Air
Cabin Fan
(Radial)
in Short
Compressor Baggage
Extension
Air
Evaporator
Cabin Fan
(Radial)
Condenser Fan
(Axial)
Expansion Valve
Condenser
Filter / Drier /
Collector
Air Intake Air Exhaust
Refrigerant Circuit
Figure 1: RACC System Schematic
Page 2 Doc # 6.02.15
15 Apr 2013 21-50-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
B. Control Panel
The control panel is situated on the center console in the cabin. It is electrically connected to the
RACC controller and provides all necessary elements to control the center unit. An integrated
display shows the preset air temperature.
Refer to Figure 2 for details about the RACC control panel.
Figure 2: RACC Control Panel
Doc # 6.02.15 Page 3
Rev. 2 21-50-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
3. Operation
If electrical power is provided to the RACC system, the blue LED on the control panel flashes.
The control panel of the RACC system in the center console allows the crew to control the fan speed
and the cabin temperature. A two digit display shows the preset cabin air temperature in °F.
A push-button is used to set the RACC system to ON (if short depressed; display is illuminated) and
OFF (if pressed and held for approximately one second).
During power-up the software version of the control panel is displayed.
The central unit is located aft of the baggage compartment. The RACC controller is located on top of
the central unit and controls the refrigerant circuit valves and the compressor with respect to the
control panel settings. With the control panel set to ON and a temperature preset lower than the
current cabin air temperature, the refrigerant cooling circuit is activated. An electrically powered
compressor takes the low-pressure low-temperature refrigerant gas and compresses it to a
high-temperature gas. A pressure switch on the compressor assembly regulates the compressor
discharge pressure. The hot refrigerant gas is cooled down in the condenser and condenses to a high
pressure liquid. An axial condenser fan forces outside air through the condenser coils and vents the
thus heated air overboard. The filter / drier / collector bottle removes moisture from the refrigerant and
stores the refrigerant. The expansion valve controls the amount of refrigerant liquid flowing to the
evaporator. The refrigerant boils in the evaporator and turns back into a low-pressure low-temperature
gas while cooling the coils of the evaporator. Two radial cabin fans force cabin air through the cooling
coils and thus remove heat from the cabin air. The cool cabin air cannot hold the moisture and water
condensates on the evaporator cooling coils. The condensate is collected under the evaporator and
is drained overboard. The refrigerant gas returns to the compressor.
A cooling fan vents air through the RH air outlet on top of the fuselage and ensures ventilation of the
rear fuselage.
Page 4 Doc # 6.02.15
15 Apr 2013 21-50-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
Trouble Shooting
1. General
The table below lists the defects you could have with the control panel in the center console. If you
have the trouble detailed in the Trouble column read across to the Possible Cause column. Then do
the repair given in the Repair column.
Trouble Possible Cause Repair
Blue LED on control panel RACC circuit breaker open. Set.
does not illuminate.
Additional alternator defective. Check RACC power supply of
the airplane.
Central unit does not power Control panel defective. Replace.
up.
Electrical control unit defective. Replace.
Insufficient cooling. Air inlet filter contaminated. Clean or replace filter.
Hot air outlet on LH fuselage Remove blockage.
blocked.
Leak in refrigerant circuit. Perform a leak test.
Repair leak.
Charge the system.
Condenser faulty. Check condenser coils for dirt
accumulation and remove dirt.
Expansion valve faulty. Replace expansion valve.
Compressor faulty. Replace compressor.
Electrical power source Check ground power source
insufficient. respective RACC power supply
of airplane.
Doc # 6.02.15 Page 101
Rev. 2 21-50-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 21-50-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
Maintenance Practices
1. Remove/ Install the Central Unit
A. Remove the Central Unit
Detail Steps/Work Items Key Items/References
(1) Remove the passenger seats. Refer to Section 25-10.
(2) Remove the seatbelt pulleys of the passenger Refer to Section 25-10.
seats.
(3) Unplug the electrical connection of the cabin fan:
S Open the baggage tray.
S Unplug the electrical connector on the rear
wall of the short baggage extension.
(4) Remove the short baggage extension. Refer to Section 25-10.
(5) Remove short baggage extension fan and the
drip tray.
(6) Remove the air ducts from the RACC central unit.
(7) Remove the metal air duct tube from the LH air
outlet.
(8) Unplug the electrical connections from the RACC
central unit to:
S 3 connectors at the RACC central unit.
S 3 heavy cables (under the passenger seats,
at the EPU connector and at the lightning
protection system).
(9) Remove the four bolts which connect the
mounting panel of the RACC central unit to the
mounting panel supports.
(10) Slide the RACC central unit forward.
(11) Lift the RACC central unit clear of the airplane.
Doc # 6.02.15 Page 201
Rev. 2 21-50-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
Compartment Fan
Overhead Air Duct
Air Outlet
Warm Air
Exhaust
RACC Central Unit
Outside Air Intake
Figure 3: RACC Central Unit Installation
Page 202 Doc # 6.02.15
15 Apr 2013 21-50-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
B. Install the Central Unit
Detail Steps/Work Items Key Items/References
(1) Lift the RACC central unit into the airplane.
(2) Slide the RACC central unit backward. Make sure
to position the mounting panel on the mounting
panel supports in the fuselage.
(3) Install the four screws which connect the
mounting panel of the RACC central unit to the
mounting panel supports.
(4) Connect the RACC central unit electrically to:
S 3 electrical connectors of the RACC unit.
S 3 heavy cables (under the passenger seats,
at the EPU connector and at the lightning
protection system).
(5) Install the metal air duct tube to the RH air outlet.
(6) Install the air ducts on the RACC central unit.
Install the short baggage extension fan and the
drip tray.
(7) Position the short baggage extension in front of
the RACC central unit.
(8) Connect the air duct of the RACC central unit to
the short baggage extension.
(9) Install the short baggage extension. Refer to Section 25-10.
(10) Connect the cabin fan electrically:
S Open the baggage tray.
S Plug in the electrical connector on the rear
wall of the short baggage extension.
(11) Install the seatbelt pulleys of the passenger Refer to Section 25-10.
seats.
(12) Install the passenger seats. Refer to Section 25-10.
(13) Perform a cooling test of the RACC system.
Doc # 6.02.15 Page 203
Rev. 2 21-50-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
Control Box
Cabin Air Out
Evaporator
Outside Air Outlet
Outside Air Inlet Condenser
Figure 4: Central Unit - Front and LH Side
Page 204 Doc # 6.02.15
15 Apr 2013 21-50-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
Control Box
Cabin Air In
Condenser Compressor
Filter Drier / Collector Bottle
Figure 5: Central Unit Back and RH Side
Doc # 6.02.15 Page 205
Rev. 2 21-50-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
2. Remove/Install the Control Panel
A. Remove the Control Panel
Detail Steps/Work Items Key Items/References
(1) Remove the center console. Refer to Section 25-10.
(2) Unplug the electrical connectors of the control
panel.
(3) Unclip the RACC control panel from the center
console.
B. Install the Control Panel
Detail Steps/Work Items Key Items/References
(1) Move the RACC control panel in position on the
center console.
(2) Push the center console into the center console
until the clips hold the panel in place on the
center console.
(3) Connect the electrical connectors to the control
panel.
(4) Install the center console. Refer to Section 25-10.
(5) Perform a RACC System Test. Refer to Paragraph 3.
Page 206 Doc # 6.02.15
15 Apr 2013 21-50-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
3. RACC System Test Procedure
Detail Steps/Work Items Key Items/References
(1) Perform an engine ground test. Refer to Section 71-00.
(2) Set the engine to 1000 to 1200 RPM.
(3) Set the AUX POWER switch to ON. The blue LED on the RACC control
panel must flash.
(4) Push the ON/OFF button on the RACC control The preset temperature display on the
panel once to switch the RACC system ON. RACC control panel must illuminate.
(5) Push the Preset Temperature DOWN button
until the preset temperature shows ‘LO’.
(6) Verify that the cabin outlet air temperature is
significantly lower than the cabin air temperature.
(7) Set the cabin air preset temperature to a Use the preset temperature UP and
convenient temperature level. DOWN buttons on the control panel.
(8) Push the ON/OFF button on the RACC control
panel for approximately 1 second to switch the
RACC system to OFF.
(9) Set the AUX POWER switch to OFF.
Doc # 6.02.15 Page 207
Rev. 2 21-50-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
4. Remove/Install Parts of the Refrigerant Circuit
Note: The refrigerant vapor cooling system is a hermetically sealed and
pressurized circuit and contains the refrigerant R134a.
WARNING: ALL MAINTENANCE AND REPLENISHMENT WHICH REQUIRES TO
OPEN AND DEPRESSURIZE THE REFRIGERANT CIRCUIT MUST BE
DONE BY AUTHORIZED PERSONNEL ACCORDING TO NATIONAL
AND INTERNATIONAL REGULATIONS FOR REFRIGERANT SYSTEMS.
Before you do any maintenance on parts of the refrigerant circuit you must remove the central unit from
the airplane. Refer to Paragraph 1.
Make sure to obey the regulations for handling the refrigerant.
A. Discharge/Charge the Refrigerant Circuit
(1) Equipment
One of the following automated discharge and charging stations or equivalent must be used:
Item Quantity Part Number
Silco CS 199. 1 Commercial.
Silco CS 195. 1 Commercial.
Silco CS 150. 1 Commercial.
(2) Discharge the Refrigerant Circuit
Detail Steps/Work Items Key Items/References
(1) Remove the central unit from the airplane. Refer to Paragraph 1.
(2) Connect the RACC system to the Follow the instructions of the
discharge/charging station. discharge/charging station.
(3) Discharge the refrigerant. Follow the instructions of the
discharge/charging station.
(4) Print the protocol of the discharge/charging station Follow the instructions of the
and add it to the RACC system documentation. discharge/charging station.
Page 208 Doc # 6.02.15
15 Apr 2013 21-50-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
(3) Charge the Refrigerant Circuit
Detail Steps/Work Items Key Items/References
(1) Make sure that all connectors of the refrigerant
circuit are tight.
(2) Charge the refrigerant circuit. Follow the instructions of the
discharge/charging station.
(3) Print the protocol of the discharge/charging Follow the instructions of the
station and add it to the RACC system discharge/charging station.
documentation.
(4) Disconnect the RACC system from the Follow the instructions of the
discharge/charging station. discharge/charging station.
(5) Install the RACC central unit in the airplane. Refer to Paragraph 1.
(6) Perform a RACC System Test. Refer to Paragraph 3.
Doc # 6.02.15 Page 209
Rev. 2 21-50-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
B. Remove/Install the Compressor
(1) Remove the Compressor
Detail Steps/Work Items Key Items/References
(1) Discharge the refrigerant circuit. Refer to Paragraph 4A (2).
(2) Unplug the electrical connectors from the
compressor.
(3) Loosen the hose connections of the refrigerant Use caps to plug the hose connectors.
circuit on the compressor.
(4) Remove the three screws which attach the
compressor to the RACC mounting panel.
(5) Move the compressor clear of the central unit.
(2) Install the Compressor
Detail Steps/Work Items Key Items/References
(1) Position the compressor on the RACC mounting
panel.
(2) Use the three screws to attach the compressor to
the RACC mounting panel.
(3) Connect the refrigerant circuit hoses to the Remove the caps from the hose
compressor. connectors.
(4) Connect the electrical connectors to the
compressor.
(5) Charge the refrigerant circuit. Refer to Paragraph 4A (3).
Page 210 Doc # 6.02.15
15 Apr 2013 21-50-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
C. Remove/Install the Filler/Drier Assembly
(1) Remove the Filler/Drier Assembly
Detail Steps/Work Items Key Items/References
(1) Discharge the refrigerant circuit. Refer to Paragraph 4A (2).
(2) Remove the electrical connectors from the
pressure sensor.
(3) Loosen the hose connections of the refrigerant Use caps to plug the hose connectors.
circuit on the filler/drier assembly.
(4) Remove the two screws which attach the
filler/drier assembly to the central unit.
(5) Move the filter/drier assembly clear of the central
unit.
(2) Install the Filler/Drier Assembly
Detail Steps/Work Items Key Items/References
(1) Position the filter/drier assembly on the RACC
mounting panel.
(2) Use the two screws to attach the filter/drier
assembly to the central unit.
(3) Connect the refrigerant circuit hoses to the Remove the caps from the hose
filter/drier assembly. connectors.
(4) Connect the electrical connectors to the pressure
sensor.
(5) Charge the refrigerant circuit. Refer to Paragraph 4A (3).
Doc # 6.02.15 Page 211
Rev. 2 21-50-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
D. Remove/Install the Expansion Valve
(1) Remove the Expansion Valve
Detail Steps/Work Items Key Items/References
(1) Discharge the refrigerant circuit. Refer to Paragraph 4A (2).
(2) Loosen the hose connections of the refrigerant Use caps to plug the hose connectors.
circuit to the expansion valve.
(3) Open the pressure line fittings which connect the
expansion valve to the evaporator.
(4) Move the expansion valve clear of the central unit.
(2) Install the Expansion Valve
Detail Steps/Work Items Key Items/References
(1) Position the expansion valve on the central unit.
(2) Attach the expansion valve to the evaporator with Use new O-rings.
the pressure line fittings.
(3) Connect the refrigerant circuit hoses to the Remove the caps from the hose
expansion valve. connectors.
(4) Charge the refrigerant circuit. Refer to Paragraph 4A (3).
Page 212 Doc # 6.02.15
15 Apr 2013 21-50-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
% Section 21-51
% Cooling (OÄM 40-316/i or later installed)
% 1. General
% If OÄM 40-316/i or later is installed, an improved recirculating air - cabin cooling (RACC) system is
% installed. The RACC system is an independent subsystem of the airplane and is electrically powered.
% It consists of the central unit (installed aft of baggage compartment) and a control panel (in the cabin,
% center console).
% 2. Description
% A. Central Unit
% The central unit operates with a refrigerant R134a vapor cycle cooling circuit. The system requires
% electrical power (28 V DC, max. 65 A) for operation, which is provided by an additional alternator.
% The central unit is subdivided into the following components:
% ) Compressor assembly (part of refrigerant circuit).
% ) Condenser assembly (part of refrigerant circuit).
% ) Evaporator assembly (part of refrigerant circuit).
% ) Condenser radial fan.
% ) Evaporator radial fan.
% ) Electrical control system.
% Refer to Figure 1 for a system schematic of the RACC system.
% Note: The refrigerant vapor cooling system is a hermetically sealed and
% pressurized circuit and contains the refrigerant R134a.
% WARNING: ALL MAINTENANCE AND REPLENISHMENT WHICH REQUIRES TO
% OPEN AND DEPRESSURIZE THE REFRIGERANT CIRCUIT MUST BE
% CARRIED OUT BY AUTHORIZED PERSONNEL ACCORDING TO
% NATIONAL AND INTERNATIONAL REGULATIONS FOR REFRIGERANT
% SYSTEMS.
Doc # 6.02.15 Page 1
Rev. 2 21-51-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
%
%
%
%
%
%
% AIRPLANE
Evaporator Fan CABIN
% (Radial)
Vents (x6)
%
%
%
% Compressor Cold Air
Evaporator Duct
%
% Compartment
Deventilation
% via Tail Spar
%
% Condenser
% Expansion Valve
%
Receiver/Drier
%
%
% Condenser Fan
(Radial)
%
%
% Compartment Exhaust
Ventilation (1 x Ø150mm) Refrigerant Circuit
%
(1 x Ø100mm)
% Air Flow
%
%
%
%
%
% Figure 1: RACC System Schematic (OÄM 40-316/i or later installed)
Page 2 Doc # 6.02.15
15 Apr 2013 21-51-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
% B. Control Panel
% The control panel is situated on the center console in the cabin. It is electrically connected to the
% RACC controller and provides all necessary elements to control the center unit. An integrated
% display shows the preset air temperature.
% Refer to Figure 2 for details about the RACC control panel.
%
%
%
%
Cabin Cabin Temperature
% Temperature UP
% ON/OFF
%
% Cabin Fan
Speed UP
%
%
%
%
% Fresh
% Air LED
%
%
%
% Cabin Fan Power Status Cabin Temperature
Speed DOWN LED DOWN
%
%
%
%
% Figure 2: RACC Control Panel (if OÄM 40-316/i or later installed)
Doc # 6.02.15 Page 3
Rev. 2 21-51-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
% 3. Operation
% If electrical power is provided to the RACC system, the power status LED on the control panel flashes.
% The control panel of the RACC system in the center console allows the crew to control the fan speed
% and the cabin temperature. A two digit display shows the preset cabin air temperature in °C.
% A push-button is used to set the RACC system to ON (if short depressed; display is illuminated) and
% OFF (if pressed and held for approximately one second).
% During power-up the software version of the control panel is displayed.
% The central unit is located aft of the baggage compartment. The RACC controller is located below the
% condenser unit and controls the refrigerant circuit valves and the compressor with respect to the
% control panel settings. With the control panel set to ON and a temperature preset lower than the
% current cabin air temperature, the refrigerant cooling circuit is activated. An electrically powered
% compressor takes the low-pressure low-temperature refrigerant gas and compresses it to a
% high-temperature gas. A pressure switch on the compressor assembly regulates the compressor
% discharge pressure. The hot refrigerant gas is cooled down in the condenser and condenses to a high
% pressure liquid. A radial condenser fan forces outside air through the condenser coils and vents the
% thus heated air overboard. The drier / receiver bottle separates moisture from liquid and filters
% contaminations from refrigerant. The expansion valve controls the amount of refrigerant liquid flowing
% to the evaporator. The refrigerant boils in the evaporator and turns back into a low-pressure
% low-temperature gas while cooling the coils of the evaporator. A radial evaporator fan forces cabin air
% through the cooling coils and thus remove heat from the cabin air. The cool cabin air cannot hold the
% moisture and water condensates on the evaporator cooling coils. The condensate is collected under
% the evaporator and is drained overboard. The refrigerant gas returns to the compressor.
% An inlet including a drip tray and an air filter enables ambient air to enter the RACC compartment
% ensuring sufficient compartment ventilation.
Page 4 Doc # 6.02.15
15 Apr 2013 21-51-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
% Trouble Shooting
% 1. General
% The table below lists the defects you could have with the control panel in the center console. If you
% have the trouble detailed in the Trouble column read across to the Possible Cause column. Then do
% the repair given in the Repair column.
% Trouble Possible Cause Repair
% The Power Status LED on RACC circuit breaker open. Set.
% control panel does not
% illuminate. Additional alternator defective. Check RACC power supply of
% the airplane.
% Central unit does not power Control panel defective. Replace.
% up.
% Electrical control unit defective. Replace.
% Insufficient cooling. Hot air outlet on fuselage Remove blockage.
% bottom blocked.
%
% Leak in refrigerant circuit. Perform a leak test.
% Repair leak.
% Charge the system.
%
% Condenser faulty. Check condenser coils for dirt
% accumulation and remove dirt.
% Expansion valve faulty. Replace expansion valve.
%
% Compressor faulty. Replace compressor.
%
% Electrical power source Check ground power source
% insufficient. respective RACC power supply
% of airplane.
%
Doc # 6.02.15 Page 101
Rev. 2 21-51-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 21-51-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
% Maintenance Practices
% 1. Remove/ Install the Central Unit
% A. Remove the Central Unit
% Detail Steps/Work Items Key Items/References
% (1) Remove the passenger seats. Refer to Section 25-10.
% (2) Remove the seatbelt pulleys of the passenger Refer to Section 25-10.
% seats.
% (3) Remove the short baggage extension. Refer to Section 25-10.
% (4) Remove the flexible air hoses from the RACC
% central unit:
% S Flexible cold air hose.
% S Flexible hot air hose.
%
% (5) Remove hot exhaust air duct from RACC central
% unit.
% (6) Unplug the electrical connections from the RACC
% central unit to:
% S 2 heavy connectors at the RACC central unit
% terminal board (LH).
% S 1 plug coming from the RACC control panel.
%
% (7) Remove drain hoses from RACC central unit:
% S Drip tray drain hose.
% S Evaporator drain hose.
%
% (8) Remove drip tray.
% (9) Remove the four bolts which connect the base
% plate of the RACC central unit to the RACC
% brackets on LH and RH side of airplane.
% (10) Slide the RACC central unit forward.
% (11) Lift the RACC central unit clear of the airplane.
Doc # 6.02.15 Page 201
Rev. 2 21-51-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
%
%
% RACC Compartment Ventilation Inlet
% (Drip Tray incl. Filter behind)
%
% Overhead Cold Air Duct Flexible Cold Air Hose
%
%
%
%
C-Profile
%
%
%
%
%
%
%
% RACC Central Unit
%
Drain Hoses
%
% Hot Exhaust Air Duct
%
Hot Exhaust Air Outlet
%
% Flexible Hot Air Hose
%
%
%
%
% Figure 3: RACC Central Unit Installation (if OÄM 316/i or later is installed)
Page 202 Doc # 6.02.15
15 Apr 2013 21-51-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
% B. Install the Central Unit
% Detail Steps/Work Items Key Items/References
% (1) Lift the RACC central unit into the airplane.
% (2) Slide the RACC central unit backward. Make sure
% to position the baseplate of the RACC central unit
% above the RACC brackets and trailing edge of
% the baseplate inside the C-profile.
% (3) Install four bolts which connect the baseplate of
% the RACC central unit to the RACC brackets on
% LH and RH side of airplane.
% (4) Install the drip tray.
% (5) Install drain hoses to the RACC central unit:
% S Drip tray drain hose.
% S Evaporator drain hose.
%
% (6) Connect electric cables to the RACC central unit
% to:
% S 2 heavy connectors of the RACC central unit
% terminal board (LH).
% S 1 plug coming from control panel.
%
% (7) Install the hot exhaust air duct to the RACC
% central unit.
% (8) Install flexible air hoses to the RACC central unit:
% ) Flexible cold air hose.
% ) Flexible hot air hose.
% (9) Install the short baggage extension. Refer to Section 25-10.
% (10) Install the seatbelt pulleys of the passenger Refer to Section 25-10.
% seats.
% (11) Install the passenger seats. Refer to Section 25-10.
% (12) Perform a cooling test of the RACC system.
Doc # 6.02.15 Page 203
Rev. 2 21-51-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
%
%
%
%
%
% Cabin Cold Air Out
%
Condenser
%
%
%
%
Evaporator
%
%
%
% Evaporator Fan
Condenser Fan
%
%
%
%
%
%
%
% Electric Fan with
% Control Box behind
%
%
%
%
%
% Figure 4: Central Unit - Front and LH Side (if OÄM 40-316/i or later installed)
Page 204 Doc # 6.02.15
15 Apr 2013 21-51-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
%
%
%
%
%
%
%
%
% Expansion Valve
%
%
% Evaporator Cover
%
%
%
%
%
%
%
%
%
%
%
Drier / Receiver Bottle
%
% Compressor
%
%
%
%
%
%
% Figure 5: Central Unit Back and RH Side (if OÄM 40-316/i or later installed)
Doc # 6.02.15 Page 205
Rev. 2 21-51-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
% 2. Remove/Install the Control Panel
% A. Remove the Control Panel
% Detail Steps/Work Items Key Items/References
% (1) Remove the center console. Refer to Section 25-10.
% (2) Unplug the electrical connectors of the control
% panel.
% (3) Unclip the RACC control panel from the center
% console.
% B. Install the Control Panel
% Detail Steps/Work Items Key Items/References
% (1) Move the RACC control panel in position on the
% center console.
% (2) Push the center console into the center console
% until the clips hold the panel in place on the
% center console.
% (3) Connect the electrical connectors to the control
% panel.
% (4) Install the center console. Refer to Section 25-10.
% (5) Perform a RACC - System test. Refer to Paragraph 3.
Page 206 Doc # 6.02.15
15 Apr 2013 21-51-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
% 3. RACC - System Test Procedure
% Detail Steps/Work Items Key Items/References
% (1) Perform an engine ground test. Refer to Section 71-00.
% (2) Set the engine to 1000 to 1200 RPM.
% (3) Set the AUX POWER switch to ON. The Power Status LED on the RACC
% control panel must flash.
% (4) Push the ON/OFF button on the RACC control The preset temperature display on the
% panel once to switch the RACC system ON. RACC control panel must illuminate.
% (5) Push the Preset Temperature DOWN button
% until the preset temperature shows ‘LO’.
% (6) Verify that the cabin outlet air temperature is
% significantly lower than the cabin air temperature.
%
% (7) Set the cabin air preset temperature to a Use the preset temperature UP and
% convenient temperature level. DOWN buttons on the control panel.
% (8) Push the ON/OFF button on the RACC control
% panel for approximately 1 second to switch the
% RACC system to OFF.
% (9) Set the AUX POWER switch to OFF.
Doc # 6.02.15 Page 207
Rev. 2 21-51-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
% 4. Remove/Install Parts of the Refrigerant Circuit
% Note: The refrigerant vapor cooling system is a hermetically sealed and
% pressurized circuit and contains the refrigerant R134a.
% WARNING: ALL MAINTENANCE AND REPLENISHMENT WHICH REQUIRES TO
% OPEN AND DEPRESSURIZE THE REFRIGERANT CIRCUIT MUST BE
% CARRIED OUT BY AUTHORIZED PERSONNEL ACCORDING TO
% NATIONAL AND INTERNATIONAL REGULATIONS FOR REFRIGERANT
% SYSTEMS.
% Before you do any maintenance on parts of the refrigerant circuit you must remove the central unit from
% the airplane. Refer to Paragraph 1.
% Make sure to obey the regulations for handling the refrigerant.
% A. Discharge/Charge the Refrigerant Circuit
% (1) Equipment
% One of the following automated discharge and charging stations or equivalent may be used:
% Item Quantity Part Number
% Silco CS 199 1 Commercial.
% Silco CS 195 1 Commercial.
% Silco CS 150 1 Commercial.
% (2) Discharge the Refrigerant Circuit
% Detail Steps/Work Items Key Items/References
% (1) Remove the central unit from the airplane. Refer to Paragraph 1.
% (2) Connect the RACC system to the discharge / Follow the instructions of the
% charging station. discharge/charging station.
% (3) Discharge the refrigerant. Follow the instructions of the
% discharge/charging station.
% (4) Print the protocol of the discharge/charging station Follow the instructions of the
% and add it to the RACC system documentation. discharge/charging station.
Page 208 Doc # 6.02.15
15 Apr 2013 21-51-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
% (3) Charge the Refrigerant Circuit
% Detail Steps/Work Items Key Items/References
% (1) Make sure that all connectors of the refrigerant
% circuit are tight.
% (2) Charge the refrigerant circuit. Follow the instructions of the
% discharge/charging station.
% (3) Print the protocol of the discharge/charging Follow the instructions of the
% station and add it to the RACC system discharge/charging station.
% documentation.
% (4) Disconnect the RACC system from the Follow the instructions of the
% discharge/charging station. discharge/charging station.
% (5) Install the RACC central unit in the airplane. Refer to Paragraph 1.
% (6) Perform a RACC system test. Refer to Paragraph 3.
Doc # 6.02.15 Page 209
Rev. 2 21-51-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
% B. Remove/Install the Compressor
% (1) Remove the Compressor
% Detail Steps/Work Items Key Items/References
% (1) Discharge the refrigerant circuit. Refer to Paragraph 4A(2).
% (2) Unplug the electrical connectors from the
% compressor.
% (3) Loosen the hose connections of the refrigerant Use caps to plug the hose connectors.
% circuit on the compressor.
% (4) Remove the three screws which attach the
% compressor to the RACC mounting panel.
% (5) Move the compressor clear of the central unit.
% (2) Install the Compressor
% Detail Steps/Work Items Key Items/References
% (1) Position the compressor on the RACC mounting
% panel.
% (2) Use the three screws to attach the compressor to
% the RACC mounting panel.
% (3) Connect the refrigerant circuit hoses to the Remove the caps from the hose
% compressor. connectors and replace O-rings of
% circuit-hoses.
% (4) Connect the electrical connectors to the
% compressor.
% (5) Charge the refrigerant circuit. Refer to Paragraph 4A(3).
Page 210 Doc # 6.02.15
15 Apr 2013 21-51-00 Rev. 2
DA 40 NG AMM Air Conditioning
AIRCRAFT
% C. Remove/Install the Filler/Drier Assembly
% (1) Remove the Filler/Drier Assembly
% Detail Steps/Work Items Key Items/References
% (1) Discharge the refrigerant circuit. Refer to Paragraph 4A(2).
% (2) Remove the electrical connectors from the
% pressure sensor.
% (3) Loosen the hose connections of the refrigerant Use caps to plug the hose connectors.
% circuit on the filler/drier assembly.
% (4) Remove the two screws which attach the
% filler/drier assembly to the central unit.
% (5) Move the filter/drier assembly clear of the central
% unit.
% (2) Install the Filler/Drier Assembly
% Detail Steps/Work Items Key Items/References
% (1) Position the filter/drier assembly on the RACC
% mounting panel.
% (2) Use the two screws to attach the filter/drier
% assembly to the central unit.
% (3) Connect the refrigerant circuit hoses to the Remove the caps from the hose
% filter/drier assembly. connectors and replace O-rings of
% circuit-hoses.
% (4) Connect the electrical connectors to the pressure
% sensor.
% (5) Charge the refrigerant circuit. Refer to Paragraph 4A(3).
Doc # 6.02.15 Page 211
Rev. 2 21-51-00 15 Apr 2013
Air Conditioning DA 40 NG AMM
AIRCRAFT
% D. Remove/Install Parts of the Refrigerant Circuit
% (1) Remove the Expansion Valve
% Detail Steps/Work Items Key Items/References
% (1) Discharge the refrigerant circuit. Refer to Paragraph 4A(2).
% (2) Open latches of evaporator cover and remove
% cover.
% (3) Remove evaporator from fixing cover.
% (4) Loosen the hose connections of the refrigerant Note and mark the correct position of
% circuit to the expansion valve and remove refrigerant hoses evaporator fixing plate
% associated evaporator fixing plate. on the expansion valve.
% (5) Remove two bolts from the expansion valve and Note and mark correct position of the
% the second evaporator fixing plate first and then expansion valve.
% remove expansion valve from evaporator.
% (6) Move the expansion valve clear of the central unit.
% (2) Install the Expansion Valve
% Detail Steps/Work Items Key Items/References
% (1) Position the expansion valve on the evaporator. Use new O-rings on evaporator-hoses.
% (2) Install associated expansion valve fixing plate with Check for correct position.
% two bolts.
% (3) Connect the refrigerant circuit hoses and the Use new O-rings on refrigerant-hoses
% second evaporator fixing plate to the expansion and check for correct position.
% valve.
% (4) Install evaporator inside fixing cover.
% (5) Install evaporator cover and close cover latches.
% (6) Charge the refrigerant circuit. Refer to Paragraph 4A(3).
Page 212 Doc # 6.02.15
15 Apr 2013 21-51-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
CHAPTER 22
AUTO FLIGHT
Doc # 6.02.15 Page 1
Rev. 2 22-TITLE 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 22-TITLE Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 22
AUTO FLIGHT
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 22-10
Autopilot, GFC 700
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Roll Servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Roll Servo Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Remove/Install the Pitch Servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5. Remove/Install the Pitch Servo Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6. Remove/Install the Pitch Trim Servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
7. Remove/Install the Pitch Trim Servo Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
8. Adjust the Bridle Cable Tension of the Roll and Pitch Servos . . . . . . . . . . . . . . 211
9. Adjust the Servo Clutch Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
10. Mechanical Test of the Autopilot System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Section 22-11
Autopilot, KAP 140
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Doc # 6.02.15 Page 1
Rev. 2 22-CONTENTS 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Flight Control Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the KCM 100 Configuration Module . . . . . . . . . . . . . . . . . . . . . . 203
4. Remove/Install the Roll Servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5. Remove/Install the Roll Servo Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6. Remove/Install the Pitch Servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
7. Remove/Install the Pitch Servo Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
8. Remove/Install the Pitch Trim Servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
9. Remove/Install the Pitch Trim Servo Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
10. Adjust the Bridle Cable Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
11. Adjust the Servo Clutch Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
12. Mechanical Test of the Autopilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Page 2 Doc # 6.02.15
15 Apr 2013 22-CONTENTS Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
CHAPTER 22
AUTO FLIGHT
1. General
This Chapter tells you about the auto flight (autopilot) system which may be installed in the DA 40 NG
airplane. This Chapter tells you about the components of the GFC 700 autopilot system of the airplane.
This Chapter does not tell you about the workshop maintenance of the equipment. For more data
about the equipment refer to the equipment manufacturer's manuals.
For more details refer to the following Sections:
) Section 22-10. Autopilot, GFC 700.
) Section 22-11. Autopilot, KAP 140.
Doc # 6.02.15 Page 1
Rev. 2 22-00-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 22-00-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
Section 22-10
Autopilot, GFC 700
1. General
This Section tells you about the GFC 700 autopilot system which may be installed in the DA 40 NG.
2. Description
The GFC 700 autopilot system is a digital flight control system that provides roll, pitch, pitch trim with
altitude control. The system has the following components (refer to Figure 1):
) Flight director (integral part of the Garmin G1000 system).
) GSA 81 roll servo.
) GSA 81 pitch servo.
) GSA 81 pitch trim servo.
) The GFC 700 autopilot system is controlled via the MFD of the Garmin G1000 integrated
cockpit system (ICS).
The GFC 700 roll axis features include wing leveler, heading select, and VOR/LOC intercept and
tracking. The GFC 700 is also coupled to the ICS for navigation information. Attitude information is
derived from the AHRS.
Pitch axis features include vertical speed, flight level change, glideslope and altitude hold along with
altitude preselect. Pitch information is derived from AHRS and GDC. Internal monitors keep constant
track of the GFC 700's status and provide for automatic shutdown of the autopilot or trim system in the
event of a malfunction.
Doc # 6.02.15 Page 1
Rev. 2 22-10-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
PFD MFD
GDU Reversionary GDU
Switch
1040 1044
GMU 44
GRS 77
GDC 74
GIA 63 W GMA GIA 63 W
1347
GSA 81
Roll Servo
GSA 81
Pitch Servo
GSA 81
Pitch Trim Servo
G1000 LRU
Digital Communication
Discrete I/O
Figure 1: GFC 700 Autopilot Schematic Diagram
Page 2 Doc # 6.02.15
15 Apr 2013 22-10-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
A. GFC 700 Flight Control
For details about operation and the indications concerning GFC 700 functions refer to Garmin
DA 40 NG Pilot's Guide, latest revision.
B. GSA 81 Roll Servo
The roll servo is located behind the rear main bulkhead on the right side. It is mounted on a mounting
plate which is made from sheet aluminum. Two aluminum clamps connect a bridle cable to the aileron
push-rod.
C. GSA 81 Pitch Servo
The pitch servo is located aft of the baggage compartment frame. It is mounted on a mounting plate
which is made from sheet aluminum. Two aluminum clamps connect a bridle cable to the elevator
push-rod.
D. GSA 81 Pitch Trim Servo
The pitch trim servo is located under the co-pilot's seat. It is mounted on a mounting plate which is
made from sheet aluminum and mounting bracket which is made from GFRP. Servo movement is
transmitted to the trim wheel through a chain gear on the servo, a cardan shaft, and a chain gear next
to the trim wheel on the right side.
Doc # 6.02.15 Page 3
Rev. 2 22-10-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
Figure 2: Roll Servo Installation
Page 4 Doc # 6.02.15
15 Apr 2013 22-10-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to install the components of the autopilot system. They also
tell you how to test and adjust the autopilot system.
2. Remove/Install the Roll Servo
A. Remove the Roll Servo
Detail Steps/Work Items Key Items/References
(1) Remove the passenger seats. Refer to Section 25-10.
(2) Dis-connect the connector from the servo.
(3) Remove the 2 screws which attach the servo to Hold the servo.
the clutch.
(4) Remove the servo clear of the airplane.
B. Install the Roll Servo
Detail Steps/Work Items Key Items/References
(1) Put the servo in place on the clutch.
(2) Install the 2 screws which attach the servo to the Refer to Figure 2.
mounting plate and clutch.
(3) Connect the connector to the servo.
(4) Do a test of the autopilot system:
S Set ELECTRIC MASTER key switch to ON.
S Set AVIONIC MASTER switch to ON.
S Observe self-test of the flight control If no error message appears, then the
computer. system is operative.
S Set AVIONIC MASTER switch to OFF.
S Set ELECTRIC MASTER key switch to OFF.
(5) Install the passenger seats. Refer to Section 25-10.
Doc # 6.02.15 Page 201
Rev. 2 22-10-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
3. Remove/Install the Roll Servo Clutch
A. Equipment
Item Quantity Part Number
Cable tension gauge. 1 Commercial.
B. Remove the Roll Servo Clutch
Detail Steps/Work Items Key Items/References
(1) Remove the roll servo. Refer to Paragraph 2.
(2) Release the clamps which connect the bridle
cable to the aileron push-rod.
(3) Remove the cable guard.
(4) Remove the 4 screws which attach the clutch to Hold the clutch.
the mounting plate.
(5) Remove the clutch clear of the airplane.
Page 202 Doc # 6.02.15
15 Apr 2013 22-10-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
C. Install the Roll Servo Clutch
Detail Steps/Work Items Key Items/References
(1) Remove the pilot's seat or the co-pilot's seat. Refer to Section 25-10. To give access
for the rigging pin.
(2) Put the clutch in place on the mounting plate.
(3) Install the 4 screws which attach the clutch to
the mounting plate.
(4) Center the aileron control system with a rigging Refer to Section 27-10.
pin at one control stick.
(5) Center the capstan. The recess for the ball in the middle of
the bridle cable must be in the
uppermost position.
(6) Install bridle cable to capstan. The ball in the middle of the bridle cable
must engage in the recess on the
capstan. Wrap bridle cable around
capstan 1.5 turns to each side.
(7) Connect the ends of the bridle cable to the Tighten clamps lightly to allow
aileron push-rod with the clamps. adjustment (see next step).
(8) Using a small plastic hammer, move the clamps Adjust tension to 156 ± 9 N (35 ± 2 lb).
along the push-rod to adjust the bridle cable Measure cable tension with cable tension
tension. gauge.
(9) Tighten the clamps.
(10) Install the cable guard.
(11) Remove the rigging pin from the control stick.
(12) Install the front seat which was removed. Refer to Section 25-10.
(13) Install the roll servo. Refer to Paragraph 2.
Doc # 6.02.15 Page 203
Rev. 2 22-10-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
4. Remove/Install the Pitch Servo
A. Remove the Pitch Servo
Detail Steps/Work Items Key Items/References
(1) Remove the trim/cover from the front face of the
baggage compartment and remove the lower
access panel from the baggage compartment
insert.
(2) Dis-connect the connector from the servo.
(3) Remove the 2 screws which attach the servo to Hold the servo.
the clutch.
(4) Remove the servo clear of the airplane.
B. Install the Pitch Servo
Detail Steps/Work Items Key Items/References
(1) Put the servo in place on the clutch.
(2) Install the 2 screws which attach the servo to
the clutch.
(3) Connect the connector to the servo.
(4) Do a test of the autopilot system:
S Set ELECTRIC MASTER key switch to ON.
S Set AVIONIC MASTER switch to ON.
S Observe self-test of the flight control If no error message appears, then the
computer. system is operative.
S Set AVIONIC MASTER switch to OFF.
S Set ELECTRIC MASTER key switch to OFF.
(5) Install the baggage compartment lower access
panel and install the trim/cover to the front face
of the baggage compartment.
Page 204 Doc # 6.02.15
15 Apr 2013 22-10-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
Figure 3: Pitch Servo Installation
Doc # 6.02.15 Page 205
Rev. 2 22-10-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
5. Remove/Install the Pitch Servo Clutch
A. Equipment
Item Quantity Part Number
Cable tension gauge. 1 Commercial.
B. Remove the Pitch Servo Clutch
Detail Steps/Work Items Key Items/References
(1) Remove the pitch servo. Refer to Paragraph 4.
(2) Release the clamps which connect the bridle
cable to the elevator push-rod.
(3) Remove the cable guard.
(4) Remove the 4 screws which attach the clutch to Hold the clutch.
the mounting plate.
(5) Remove the clutch clear of the airplane.
Page 206 Doc # 6.02.15
15 Apr 2013 22-10-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
C. Install the Pitch Servo Clutch
Detail Steps/Work Items Key Items/References
(1) Remove the pilot's seat or the co-pilot's seat. Refer to Section 25-10. To give access
for the rigging pin.
(2) Put the clutch in place on the mounting plate.
(3) Install the 4 screws which attach the clutch to
the mounting plate.
(4) Center the elevator control system with a rigging Refer to Section 27-30.
pin at one control stick.
(5) Center the capstan. The recess for the ball in the middle of
the bridle cable must be in the under
most position.
(6) Install bridle cable to capstan. The ball in the middle of the bridle cable
must engage in the recess on the
capstan. Wrap bridle cable around
capstan 1.5 turns to each side.
(7) Connect the ends of the bridle cable to the Tighten clamps lightly to allow
elevator push-rod with the clamps. adjustment (see next step).
(8) Using a small plastic hammer, move the clamps Adjust tension to 156 ± 9 N (35 ± 2 lb).
along the push-rod to adjust the bridle cable Measure cable tension with cable
tension. tension gauge.
(9) Tighten the clamps.
(10) Install the cable guard.
(11) Remove the rigging pin from the control stick.
(12) Install the front seat which was removed. Refer to Section 25-10.
(13) Install the pitch servo. Refer to Paragraph 4.
Doc # 6.02.15 Page 207
Rev. 2 22-10-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
Figure 4: Pitch Trim Servo Installation
Page 208 Doc # 6.02.15
15 Apr 2013 22-10-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
6. Remove/Install the Pitch Trim Servo
A. Remove the Pitch Trim Servo
Detail Steps/Work Items Key Items/References
(1) Remove the co-pilot's seat. Refer to Section 25-10.
(2) Dis-connect the connector from the servo.
(3) Remove the 2 screws which attach the servo to Hold the servo.
the clutch.
(4) Remove the servo clear of the airplane.
B. Install the Pitch Trim Servo
Detail Steps/Work Items Key Items/References
(1) Put the servo in place on the clutch.
(2) Install the 2 screws which attach the servo to
the clutch.
(3) Connect the connector to the servo.
(4) Do a test of the autopilot system:
S Set ELECTRIC MASTER key switch to ON.
S Set AVIONIC MASTER switch to ON.
S Observe self-test of the flight control If no error message appears, then the
computer. system is operative.
S Set AVIONIC MASTER switch to OFF.
S Set ELECTRIC MASTER key switch to OFF.
(5) Install the co-pilot's seat. Refer to Section 25-10.
Doc # 6.02.15 Page 209
Rev. 2 22-10-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
7. Remove/Install the Pitch Trim Servo Clutch
A. Remove the Pitch Trim Servo Clutch
Detail Steps/Work Items Key Items/References
CAUTION: DO NOT APPLY STRONG FORCES TO THE CARDAN SHAFT. THE
UPPER CARDAN JOINT CONNECTS TO A PART WHICH IS WEAK
BY DESIGN TO GIVE OCCUPANT PROTECTION IN AN
EMERGENCY LANDING.
(1) Remove the pitch trim servo. Refer to Paragraph 6.
(2) Remove the screws which hold the cap to the
capstan.
(3) Remove the cap from the capstan.
(4) Release chain tension with chain adjuster. On the chain gear next to the servo.
(5) Remove the chain from the chain gear.
(6) Remove the 4 screws which attach the clutch Hold the clutch and the chain adjuster.
and the chain adjuster to the mounting plate.
B. Install the Pitch Trim Servo Clutch
Detail Steps/Work Items Key Items/References
(1) Put the clutch and the chain adjuster in place on
the mounting plate.
(2) Install the 4 screws which attach the clutch and
the chain adjuster to the mounting plate.
(3) Install the chain to the chain gear.
(4) Put the cap in place on the capstan.
(5) Install the screws which hold the cap to the
capstan.
(6) Install the pitch trim servo. Refer to Paragraph 6.
Page 210 Doc # 6.02.15
15 Apr 2013 22-10-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
8. Adjust the Bridle Cable Tension of the Roll and Pitch Servos
A. Equipment
Item Quantity Part Number
Cable tension gauge. 1 Commercial.
B. Adjustment Procedure
Detail Steps/Work Items Key Items/References
(1) Loosen the bolts in the clamps which connect Do not remove the bolts. Loosen just
the bridle cable to the push-rod. enough so that the next step can be
done.
(2) Using a small plastic hammer, move the clamps Adjust tension to 156 ± 9 N (35 ± 2 lb)
along the push-rod to adjust the bridle cable for the pitch and roll servos.
tension. Measure cable tension with cable
tension gauge.
(3) Tighten the bolts in the clamps which connect
the bridle cable to the push-rod.
Doc # 6.02.15 Page 211
Rev. 2 22-10-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
9. Adjust the Servo Clutch Torques
A. Equipment
Item Quantity Part Number
Garmin slip clutch adjustment fixture. 1 T10-00110-01.
B. Adjustment Procedure
Detail Steps/Work Items Key Items/References
(1) Remove the clutch from the airplane. Refer to this Section.
(2) Clean the servo output gears.
(3) Install the clutch assembly on the slip clutch test Refer to the equipment manufacturers'
stand. documentation.
(4) Measure clockwise (CW) and counter-clockwise Refer to the equipment manufacturers'
(CCW) clutch torque, adjust if necessary. documentation.
The correct clutch torques are:
S Roll servo 4.52 ± 0.56 Nm
(40 ± 5 lbf.in.)
S Pitch servo 5.08 ± 0.68 Nm
(45 ± 6 lbf.in.)
S Pitch trim servo 4.07 ± 0.56 Nm
(36 ± 5 lbf.in.)
(5) Remove the clutch assembly from the slip clutch
test stand.
(6) Apply grease to the servo output gears.
(7) Install the clutch to the airplane. Refer to this Section.
Page 212 Doc # 6.02.15
15 Apr 2013 22-10-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
10. Mechanical Test of the Autopilot System
Do this check at the intervals given in Section 05-10.
Detail Steps/Work Items Key Items/References
(1) Check bridle cable tension for the roll servo, Refer to this Section.
adjust if necessary.
(2) Check bridle cable tension for the pitch servo, Refer to this Section.
adjust if necessary.
(3) Check the clutch torque settings for the roll Refer to this Section.
servo, adjust if necessary.
(4) Check the clutch torque settings for the pitch Refer to this Section.
servo, adjust if necessary.
(5) Check the clutch torque settings for the pitch Refer to this Section.
trim servo, adjust if necessary.
Doc # 6.02.15 Page 213
Rev. 2 22-10-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 214 Doc # 6.02.15
15 Apr 2013 22-10-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
Section 22-11
Autopilot, KAP 140
Note: The information contained in this Section refers to airplanes with an optional
autopilot installed.
1. General
This Section tells you about the KAP 140 autopilot system in the DA 40 NG airplane.
2. Description
The KAP 140 autopilot system is a digital flight control system that provides roll, pitch, and pitch trim
steering with altitude preselect. The system has the following components (refer to Figure 1):
) KC 140 flight control computer (FCC).
) KCM 100 configuration module.
) Turn co-ordinator with autopilot pick-off.
) KS 271C roll servo.
) KS 270C pitch servo.
) KS 272C pitch trim servo.
) KM 275 and KM 277 servo mounts.
) Coupling to the Garmin G1000 integrated cockpit system (ICS).
Heading input is supplied for the KAP 140 autopilot by the Garmin G1000 integrated cockpit system
(ICS). Refer to Section 31-40 for more data about the ICS.
The KAP 140 roll axis features includes wing leveler, heading select, and VOR/LOC intercept and
tracking. The KAP 140 is also coupled to the ICS for navigation information. Roll rate information is
derived from the turn coordinator.
Pitch axis features include vertical speed, glideslope and altitude hold along with the optional altitude
preselect. Pitch information is derived from a pressure sensor and accelerometer. Internal monitors
keep constant track of the KAP 140's status and provide for automatic shutdown of the autopilot or trim
system in the event of a malfunction.
Doc # 6.02.15 Page 1
Rev. 2 22-11-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
Garmin 1000 Integrated Cockpit System
Turn & Bank
Indicator
D .C .
E LE C .
OFF
TU R N C O OR D IN ATO R
L R
2 MIN.
N O P IT CH
IN FO RM ATI ON
HSI Information
Trim Fail Alert
Stick Switches
Altitude
Information
KC 140 FCC
Aircraft Static
System Roll Servo
Alternate
Static
Pitch Servo
Remote Terminal Pitch Trim Servo
Interface Connector
KCM 100
Sonalert
Figure 1: Autopilot System Schematic Diagram
Page 2 Doc # 6.02.15
15 Apr 2013 22-11-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
A. Bendix/King KAP 140 Flight Control Computer
Figure 2 shows the Bendix/King KAP 140 flight control computer. It is located in the instrument
panel, at the bottom.
The Bendix/King KAP 140 has the following annunciators on the front panel, above the AP button:
) P (pitch axis) annunciator. It indicates failure of the pitch axis and will either disengage the
autopilot or does not allow engagement of the pitch axis. The P annunciator may illuminate with
the autopilot disengaged. This condition can occur during maneuvering flight when g-thresholds
are exceeded. The autopilot monitor will not allow engagement during illumination.
) R (roll axis) annunciator. It indicates failure of the roll axis and will disengage the autopilot or
does not allow engagement.
The Bendix/King KAP 140 controls the following annunciator on the ICS alerts panel (also see
Section 31-40):
TRIM FAIL annunciator. It illuminates whenever the automated pre-flight self test detects a pitch
trim fault or a continuous monitoring system detects a pitch trim fault in flight.
The Bendix/King KAP 140 has a display which shows the following:
Pitch and roll mode displays. Displays the active pitch modes (VS, ALT, ARM, ALT, GS ARM, GS)
and roll modes (ROL, HDG, NAV ARM, NAV, APR ARM, APR, REV ARM, REV). Also displayed
will be a flashing AP annunciation (5 seconds) at each autopilot disconnect, accompanied by an
aural alert (for 2 seconds).
PT (pitch trim) annunciation. It indicates the direction of required pitch trim. With electric trim
installed, the annunciation simply provides status to the autopilot request for auto trim. A solid
indication represents the lowest demand level for trim, whereas a flashing annunciation implies a
greater demand. A solid PT annunciation without an arrow head is an indication of a pitch trim fault.
During MET operation, this annunciation can be caused by a stuck MET switch. If the stuck switch
fault clears, trim operation will resume.
Doc # 6.02.15 Page 3
Rev. 2 22-11-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
Altitude Alerter/
Vertical Speed/
Pitch Trim Baro Setting
Annunciation Display
Pitch and Roll Altitude Alert Altitude Arm Baro Set
Mode Displays Annunciation Button Button
Pitch Axis BENDIX/KING
Annunciator KAP 140
APR A
VS P
A T
10.500
ALERT FT
P R
GS R
M ALT R
M
Roll Axis
Annunciator
Autopilot Navigation Mode Approach Mode Altitude Hold Rotary Knobs
Engage/Disengage Selector Button Selector Button Mode Selector
Button Button
Heading Mode Mounting Back Course Vertical Trim
Selector Button Screw Approach Mode Buttons
Selector Button
Figure 2: Bendix/King KAP 140 Flight Control Computer
Page 4 Doc # 6.02.15
15 Apr 2013 22-11-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
ALERT (altitude alert) annunciation. This annunciation is used when the altitude preselect option
is installed.
) It illuminates continuously in the region of from 200 to 1000 feet from the selected altitude if the
airplane was previously outside of this region.
) It flashes for two seconds the first time the airplane crossed the selected altitude.
) If flashes continuously in the 200 to 1000 feet region if the airplane was previously inside of this
region (i.e., at the selected altitude). Associated with the visual alerting is an aural alert (5 short
tones) which occurs 1000 feet from the selected altitude upon approaching the altitude and
200 feet from the selected altitude on leaving the altitude.
) Altitude alert/vertical speed/baro setting display. This feature is used only if the altitude preselect
option is installed. Normally the altitude alerter selected altitude is displayed. If the UP or DN
button is pushed while in VS hold, the display changes to the command reference for the VS
mode in FPM for 3 seconds. If the BARO button is pushed, the display changes to the autopilot
baro setting in either IN HG or HPA for 3 seconds.
The flight control computer has these controls on the front panel:
) Rotary knobs. These are used to set the altitude alert reference altitude; or may be used
immediately after pressing the BARO button, to adjust the autopilot baro setting to match that
of the airplane’s altimeter when manual adjustment is required.
) AP (autopilot engage/disengage) button. When pushed, it engages the autopilot if all logic
conditions are met. The autopilot will engage in the basic roll (ROL) mode which functions as
a wing leveler and in the vertical speed (VS) hold mode. The commanded vertical speed may
be displayed manually in the upper right corner of autopilot display area if either UP or DN
button is pressed. The captured VS will be the vertical speed present at the moment of AP
button press. When pressed again, it will disengage the autopilot.
) HDG (heading) mode selector button. When pushed, it will select the 'heading' mode, which
commands the airplane to turn to and maintain the heading selected by the heading bug on the
HSI. A new heading may be selected at any time and will result in the airplane turning to the
new heading. The button can also be used to toggle between HDG and ROL modes. This button
may be used to engage the autopilot.
) NAV (navigation) mode selector button. When pushed, will select the navigation mode. The
mode provides automatic beam capture and tracking of VOR, LOC or GPS as selected for
presentation on the HSI. NAV mode is recommended for enroute navigation tracking.
Doc # 6.02.15 Page 5
Rev. 2 22-11-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
) APR (approach) mode selector button. When pushed, it will select the navigation mode. The
mode provides automatic beam capture and tracking of VOR, GPS, LOC, and glideslope (GS)
on an ILS, as selected for presentation on the ICS. APR mode tracking sensitivity is
recommended for instrument approaches.
) REV (back course approach) mode selector button. When pushed, it will select the back course
approach mode. This mode functions identically to the approach mode except that the autopilot
response to LOC signals is reversed.
) ALT (altitude hold) mode select button. When pushed, it will select the altitude hold mode. This
mode provides capture and tracking of the selected altitude. The selected altitude is the altitude
at the moment the ALT button is pressed. If the ALT button is pressed with an established VS
rate present, there will be approximately a 10% (of VS rate) overshoot, with the airplane
returned positively to the selected altitude. This button may be used to engage the autopilot.
) UP/DN (vertical trim) buttons. The action of these buttons is dependent upon the vertical mode
present when pressed. If VS mode is active, the initial button stroke will bring up the
commanded vertical speed in the display. Subsequent immediate button strokes will increment
the vertical commanded either up or down at the rate of 100 ft/min per button press, or at the
rate of approximately 300 ft/min per second if pressed continuously. If the ALT mode is active,
incremental button strokes will move the altitude hold reference altitude either up or down by
20 feet per press, or if held continuously will command the airplane up or down at the rate of
500 ft/min, synchronizing the altitude hold reference to the actual airplane altitude upon button
release. (Note that the altitude hold reference is not displayed. The display will continue to show
the altitude alert reference.)
) ARM (altitude arm) button (only if altitude preselect option is installed). It toggles altitude arming
on or off. When ALT ARM is annunciated, the autopilot will capture the altitude alert displayed
altitude (provided the airplane is climbing or descending in VS to the displayed altitude). ALT
hold arming when the autopilot is engaged is automatic upon altitude alert altitude selection via
the rotary knobs. Note that the alert functions are independent of the arming process, thus
providing full time alerting, even when the autopilot is disengaged.
) BARO (baro set) button. When pushed and released, it will change the display from the altitude
alert selected altitude to the baro setting display (either IN HG or HPA) for 3 seconds. If pushed
and held for 2 seconds, it will change the baro setting display from IN HG to HPA or vice versa.
Once the baro setting display is visible, the rotary knobs may be used to manually adjust the
baro setting if the system configuration does not employ automatic correction.
Page 6 Doc # 6.02.15
15 Apr 2013 22-11-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
The flight control computer is connected to these controls on the control sticks:
) AP DISC (autopilot disconnect) switch on pilot’s and co-pilot’s stick. When pressed, it will
disengage the autopilot, and interrupt electric trim power.
) Manual electric trim switches on the pilot’s stick. When both switches are pressed in the same
direction, they will activate pitch trim in the selected direction. If only one switch is moved, the
trim system will not operate. If one switch fails or is moved and held for 3 seconds, the trim
monitoring system will detect a switch failure resulting in a PT annunciation on the autopilot
display and the disabling of the electric trim system. Autopilot power will have to be cycled to
clear the fault. Use of manual electric trim during autopilot operation will disengage the autopilot.
) CWS (control wheel steering) mode button on the pilot’s stick. When pressed and held, it
disengages the pitch, roll and pitch trim clutches allowing the pilot to maneuver the airplane by
hand. Pressing the CWS button will also sync the autopilot ALT or VS commands to the actual
altitude or vertical speed present at the time the button is released.
B. KCM 100 Configuration Module
The data which is specific to the DA 40 NG (for example: gain settings) is stored in the KCM 100
configuration module. It is located on the instrument panel floor, between the instrument panel and
the instrument panel frame.
C. KS 271C Roll Servo
The roll servo is located behind the rear main bulkhead on the right side. It is mounted on a
mounting plate which is made from sheet aluminum. Two aluminum clamps connect a bridle cable
to the aileron push-rod.
D. KS 270C Pitch Servo
The pitch servo is located aft of the baggage compartment frame. It is mounted on a mounting plate
which is made from sheet aluminum. Two aluminum clamps connect a bridle cable to the elevator
push-rod.
E. KS 272C Pitch Trim Servo
The pitch trim servo is located under the co-pilot's seat. It is mounted on a mounting plate which
is made from sheet aluminum and mounting bracket which is made from GFRP. Servo movement
is transmitted to the trim wheel through a chain gear on the servo, a cardanshaft, and a chain gear
next to the trim wheel on the right side.
Doc # 6.02.15 Page 7
Rev. 2 22-11-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 8 Doc # 6.02.15
15 Apr 2013 22-11-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to install the components of the autopilot system. They also
tell you how to test and adjust the autopilot system.
2. Remove/Install the Flight Control Computer
A. Remove the Flight Control Computer
Detail Steps/Work Items Key Items/References
(1) Open the AUTOPILOT circuit-breaker.
(2) Put a 3/32 Allen wrench into the access hole for
the locking screw. Engage the screw.
(3) Turn the screw counter-clockwise until the unit
disengages from the mounting rack.
CAUTION: DO NOT PULL ON THE KNOBS. DO NOT PRY THE FACE-PLATE. IF
YOU PULL ON THE KNOBS, OR PRY THE FACE- PLATE, YOU CAN
DAMAGE THE UNIT.
CAUTION: DO NOT TOUCH THE CONNECTOR CARD AT THE REAR OF THE
UNIT. THE ELECTROSTATIC CHARGE ON YOUR BODY CAN
DAMAGE THE UNIT.
(4) Pull gently on the sides of the unit to remove it
from the mounting rack.
(5) Install the protective covers on the rear
connectors of the flight control computer.
Doc # 6.02.15 Page 201
Rev. 2 22-11-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
B. Install the Flight Control Computer
Detail Steps/Work Items Key Items/References
(1) Remove the protective covers from the
connectors on the replacement unit.
(2) Slide the unit into the rack. Engage the locking
screw so that the latch front-lobe touches the
rack.
(3) Turn the locking screw clockwise so that the rear
lobe engages the mounting rack.
CAUTION: DO NOT OVER-TIGHTEN THE LOCKING SCREW. YOU CAN
DAMAGE THE LOCKING MECHANISM.
(4) Continue to turn the screw until the unit is fully
installed in the mounting rack.
(5) Close the AUTOPILOT circuit-breaker.
(6) Check and adjust the servo nulls. Refer to the Installation Manual for the
KAP 140 Flight Control System.
(7) Do a test of the autopilot system:
S Set the ELECTRIC MASTER key switch to
ON.
S Set AVIONIC MASTER switch to ON.
S Observe self-test of the flight control If no error message appears, then the
computer. system is operative.
S Set AVIONIC MASTER to OFF.
S Set ELECTRIC MASTER key switch to
OFF.
Page 202 Doc # 6.02.15
15 Apr 2013 22-11-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
3. Remove/Install the KCM 100 Configuration Module
A. Remove the KCM 100 Configuration Module
Detail Steps/Work Items Key Items/References
(1) Open the AUTOPILOT circuit-breaker. Instrument panel, right side.
(2) Remove the instrument panel cover. Refer to Section 25-10.
(3) Remove the KCM 100:
S Remove the two screws that attach the
KCM 100 to the instrument panel floor.
S Disconnect the electric cable.
S Move the configuration module free of the
instrument panel.
Doc # 6.02.15 Page 203
Rev. 2 22-11-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
B. Install the KCM 100 Configuration Module
Detail Steps/Work Items Key Items/References
CAUTION: WHEN A NEW CONFIGURATION MODULE IS INSTALLED, YOU
MUST MAKE SURE THAT IT HAS THE PART NUMBER WHICH IS
SHOWN IN THE EQUIPMENT LIST IN CHAPTER 6 OF THE
AIRPLANE FLIGHT MANUAL. THE CONFIGURATION MODULE
CONTAINS INFORMATION WHICH IS SPECIFIC FOR THE DA 40 NG
AIRPLANE.
(1) Slide the KCM 100 into position. Connect the
electric cable and engage the two locking screws.
(2) Install the instrument panel cover. Refer to Section 25-10.
(3) Close the AUTOPILOT circuit-breaker. Instrument panel, right side.
(4) Upload the software.
(5) Check and adjust the servo nulls. Refer to the Installation Manual for the
KAP 140 Flight Control System.
(6) Do a test of the autopilot system:
S Set the ELECTRIC MASTER key switch to
ON.
S Set AVIONIC MASTER switch to ON.
S Observe self-test of the flight control If no error message appears, then the
computer. system is operative.
S Set AVIONIC MASTER to OFF.
S Set ELECTRIC MASTER key switch to OFF.
Page 204 Doc # 6.02.15
15 Apr 2013 22-11-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
4. Remove/Install the Roll Servo
A. Remove the Roll Servo
Detail Steps/Work Items Key Items/References
(1) Remove the passengers' seat. Refer to Section 25-10.
(2) Dis-connect the connector from the servo.
(3) Remove the 2 screws which attach the servo to Hold the servo.
the mounting plate and the clutch.
(4) Remove the servo clear of the airplane.
B. Install the Roll Servo
Detail Steps/Work Items Key Items/References
(1) Put the servo in place on the mounting plate.
(2) Install the 2 screws which attach the servo to the
mounting plate and clutch.
(3) Connect the connector to the servo.
(4) Do a test of the autopilot system:
S Set ELECTRIC MASTER key switch to ON.
S Set AVIONIC MASTER switch to ON.
S Observe self-test of the flight control If no error message appears, then the
computer. system is operative.
S Set AVIONIC MASTER switch to OFF.
S Set ELECTRIC MASTER key switch to OFF.
(5) Install the passengers' seat. Refer to Section 25-10.
Doc # 6.02.15 Page 205
Rev. 2 22-11-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
5. Remove/Install the Roll Servo Clutch
A. Equipment
Item Quantity Part Number
Cable tension gauge. 1 Commercial.
B. Remove the Roll Servo Clutch
Detail Steps/Work Items Key Items/References
(1) Remove the roll servo. Refer to Paragraph 3.
(2) Release the clamps which connect the bridle
cable to the aileron push-rod.
(3) Remove the bridle cable.
(4) Remove the 2 screws which attach the clutch to Hold the clutch.
the mounting plate.
(5) Remove the clutch clear of the airplane.
Page 206 Doc # 6.02.15
15 Apr 2013 22-11-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
C. Install the Roll Servo Clutch
Detail Steps/Work Items Key Items/References
(1) Remove the pilot's seat or the co-pilot's seat. Refer to Section 25-10. To give access
for the rigging pin.
(2) Put the clutch in place on the mounting plate.
(3) Install the 2 screws which attach the clutch to
the mounting plate.
(4) Center the aileron control system with a rigging Refer to Section 27-10.
pin at one control stick.
(5) Center the capstan. The recess for the ball in the middle of
the bridle cable must be in the
uppermost position.
(6) Install bridle cable to capstan. The ball in the middle of the bridle cable
must engage in the recess on the
capstan. Wrap bridle cable around
capstan one turn to each side.
(7) Connect the ends of the bridle cable to the Tighten clamps lightly to allow
aileron push-rod with the clamps. adjustment (see next step).
(8) Using a small plastic hammer, move the clamps Adjust tension to 89 ± 22 N (20 ± 5 lbf).
along the push-rod to adjust the bridle cable Measure cable tension with cable tension
tension. gauge.
(9) Tighten the clamps.
(10) Remove the rigging pin from the control stick.
(11) Install the front seat which was removed. Refer to Section 25-10.
(12) Install the roll servo. Refer to Paragraph 3.
Doc # 6.02.15 Page 207
Rev. 2 22-11-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
6. Remove/Install the Pitch Servo
A. Remove the Pitch Servo
Detail Steps/Work Items Key Items/References
(1) Remove the trim/cover from the front face of the
baggage compartment and remove the lower
access panel from the baggage compartment
insert.
(2) Dis-connect the connector from the servo.
(3) Remove the 2 screws which attach the servo to Hold the servo.
the mounting plate and the clutch.
(4) Remove the servo clear of the airplane.
B. Install the Pitch Servo
Detail Steps/Work Items Key Items/References
(1) Put the servo in place on the mounting plate.
(2) Install the 2 screws which attach the servo to
the mounting plate and clutch.
(3) Connect the connector to the servo.
(4) Do a test of the autopilot system:
S Set ELECTRIC MASTER key switch to ON.
S Set AVIONIC MASTER switch to ON.
S Observe self-test of the flight control If no error message appears, then the
computer. system is operative.
S Set AVIONIC MASTER switch to OFF.
S Set ELECTRIC MASTER key switch to OFF.
(5) Install the baggage compartment lower access
panel and install the trim/cover to the front face
of the baggage compartment.
Page 208 Doc # 6.02.15
15 Apr 2013 22-11-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
7. Remove/Install the Pitch Servo Clutch
A. Equipment
Item Quantity Part Number
Cable tension gauge. 1 Commercial.
B. Remove the Pitch Servo Clutch
Detail Steps/Work Items Key Items/References
(1) Remove the pitch servo. Refer to Paragraph 5.
(2) Release the clamps which connect the bridle
cable to the elevator push-rod.
(3) Remove the bridle cable.
(4) Remove the 2 screws which attach the clutch to Hold the clutch.
the mounting plate.
(5) Remove the clutch clear of the airplane.
Doc # 6.02.15 Page 209
Rev. 2 22-11-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
C. Install the Pitch Servo Clutch
Detail Steps/Work Items Key Items/References
(1) Remove the pilot's seat or the co-pilot's seat. Refer to Section 25-10. To give access
for the rigging pin.
(2) Put the clutch in place on the mounting plate.
(3) Install the 2 screws which attach the clutch to
the mounting plate.
(4) Center the elevator control system with a rigging Refer to Section 27-30.
pin at one control stick.
(5) Center the capstan. The recess for the ball in the middle of
the bridle cable must be in the
uppermost position.
(6) Install bridle cable to capstan. The ball in the middle of the bridle cable
must engage in the recess on the
capstan. Wrap bridle cable around
capstan one turn to each side.
(7) Connect the ends of the bridle cable to the Tighten clamps lightly to allow
elevator push-rod with the clamps. adjustment (see next step).
(8) Using a small plastic hammer, move the clamps Adjust tension to 89 ± 22 N (20 ± 5 lbf).
along the push-rod to adjust the bridle cable Measure cable tension with cable
tension. tension gauge.
(9) Tighten the clamps.
(10) Remove the rigging pin from the control stick.
(11) Install the front seat which was removed. Refer to Section 25-10.
(12) Install the pitch servo. Refer to Paragraph 5.
Page 210 Doc # 6.02.15
15 Apr 2013 22-11-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
8. Remove/Install the Pitch Trim Servo
A. Remove the Pitch Trim Servo
Detail Steps/Work Items Key Items/References
(1) Remove the co-pilot's seat. Refer to Section 25-10.
(2) Dis-connect the connector from the servo.
(3) Remove the 2 screws which attach the servo to Hold the servo.
the mounting plate and the clutch.
(4) Remove the servo clear of the airplane.
B. Install the Pitch Trim Servo
Detail Steps/Work Items Key Items/References
(1) Put the servo in place on the mounting plate.
(2) Install the 2 screws which attach the servo to the The upper forward screw also holds the
mounting plate and clutch. chain adjuster. Ensure proper chain
tension.
(3) Connect the connector to the servo.
(4) Do a test of the autopilot system:
S Set ELECTRIC MASTER key switch to ON.
S Set AVIONIC MASTER switch to ON.
S Observe self-test of the flight control If no error message appears, then the
computer. system is operative.
S Set AVIONIC MASTER switch to OFF.
S Set ELECTRIC MASTER key switch to OFF.
(5) Install the co-pilot's seat. Refer to Section 25-10.
Doc # 6.02.15 Page 211
Rev. 2 22-11-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
9. Remove/Install the Pitch Trim Servo Clutch
A. Remove the Pitch Trim Servo Clutch
Detail Steps/Work Items Key Items/References
CAUTION: DO NOT APPLY STRONG FORCES TO THE CARDAN SHAFT. THE
UPPER CARDAN JOINT CONNECTS TO A PART WHICH IS WEAK
BY DESIGN TO GIVE OCCUPANT PROTECTION IN AN
EMERGENCY LANDING.
(1) Remove the pitch trim servo. Refer to Paragraph 7.
(2) Remove the screw which holds the cap to the
capstan.
(3) Remove the cap from the capstan.
(4) Release chain tension with chain adjuster. On the chain gear next to the servo.
(5) Remove the chain from the chain gear.
(6) Remove the 2 screws which attach the clutch Hold the clutch and the chain adjuster.
and the chain adjuster to the mounting plate.
B. Install the Pitch Trim Servo Clutch
Detail Steps/Work Items Key Items/References
(1) Put the clutch and the chain adjuster in place on
the mounting plate.
(2) Install the 2 screws which attach the clutch and
the chain adjuster to the mounting plate.
(3) Install the chain to the chain gear.
(4) Put the cap in place on the capstan.
(5) Install the screw which holds the cap to the
capstan.
(6) Install the pitch trim servo. Refer to Paragraph 7.
Page 212 Doc # 6.02.15
15 Apr 2013 22-11-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
10. Adjust the Bridle Cable Tension
A. Equipment
Item Quantity Part Number
Cable tension gauge. 1 Commercial.
B. Adjustment Procedure
Detail Steps/Work Items Key Items/References
(1) Loosen the bolts in the clamps which connect Do not remove the bolts. Loosen just
the bridle cable to the push-rod. enough so that the next step can be
done.
(2) Using a small plastic hammer, move the clamps Adjust tension to 89 ± 22 N (20 ± 5 lbf).
along the push-rod to adjust the bridle cable Measure cable tension with cable
tension. tension gauge.
(3) Tighten the bolts in the clamps which connect
the bridle cable to the push-rod.
Doc # 6.02.15 Page 213
Rev. 2 22-11-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
11. Adjust the Servo Clutch Torques
A. Equipment
Item Quantity Part Number
Goodrich slip clutch test stand. 1 20-9855-03.
B. Adjustment Procedure
Detail Steps/Work Items Key Items/References
(1) Remove the clutch from the airplane. Refer to this Section.
(2) Install the clutch assembly on the slip clutch test Refer to the equipment manufacturers'
stand. documentation.
(3) Measure clockwise (CW) and counter-clockwise Refer to the equipment manufacturers'
(CCW) clutch torque, adjust if necessary. documentation.
The correct clutch torques are:
Roll servo 2.03 ± 0.23 Nm
(18 ± 2 lbf.in.)
Pitch servo 3.39 ± 0.34 Nm
(30 ± 3 lbf.in.)
Pitch trim servo 4.07 ± 0.45 Nm
(36 ± 4 lbf.in.)
(4) Remove the clutch assembly from the slip clutch
test stand.
(5) Install the clutch to the airplane. Refer to this Section.
Page 214 Doc # 6.02.15
15 Apr 2013 22-11-00 Rev. 2
DA 40 NG AMM Auto Flight
AIRCRAFT
12. Mechanical Test of the Autopilot
Do this check at the intervals given in Section 05-10.
Detail Steps/Work Items Key Items/References
(1) Check bridle cable tension for the roll servo, Refer to this Section.
adjust if necessary.
(2) Check bridle cable tension for the pitch servo, Refer to this Section.
adjust if necessary.
(3) Check the clutch torque settings for the roll Refer to this Section.
servo, adjust if necessary.
(4) Check the clutch torque settings for the pitch Refer to this Section.
servo, adjust if necessary.
(5) Check the clutch torque settings for the pitch Refer to this Section.
trim servo, adjust if necessary.
(6) Perform Pitot and Static System Leak Tests. Refer to Section 34-10.
Doc # 6.02.15 Page 215
Rev. 2 22-11-00 15 Apr 2013
Auto Flight DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 216 Doc # 6.02.15
15 Apr 2013 22-11-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
CHAPTER 23
COMMUNICATIONS
Doc # 6.02.15 Page 1
Rev. 2 23-TITLE 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 23-TITLE Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 23
COMMUNICATIONS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 23-10
Speech Communication
with G1000 System Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a COM VHF Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install a PTT Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Remove/Install the Cabin Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Section 23-11
Speech Communication
with Conventional Cockpit Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Doc # 6.02.15 Page 1
Rev. 2 23-CONTENTS 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the NAV/COM Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install a COM VHF Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. NAV/COM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Section 23-50
Audio Integrating
with G1000 System Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the GMA 1347 Audio Control Panel . . . . . . . . . . . . . . . . . . . . . . 201
Section 23-51
Audio Integrating
with Conventional Cockpit Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Page 2 Doc # 6.02.15
15 Apr 2013 23-CONTENTS Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the PM 1000 II Intercom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Test the PM 1000 II Intercom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Section 23-60
Static Discharging
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Doc # 6.02.15 Page 3
Rev. 2 23-CONTENTS 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 23-CONTENTS Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
CHAPTER 23
COMMUNICATIONS
1. General
This Chapter tells you about the communications system in the DA 40 NG. This Section tells you about
the intercom system which lets the pilots and passengers talk to each other. It also tells you about the
radio system which lets the pilots talk to the ground and other airplane.
This Chapter does not tell you about the communications equipment. Refer to the equipment
manufacturers' manual for data about the equipment. Refer to Chapter 92 for the wiring diagrams.
Note: Equipment which is certified for installation in the DA 40 NG is listed in Section 6.5
of the Airplane Flight Manual. Such equipment may be installed in accordance with
the Airplane Maintenance Manual.
Any equipment which is not listed in Section 6.5 of the Airplane Flight Manual is
called "Additional Equipment". The installation of Additional Equipment is a
modification which must be handled in accordance with national regulations or a
Service Bulletin.
2. Description
A. Communication System if G1000 System Is Installed
The DA 40 NG communication system can have these components:
) GMA 1347 audio panel.
) NAV/COM transceivers (integral with the Garmin GIA 63 integrated avionics units).
) COM VHF antennas.
) NAV antenna (integral with the horizontal stabilizer).
) Push-to-talk (PTT) switches. A PTT switch is located in each of the pilots control sticks.
) Head-set-sockets. Head-set-sockets are located on the back of the center console for both
the pilots and the passengers.
) Cabin speaker. A cabin speaker is mounted in the roof of the cockpit.
Doc # 6.02.15 Page 1
Rev. 2 23-00-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
B. Communication System if Conventional Cockpit Is Installed
The DA 40 NG communication system can have these components:
) NAV/COM transceiver.
) Intercom system.
) COM VHF antenna.
) NAV (VOR/LOC/GS) antenna.
) Push-to-talk (PTT) switches. A PTT switch is located on each of the pilots' control sticks.
) Head-set-sockets. Head-set-sockets are located on the back of the center console for both
the pilots and the passengers.
) Cabin speaker. The cabin speaker is located in the roof of the cockpit.
Page 2 Doc # 6.02.15
15 Apr 2013 23-00-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
Section 23-10
Speech Communication
with G1000 System Installed
1. General
This Section tells you about the speech communication system in the DA 40 NG. It does not tell you
about the speech communication equipment. Refer to the equipment manufacturers' manuals for more
data about the equipment.
Figure 1: Antenna Locations
Doc # 6.02.15 Page 1
Rev. 2 23-10-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
Manouvering speed : Limita tio ns for GFC 7 00 Au top ilot Sys te m:
V =11
1 KIAS (above 1036 u p to 1200 kg / above 2284 up t o 2646 lb)
A
Do not use AP fi “Alternate St atic” is o pen .
VA=94 KIAS (780 to 1036 kg / 1720 to 2284lb) Ess Bus Con du ct AP and tr im c heck pr ior to e ach flight (s ee AFM) .
This airplane may only be oper ated in accordance with theAirplane Flight not for
Manual. It can be o perated in the "Normal" and "Utility" categories in Autopilot OFF dur ing take-o ff a nd landing.
non-icing conditions. Pr ovided th at national operational requirements normal Maximum spe ed for au topil ot o per atio n is 165 KIAS.
are met and the appropr iate equipment is installed, this airplane is ap- operation Minimu m speed f or aut opilo t oper atio n is 70 KIAS.
proved for the following kinds of operation: day VFR, night VFR and SeeAFM Minimu m altitude for au topilot oper ation:
IFR. All aerobatics maneuvers including spinning are prohibited. For Cr uise, Climb , Descent and Maneuv ering: 800 feet AGL
further operational limitations refer to the Airplane Flight Manual.
No smoking App roa ch: 2 00 feet AGL
Active Frequency Stand-by Frequency COM Volume Control
(COM 1) (COM 1) Automatic Squelch
° 121.500 122.650 COM1 VOL PUSH
SQ
122.650 118.750 COM2 Frequency Transfer Key/
COM
EMERG Emergency Frequency
Active Frequency COM Selector Knob
6
(COM 2)
PUSH
1-2
CRS BARO
Stand-by Frequency
(COM 2)
PUSH
Figure 2: Garmin G1000 Primary Flight Display Panel
Page 2 Doc # 6.02.15
15 Apr 2013 23-10-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
2. Description
The DA 40 NG has dual VHF radio communications transceivers (COM 1 and COM 2) which are
integral with the GIA 63 integrated avionics units. The No.1 GIA 63 and No.2 GIA 63 units are remotely
located in the aft fuselage avionics rack. The COM 1 antenna is located on the upper surface of the
fuselage, aft of the cockpit. The COM 2 antenna is located on the lower surface of the fuselage, aft of
the cockpit. Refer to Section 31-40 for more data about the Garmin 1000 ICS.
Figure 2 shows the Garmin 1000 primary flight display (PFD). The speech communication system is
integral with the Garmin 1000 integrated cockpit system (ICS). Power is supplied to the dual VHF
communications transceivers when the ICS is switched on. The COM selector knob is located at the
top-right corner of each ICS display panel. A digital display in the top right corner of the primary flight
display (PFD) screen shows which COM system and frequency is in use.
Both the active and stand-by frequencies are shown for both COM 1 and COM 2 systems. Pushing
the inner knob of the COM selector will toggle the active COM system between COM 1 and COM 2.
Push the COM FREQUENCY TRANSFER key to toggle between the active and standby frequency
of the selected communication system. A box is displayed around the stand by frequency.
Pressing and holding the COM FREQUENCY TRANSFER key for approximately 2 seconds will
over-ride all previous selections and select the EMERGENCY COM frequency of 121.5 MHz.
You can only change the frequency that is currently selected as the stand by frequency. You must
rotate the large outer COM selector knob to select the MHz value of the frequency and rotate the small
inner knob of the COM selector to select the KHz value of the frequency.
Above the COM knob is the VOL knob. You control the volume level of the active radio receiver with
the VOL knob. Press the knob to toggle the ON/OFF selection of the automatic squelch control.
The pilots use the audio control panel to control all the audio systems of the DA 40 NG. Both speech
and navigational audio can be sent to the pilots or passengers headphones. Or can be played on the
cockpit loudspeaker. Refer to Section 23-50 for more data about the audio control unit.
Doc # 6.02.15 Page 3
Rev. 2 23-10-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 23-10-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
Trouble-Shooting
1. General
This table tells you how to trouble-shoot the speech communication system. See Section 23-50 for
trouble-shooting the audio integrating system.
If you have the trouble detailed in the Trouble column read across to the Possible Cause column. Then
do the repair given in the Repair column.
Trouble Possible Cause Repair
Radio check reports readability Mic. output low. Replace the defective mic.
good, strength poor due to low
Faulty related GIA 63 IAU. Replace the related
modulation on COM 1/COM 2.
GIA 63 IAU.
Radio check reports readability Faulty related GIA 63 IAU. Replace the related
poor, strength good. GIA 63 IAU.
Faulty mic. Replace the mic.
Radio check reports readability Co-ax connector faulty. Examine the co-ax and
poor, strength poor on connections for condition and
COM 1/COM 2. security.
Received audio is poor. Faulty related GIA 63 IAU. Replace the related
GIA 63 IAU.
Faulty antenna. Replace the antenna.
Short range in transmit mode, Faulty related GIA 63 IAU. Replace the related
but reception is OK, GIA 63 IAU.
COM 1/COM 2.
No voice modulation when Audio integrating fault. Refer to Section 23-50.
transmitting from one pilots Related head-set defective. Replace related head-set.
side. The other pilots side OK.
Cannot transmit. Transmit Faulty PTT switch. Replace PTT switch.
annunciator not shown in COM
PTT wiring circuit defective. Do a test of the PTT wiring
display.
circuit. Refer to Chapter 92 for
the wiring diagrams.
Faulty related GIA 63 IAU. Replace the related
GIA 63 IAU.
Air enters cockpit through Speaker membrane broken. Replace speaker.
speaker.
Doc # 6.02.15 Page 101
Rev. 2 23-10-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 23-10-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to replace the main components of the speech communication system.
Refer to the equipment manufacturers' manuals for more data about the equipment. The
communications transceivers are integral with the GIA 63 integrated avionics units (IAU). Refer to
Section 31-40 for data about replacing the GIA 63 IAUs.
2. Remove/Install a COM VHF Antenna
Use this procedure for both COM 1 and COM 2 antennas. Access to both the antennas is through the
rear baggage compartment.
A. Remove a COM VHF Antenna
Detail Steps/Work Items Key Items/References
(1) Remove the aft baggage compartment. Refer to Section 25-10.
(2) Identify the antenna that you will replace. Lower antenna COM 2, top antenna
COM 1.
(3) Disconnect the co-axial cable from the antenna. At the bayonet connector.
(4) Remove the antenna:
S Remove the 3 nuts and washers that attach
the antenna to the airplane structure.
S Move the antenna clear of the airplane. If necessary, cut the sealant around the
base of the antenna. You must not
damage the fuselage skin.
Doc # 6.02.15 Page 201
Rev. 2 23-10-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
B. Install a COM VHF Antenna
Detail Steps/Work Items Key Items/References
(1) Carefully remove any sealant from the area Take care not to damage the fuselage.
where the antenna attaches to the fuselage. If necessary, use a commercial solvent.
(2) Install the antenna:
S Move the antenna into position on the
fuselage.
S Make sure that the bonding strip for the
antenna is correctly located.
S Install the 3 washers and nuts that attach
the antenna to the fuselage.
(3) Connect the co-axial cable to the antenna. At the bayonet connector.
(4) Do a test for the correct operation of the related Refer to the Airplane Flight Manual.
speech communications system.
(5) Install the aft baggage compartment. Refer to Section 25-10.
(6) Seal the outer edge of the antenna to the Use Dow Corning 732 RTV or
fuselage skin with sealant. equivalent. Follow the sealant
manufacturer’s instructions.
Page 202 Doc # 6.02.15
15 Apr 2013 23-10-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
3. Remove/Install a PTT Switch
Use this procedure for both pilot’s and co-pilot’s switches.
A. Remove a PTT Switch
Detail Steps/Work Items Key Items/References
(1) Set the ELECTRIC MASTER key switch to OFF. Instrument panel, center.
(2) Open the AUDIO circuit breaker. Instrument panel, right side.
(3) Remove the PTT switch:
S Leverage the switch with a small Handle with care. You must not damage
screwdriver out of the stick's bar end. the bar end.
S Disconnect the electrical cable from the
switch and move the switch clear of the
pilot's compartment.
(4) Remove the electrical cable, if necessary:
S Remove the appropriate pilot's seat. Refer to Section 25-10.
S Unplug the cable. At the connector behind the main
bulkhead.
S Pull the cable downward out. Through the hole in the stick.
Doc # 6.02.15 Page 203
Rev. 2 23-10-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
B. Install a PTT Switch
Detail Steps/Work Items Key Items/References
(1) Install the electrical cable, if removed before:
S Push the cable through the inside of the Through the hole in the stick.
stick.
S Connect the lower end of cable. At the connector behind the main
bulkhead.
(2) Install the PTT switch:
S Connect the electrical cable to the switch Put the single cables to the switch.
and move the switch into position at the bar
end of the stick.
S Push the switch in to the cut out of the bar Push carefully. You must not damage
end. the switch.
(3) Install the pilot's seat. If removed. Refer to Section 25-10.
(4) Reset the AUDIO circuit breaker. Instrument panel, right side.
Page 204 Doc # 6.02.15
15 Apr 2013 23-10-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
4. Remove/Install the Cabin Speaker
A. Remove the Cabin Speaker
Detail Steps/Work Items Key Items/References
(1) Remove the map light for the passenger Clean up the silicone from the hole.
compartment from the overhead console.
(2) Disconnect the connectors from the map light
for the passenger compartment.
(3) Remove the air vent on the co-pilot's side from Clean up the silicone from the hole.
the overhead console.
(4) Remove the map light for the co-pilot from the Clean up the silicone from the hole.
overhead console.
(5) Disconnect the connectors from the map light
for the co-pilot.
(6) Remove the cabin speaker cover.
(7) Disconnect the cabin speaker connector.
(8) Remove the speaker from the overhead
console.
Doc # 6.02.15 Page 205
Rev. 2 23-10-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
B. Install the Cabin Speaker
Detail Steps/Work Items Key Items/References
(1) Install the cabin speaker in the overhead
console.
(2) Connect the cabin speaker connector.
(3) Install the cabin speaker cover.
(4) Connect the map light for the co-pilot.
(5) Install the map light for the co-pilot. Seal with silicone.
(6) Install the air vent on the co-pilot's side. Seal with silicone.
(7) Connect the map light for the passenger
compartment.
(8) Install the map light for the passenger Seal with silicone. Do not use excessive
compartment. silicone because of the emergency
latch.
Page 206 Doc # 6.02.15
15 Apr 2013 23-10-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
Section 23-11
Speech Communication
with Conventional Cockpit Installed
1. General
This Section tells you about the speech communication system in the DA 40 NG with conventional
cockpit installed. It does not tell you about the speech communication equipment. Refer to the
equipment manufacturers' manuals for more data about the equipment.
This Section also tells you about the NAV function of the NAV/COM receivers. Refer to Section 34-52
for more information about the VOR/LOC/GS system. Refer to Section 23-51 for information about the
audio system.
The NAV/COM system can have the following components:
) NAV/COM (Garmin SL 30).
) COM antenna.
) NAV (VOR/LOC/GS) antenna.
Figure 1 shows the antenna locations.
Doc # 6.02.15 Page 1
Rev. 2 23-11-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
COMM 1 VHF- NAV
Transponder/DME
DME COMM 1
VHF- NAV
Transponder
Figure 1: Antenna Locations
Page 2 Doc # 6.02.15
15 Apr 2013 23-11-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
Active Standby Function Bearing To/From
Graphic
Frequency Frequency Annunciators Indication
CDI
Photocell
Transmit
Annunciator TX
PULL SQUELCH Small
Power/
VOL
Inner
Volume/ OFF Knob
Squelch
Frequency Comm Nav System OBS Ident Enter Large Outer
Flip/Flop Radio Radio Settings Select Knob
Mode Select To/From Select
Figure 2: Garmin SL 30 NAV/COM
Doc # 6.02.15 Page 3
Rev. 2 23-11-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
2. Description
The Garmin SL 30 NAV/COM consists of a transmitter/receiver for communication (COM) and a
receiver for navigation information (NAV). These are combined with operating controls and course
deviation indicator (CDI) in one unit. For the COM part 760 channels are spaced 25 kHz apart and
cover a frequency range from 118.000 MHz to 136.975 MHz. In the NAV part 200 VOR/LOC-channels
are spaced 50 kHz apart and cover a frequency range from 108.00 MHz to117.95 MHz.
Refer to the Garmin SL 30 Pilot's Guide, Garmin P/N 190-00486-00 for complete descriptions of the
SL 30 and operating procedures.
The SL 30 NAV/COM uses a single line by 32-character 5x7 dot matrix alphanumeric display.
A photocell is located in the top left corner of the from panel display. The photocell automatically
controls the light intensity of the display LEDs from low brightness at night to high brightness during
daylight operation. The lens is polarized to reduce reflections. Using polarized sunglasses may make
it difficult to view the display.
) Power On/Off - Volume - Squelch. The knob on the left side of the SL 30 control power on/off,
volume, and squelch test. Rotate the knob clockwise (CW) past the detent to turn the power on.
Continuing to rotate the knob to the right increases speaker and headphone amplifier volume level.
Rotate the knob to the left to reduce the volume level. Pull the knob out to disable automatic
squelch.
) Large/Small knobs. The dual concentric knobs on the right side of the SL 30 are sed to select
frequencies, to view the features within a function, or make changes. Details are provided in the
appropriate sections of the SL 30 Pilot's Guide.
) Flip/Flop. Press the FLIP/FLOP button to switch between the active (left-most) and standby
(right-most) frequency. Switching between COM frequencies is disabled during transmissions.
) COM. Press COM to select the COM radio mode. The annunciator will light above the button when
you are in COM mode. Press COM a second time to monitor the Standby frequency.
) 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 the System mode.
) OBS. Press OBS to see the current OBS setting and graphic CDI. If the annunciator above the
OBS button lights, you may use the large and small knobs to change the displayed OBS values.
) T/F. Press T/F to toggle between the bearing TO or radial FROM the active VOR. The T/F button
does not operate for localizer frequencies.
Page 4 Doc # 6.02.15
15 Apr 2013 23-11-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
) ID. Press ID to select the NAV audio and toggle between voice or ident. Pressing ID will cancel the
VOR monitor function. Selecting the monitor function will suspend the ID function until the monitor
function is disabled.
) SEL. Press SEL to choose from a list of channel types or to change values. In COM or NAV modes,
press SEL to choose frequencies from the available lists. Press SEL again if you want to cancel
the selection process. The annunciator will light above the button when this function is active.
) ENT. Press ENT to save selected values, confirm a prompt, or to save the standby frequency.
Doc # 6.02.15 Page 5
Rev. 2 23-11-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 6 Doc # 6.02.15
15 Apr 2013 23-11-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the speech communication system. Refer to
Section 34-52 for Trouble-Shooting the VOR/LOC/GS system.
If you have the trouble detailed in the Trouble column read across to the Possible Cause column. Then
do the repair given in the Repair column.
Trouble Possible Cause Repair
LCD display hard to read. Contrast adjustment not Adjust contrast.
correct.
Radio check reports readability Mic. output low. Replace the defective mic.
good, strength poor due to low
Faulty radio. Replace the radio.
modulation.
Radio check reports readability Faulty radio. Replace the radio.
poor, strength good.
Faulty mic. Replace the mic.
Radio check reports readability Co-ax connector faulty. Examine the co-ax and
poor, strength poor. connections for condition and
security.
Received audio is poor. Faulty radio. Replace the radio.
Faulty antenna. Replace the antenna.
Short range in transmit mode, Faulty radio. Replace the radio.
but reception is ok.
No voice modulation when Audio integrating fault. Refer to Section 23-51.
transmitting from one pilot's
Head-set defective. Replace head-set.
side. The other pilots side OK.
Cannot transmit. Transmit Faulty PTT switch. Replace PTT switch.
annunciator not shown in COM
PTT wiring circuit defective. Do a test of the PTT wiring
display.
circuit. Refer to Chapter 92 for
the wiring diagrams.
Faulty radio. Replace the radio.
Doc # 6.02.15 Page 101
Rev. 2 23-11-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 23-11-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to remove/install the main components of the speech communication
system. Refer to the equipment manufacturer's manuals for more data about the equipment.
2. Remove/Install the NAV/COM Unit
A. Remove the NAV/COM Unit
Detail Steps/Work Items Key Items/References
(1) Open the COM1 and NAV1 circuit breakers.
(2) Put a 3/32 Allen wrench into the access hole for
the locking screw. Engage the wrench into the
screw.
(3) Turn the screw counter-clockwise until the unit
disengages from the mounting rack.
CAUTION: DO NOT PULL ON THE KNOBS. DO NOT PRY THE FACE-PLATE.
YOU CAN DAMAGE THE UNIT.
CAUTION: DO NOT TOUCH THE CONNECTOR CARD AT THE REAR OF THE
UNIT. THE ELECTROSTATIC CHARGE OF YOUR BODY CAN
DAMAGE THE UNIT.
(4) Pull gently on the side of the unit to remove it
from the mounting rack.
(5) Install the protective covers on the rear
connectors of the unit.
Doc # 6.02.15 Page 201
Rev. 2 23-11-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
B. Install the NAV/COM Unit
Detail Steps/Work Items Key Items/References
(1) Remove the protective covers from the
connectors on the rear of the unit.
(2) Slide the unit into the rack. Engage the locking
screw so that the lobe of the front latch touches
the rack.
(3) Turn the locking screw so that the rear lobe
engages the mounting rack.
CAUTION: DO NOT OVER-TIGHTEN THE LOCKING SCREW. YOU CAN
DAMAGE THE LOCKING MECHANISM.
(4) Continue to turn the locking screw until the unit is
fully installed in the mounting rack.
(5) Close the COM1 and NAV1 circuit breakers.
(6) Do a function test of the system. Refer to Paragraph 4.
Page 202 Doc # 6.02.15
15 Apr 2013 23-11-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
3. Remove/Install a COM VHF Antenna
A. Remove a COM VHF Antenna
Detail Steps/Work Items Key Items/References
(1) Remove the screws which attach the antenna to
the fuselage.
(2) Carefully pull the antenna clear of the fuselage If necessary, carefully cut the sealant
and hold it. around the base of the antenna. You
must not damage the fuselage skin.
(3) Release the co-axial connector from the antenna.
(4) Release the bonding cable from the antenna.
(5) Move the antenna clear of the airplane.
B. Install a COM VHF Antenna
Detail Steps/Work Items Key Items/References
(1) Carefully remove any sealant from the area
where the antenna attaches to the fuselage.
(2) Move the antenna close to where it attaches to
the fuselage and:
S Attach the co-axial connector to the antenna.
S Attach the bonding cable to the antenna.
(3) Put the antenna in position on the fuselage and
install the screws which attach the antenna to the
fuselage.
(4) Seal the outer edge of the antenna to the Use Dow Corning 732 RTV or
fuselage skin with sealant. equivalent. Follow the sealant
manufacturer’s instructions.
(5) Do a function test of the system. Refer to Paragraph 4.
Doc # 6.02.15 Page 203
Rev. 2 23-11-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
4. NAV/COM Test
If possible, do an operational flight check after the radio has been replaced. Alternatively use a
NAV/COM test set to make sure that the system operates correctly. Refer to the manufacturer's
Installation Manual for performance specifications.
Detail Steps/Work Items Key Items/References
(1) Do a test of each control function. Refer to Section 23-11 and
Section 34-52.
(2) At a sufficient altitude, contact a ground station at If possible, select stations with
least 50 NM away and another close by. frequencies at both the high and low
end of the NAV/COM band.
(3) Test the VOR system at 4000 ft. Select a VOR
frequency within a 40 NM range. Listen to the
station identifier. Test the operation of the tone
identifier filter. Fly inbound and outbound on a
selected VOR radial. Look for the correct
LEFT/RIGHT and TO/FROM indications. Monitor
the VOR accuracy.
(4) Do a test of localizer (LOC) and glideslope (GS)
operation and accuracy on a suitable runway.
(5) If necessary, adjust the viewing contrast of the Through the access hole in the front
LCD display. panel.
Page 204 Doc # 6.02.15
15 Apr 2013 23-11-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
Section 23-50
Audio Integrating
with G1000 System Installed
1. General
The DA 40 NG has a voice-operated (VOX) intercom. This gives full hands-free intercom when
head-sets are used. The pilot controls the intercom system with the audio control panel. The audio
control panel is located in the instrument panel between the integrated cockpit system (ICS) display
screens. Figure 1 shows the audio control panel.
Push to talk (PTT) switches are installed in the handles of both control sticks. The jack sockets for all
the head-sets are located at the back of the center console.
An amplifier in the radio receiver system operates a loudspeaker located in the roof of the passenger
cabin.
Doc # 6.02.15 Page 1
Rev. 2 23-50-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
Manouvering speed: Limita tio ns for GFC 7 00 Autopi lot Sys tem:
V A=11
1 KIAS (above 1036 up to 1200 kg / above 2284 up to 2646 lb)
Do not use AP fi “Alterna te St atic” is o pen .
V =94 KIAS (780 to 1036 k
A
g / 1720 to 2284lb) Ess Bus Condu ct AP and tr im c heck pr ior to each fligh t (s ee AFM) .
This airplane may only be oper ated in acco rdance with t heAirplane Flight
Manual. It can be operated in the "Normal" and "Utility" ca tegories in
not for Autopilot OFF dur ing take-o ff and land ing.
non-icing conditions. Provided that national operational requirements normal Maximum spe ed for autopil ot o per atio n is 165 KIAS.
are met and the appropr iate equipment is insta led, this airplane is ap- operation Minimum speed f or aut opilo t op er ation is 70 KIAS.
proved for the following kinds of opera tion: day VFR, night VFRand SeeAFM Minimum altitude for au topilot o per atio n:
IFR. All aerobat c
i s ma neuvers including spinnin g are prohibited. For Cr uise, Climb , Descent and Maneuv ering: 800 feet AGL
further operational limitations refer to the Airplane Flight Manual.
Approach: 200 feet AGL
No smoking
COM1 COM1
MIC
COM2 COM2
MIC
COM3 COM3
MIC
COM TEL
1/2
PA SPKR
MKR HI
MUTE SENS
DME NAV1
ADF NAV2
AUX
MAN PLAY
SQ
CREW
PILOT COPLT
ICS ISOLATION
PILOT COPLT
PASS
DISPLAY BACKUP
Figure 1: Audio Control Panel
Page 2 Doc # 6.02.15
15 Apr 2013 23-50-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
2. Description and Operation
Figure 1 shows the GMA 1347 Audio Control Panel of the DA 40 NG airplane. The audio control panel
is powered with the Garmin 1000 ICS and is an integral component of the integrated cockpit system.
The audio control panel makes an interface between the audio systems of the integrated cockpit
system (ICS) and the pilot’s/crew headsets.
The audio control panel is located in the instrument panel between the ICS displays. The control panel
keys have LED annunciator labels and has backlighting which is controlled by the ICS. When a key
is active the annunciator is lit by the LED. The control panel performs a self-test when power is applied
to the panel which then re-sets the panel to the operating condition that was set when the panel was
last powered-off. If the control panel fails the self-test the panel switches to a fail-safe mode and all
fail-safe audio output is directed to the pilot's headset.
The control panel has these keys and selectors:
) COM 1 MIC key. Press this key to select COM 1 as the active microphone source and to
automatically de-select any COM MIC key that may have been previously selected. The COM 1
MIC key annunciator illuminates and the COM 1 caption on the ICS display screen is highlighted.
) COM 2 MIC key. Press this key to select COM 2 as the active microphone source and to
automatically de-select any COM MIC key that may have been previously selected. The COM 2
MIC key annunciator illuminates and the COM 2 caption on the ICS display screen is highlighted.
) COM 3 MIC key. This key is not active in the DA 40 NG installation.
) COM 1/2 key. Press this key to toggle the selection of the split com function. When COM 1/2 is
selected COM 1 becomes the dedicated COM system for the pilot's mic/audio and COM 2 becomes
the dedicated COM system for the co-pilot's mic/audio. When the split com function is selected both
the pilot and co-pilot can transmit simultaneously using separate COM systems. The pilot can also
monitor all the NAV audio as selected. The co-pilot can only monitor the COM 2 audio.
) COM 1 key. Press this key to select COM 1 as the active audio source. Selecting COM 1 audio
using this key maintains COM 1 as an audio source independent of any other selection. The
annunciator illuminates when the COM 1key is activated.
) COM 2 key. Press this key to select COM 2 as the active audio source. Selecting COM 2 audio
using this key maintains COM 2 as an audio source independent of any other selection. The
annunciator illuminates when the COM 2 key is activated.
) COM 3 key. This key is not active in the DA 40 NG installation.
) TEL key. This key is not active in the DA 40 NG installation.
Doc # 6.02.15 Page 3
Rev. 2 23-50-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
) PA key. This key is not active in the DA 40 NG installation.
) SPKR key. Press this key to select the cabin speaker. When selected, the cabin speaker will
broadcast all the selected audio channels and all unswitched/unmuted audio warnings. The
speaker will be muted when a COM microphone is keyed. The annunciator illuminates when the
SPKR key is activated.
) MKR/MUTE key. Press this key to select MKR audio. When selected the key annunciator is
illuminated. When a marker beacon audio tone is generated it can be heard over the headsets and
the related caption will show on the ICS primary flight display. Pressing the MKR/MUTE key while
a marker beacon tone is being generated will cause the audio to be muted but the caption on the
ICS display will remain. When the next marker beacon signal is generated the it will be heard over
the headsets. Pressing the MKR/MUTE key while the marker beacon audio system is in the mute
mode will cause the audio signal to be deactivated and the key annunciator will go out.
) HI SENS key. Press this key to increase the sensitivity of the marker beacon receiver. The
annunciator illuminates when the HI SENS key is activated.
) DME, ADF, NAV 1, NAV 2 keys. Press one of these keys to select the related audio source. The
related annunciator illuminates when the key is activated.
) AUX key. This key is not active in the DA 40 NG installation.
) MAN SQ key. Press this key to make the pilot/co-pilot/pass ICS volume control knob a push toggle
switch for setting ICS squelch levels manually. The annunciator illuminates when the MAN SQ key
is activated.
) PLAY key. Press this key to replay the digital recording made by the ICS. The digital recording of
recent audio activity will be heard over the headsets. The annunciator illuminates when the PLAY
key is activated.
Page 4 Doc # 6.02.15
15 Apr 2013 23-50-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
) PILOT, COPLT keys. These keys control the intercom system (ICS) isolation system. The ICS
isolation system has four modes of operation which can all be selected using a combination of the
PILOT and COPLT keys. The system has these modes of operation:
) Pilot Mode. Pilot mode is selected when only the PILOT key is annunciated. In pilot mode the
pilot can hear the selected radios. The co-pilot and passengers can only communicate with each
other.
) Co-Pilot Mode. Co-pilot mode is selected when only the COPLT key is annunciated. In co-pilot
mode the co-pilot’s headset is isolated. The pilot and passengers can hear the selected radios,
and communicate with each other.
) Crew Mode. Crew mode is selected when both the PILOT and CO-PILOT keys are annunciated.
In crew mode both the pilot and co-pilot can hear the selected radios and communicate with
each other.
) All Mode. All mode is selected when neither the PILOT or CO-PILOT keys are annunciated. In
all mode both the pilots and the passengers can hear the selected radios and are able to
communicate with each other.
) VOLUME/SQ knob. This knob has two functions depending on the selection of the MAN SQ key.
) MAN SQ key deselected. When the MAN SQ key is deselected the ICS squelch levels are set
automatically. The VOLUME/SQ knob acts as a volume control and the VOL caption to the lower
left of the knob illuminates. Rotate the inner knob clockwise to increase the volume level of the
pilot's ICS and rotate the inner knob counter-clockwise to reduce the volume of the pilot’s ICS.
Rotate the outer knob clockwise to increase the volume level of the co-pilot’s and passenger’s ICS.
Rotate the outer knob counter-clockwise to reduce the volume level of the co-pilot's and
passenger’s ICS.
) MAN SQ key selected. When the MAN SQ is selected the ICS squelch levels can set manually and
pressing the VOLUME/SQ knob toggles the manual squelch ON/OFF. Manual squelch is toggled
ON when the SQ caption to the lower right of the knob illuminates. Rotate the inner knob clockwise
to increase the squelch threshold of the pilot’s ICS and rotate the inner knob counter-clockwise to
reduce the squelch threshold of the pilot’s ICS. Rotate the outer knob clockwise to increase the
squelch threshold of the co-pilot’s and passenger’s ICS. Rotate the outer knob counter-clockwise
to reduce the squelch threshold of the co-pilot's and passenger’s ICS.
) DISPLAY BACKUP button. Pressing the red DISPLAY BACKUP button at the bottom of the audio
control panel selects the backup mode for all the displays.
Doc # 6.02.15 Page 5
Rev. 2 23-50-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 6 Doc # 6.02.15
15 Apr 2013 23-50-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
Trouble-Shooting
1. General
This table tells you how to trouble-shoot the audio integrating system. See Section 23-10 for
trouble-shooting the speech communication system.
If you find the trouble in column 1 do the repair given in column 3.
Trouble Possible Cause Repair
No voice modulation when Faulty head-set. Replace head-set.
transmitting from co-pilot’s side
Open mic audio line. Do a test of the mic audio
on head-set. Pilot’s side OK.
wiring. Refer to Chapter 92 for
the wiring diagrams.
Replace GMA 1347.
Faulty GMA 1347.
No voice modulation when Faulty head-set. Replace head-set.
transmitting from pilot’s side on
Open mic audio line. Do a test of the mic audio
head-set. Co-pilot’s side OK.
wiring. Refer to Chapter 92 for
the wiring diagrams.
Faulty GMA 1347. Replace GMA 1347.
No intercom audio on pilot’s ICS mode set incorrectly. Set mode to required position,
head-set. Receives radio refer to Section 23-50
transmissions correctly. Paragraph 2.
Faulty GMA 1347. Replace the GMA 1347.
No audio on pilot’s head-set Faulty head-set. Replace head-set.
with the ICS set to OFF.
Open audio line. Do a test of the head-set audio
wiring. Refer to Chapter 92 for
the wiring diagrams.
No audio on co-pilot’s or Open audio line. Do a test of the head-set audio
passenger’s headsets. wiring. Refer to Chapter 92 for
the wiring diagrams.
Faulty GMA 1347. Replace the GMA 1347.
Doc # 6.02.15 Page 101
Rev. 2 23-50-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 23-50-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to remove/install the GMA 1347 audio control panel. It also tells you how
to adjust/test the ICS. Refer to the equipment manufacturers manuals for more data about the audio
integrating system.
2. Remove/Install the GMA 1347 Audio Control Panel
A. Remove the GMA 1347 Audio Control Panel
Detail Steps/Work Items Key Items/References
(1) Make sure that the ELECTRIC MASTER key Instrument panel, lower center.
switch is set to OFF.
(2) Remove the audio control unit:
S Insert a 3/32 in hexagonal drive wrench into Refer to Figure 1.
the access hole in the front of the panel.
S Rotate the locking mechanism
counter-clockwise to release the lock.
S Pull the audio control panel towards you and
clear of the instrument panel.
Doc # 6.02.15 Page 201
Rev. 2 23-50-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
B. Install the GMA 1347 Audio Control Panel
Detail Steps/Work Items Key Items/References
(1) Examine the connectors at the rear of the audio
control panel. Look specially for bent or
damaged pins.
(2) Insert a 3/32 in hexagonal drive wrench into the
access hole in the front of the panel and rotate
the locking mechanism 90° counter-clockwise to
make sure that the locking mechanism is in the
unlocked position.
(3) Install the audio control panel:
S Move the audio control panel into position at
the instrument panel.
S Carefully slide the panel into position in the Make sure that the audio control panel
instrument panel. fully engages with the connectors at the
rear of the panel.
S Insert a 3/32 in hexagonal drive wrench into Make sure that you cannot pull the audio
the access hole in the front of the panel and control panel towards you!
rotate the locking mechanism clockwise to
lock the panel into position.
(4) Do a test for the correct operation of the audio Refer to the G1000 Line Maintenance
control panel. If you have installed a Manual for data about installing software
replacement audio control panel you may have and testing the audio control panel.
to update the Garmin G1000 integrated cockpit
system software.
Page 202 Doc # 6.02.15
15 Apr 2013 23-50-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
Section 23-51
Audio Integrating
with Conventional Cockpit Installed
1. General
The audio system in the DA 40 NG with conventional cockpit has the following components:
) PM 1000 II voice-activated (VOX) intercom, see Figure 1.
) Sockets for four head-sets on the rear face of the center console.
) Push-to-talk (PTT) switches in the handles of both control sticks.
) Cockpit speaker in the roof of the cockpit.
) Socket for hand-held microphone on the bottom left side.
The voice-activated intercom gives full hands-free intercom when head-sets are used.
Doc # 6.02.15 Page 1
Rev. 2 23-51-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
Squelch Control LED Squelch Control
Pilot Co-Pilot
PWR/XMT PM1000II
PILOT CO-PILOT
ISO
ALL
OFF
VOLUME SQUELCH VOLUME SQUELCH
Volume Control Mode Switch Volume Control
Pilot Co-Pilot
Figure 1: PM 1000 II Intercom
Page 2 Doc # 6.02.15
15 Apr 2013 23-51-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
2. Description
A. PM 1000 II Intercom
Figure 1 shows the PM 1000 II Intercom. It is mounted above the NAV/COM 1 set in the avionics
rack in the instrument panel, see Chapter 31.
The PM 1000 II is a four channel VOX intercom with individual amplifiers for each outlet. The
head-set jack-plugs connect to the PM 1000 II. When the unit is set to OFF (or when the power
fails), an internal relay connects the pilots head set to the airplane radio. This gives fail-safe
operation. A two-color LED in the control panel shows green when the power is on and red during
radio transmissions. The LED functions as stuck mic indicator.
The PM 1000 II has these controls:
) A pilot's ON/OFF/VOLUME/SQUELCH switch. Turn the inner knob clockwise to switch the
intercom ON. Turn the knob to control the volume in the pilots headset. The outer (squelch)
knob adjusts the level at which the mic operates the intercom. When the knob is set fully
counter-clockwise the ambient noise will operate the intercom. This gives a “hot mic” effect. Set
the squelch to operate at a level that is correct for you. The VOX system has a one second
delay, this prevents “choppy” speech.
) A co-pilot's VOLUME/SQUELCH switch. Turn the inner knob to adjust the volume in the
co-pilots headset. The outer (squelch) knob adjusts the level at which the co-pilots and
passenger mics operate the intercom. When the knob is set fully counter-clockwise the ambient
noise will operate the intercom. This gives a “hot mic” effect. Set the squelch to operate at a
level that is correct for you. The VOX system has a one second delay, this prevents “choppy”
speech.
) An ISO/ALL/CREW switch. The PM 1000 II has three modes of operation:
) ALL. The pilot, co-pilot and passengers can all hear the radio. Both the pilots and the
passengers can communicate on the intercom.
) ISO. The pilot is connected only to the airplane radio. He is isolated from the intercom. The
co-pilot can communicate with the passengers but the co-pilot can not make or hear
transmissions on the airplane radio.
) CREW. The pilot and co-pilot are connected on one intercom channel while the passengers
are on a separate and independent channel. The pilot and co-pilot are connected to the
airplane radio. Passengers can continue to communicate with themselves without disturbing
the pilot and co-pilot.
Doc # 6.02.15 Page 3
Rev. 2 23-51-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 23-51-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the audio integrating system and the marker
beacon receiver system. If you have the trouble detailed in the Trouble column read across to the
Possible Cause column. Then do the repair given in the Repair column.
Trouble Possible Cause Repair
No voice modulation when Faulty head-set. Replace head-set.
transmitting from co-pilot's side
Open mic audio line. Do a test of the mic audio
on head-set. Pilot's side OK.
wiring. Refer to Chapter 92 for
the wiring diagrams.
Faulty intercom. Replace the intercom.
No voice modulation when Faulty head-set. Replace head-set.
transmitting from pilot’s side on
Open mic audio line. Do a test of the mic audio
head-set. Co-pilot’s side OK.
wiring. Refer to Chapter 92 for
the wiring diagrams.
Faulty intercom. Replace the intercom.
Cannot transmit. Transmit Faulty mic PTT switch. Replace the defective PTT
annunciator (if available) not switch.
showing on COM display.
PTT wiring circuit open. Do a test of the PTT wiring.
Refer to Chapter 92 for the
wiring diagrams.
Faulty COM unit. Replace the COM unit.
No intercom audio on pilot’s ISO mode (PM 1000 II) Select All mode.
head-set. Receives radio selected.
transmissions correctly.
Faulty intercom. Replace the intercom.
No audio on pilot’s head-set Faulty head-set. Replace head-set.
with the intercom or audio
Open audio line. Do a test of the head-set audio
panel switched OFF.
wiring. Refer to Chapter 92 for
the wiring diagrams.
Doc # 6.02.15 Page 101
Rev. 2 23-51-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
Trouble Possible Cause Repair
No audio on co-pilot’s or Open audio line. Do a test of the head-set audio
passenger headsets. wiring. Refer to Chapter 92 for
the wiring diagrams.
Faulty intercom. Replace the intercom.
Page 102 Doc # 6.02.15
15 Apr 2013 23-51-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to remove/install the intercom. It also tells you how to test the intercom.
Refer to the equipment manufacturers' manuals for more data about the audio integrating system.
2. Remove/Install the PM 1000 II Intercom
A. Remove the PM 1000 II Intercom
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THE ENGINE IS SAFE BEFORE YOU DO ANY WORK
ON THE AIRPLANE. IF THE ENGINE STARTS THE PROPELLER CAN
CAUSE INJURY OR DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to IDLE.
(2) Disconnect the airplane battery. Refer to Section 24-31.
(3) Remove the instrument panel cover. Refer to Section 25-10.
(4) Disconnect the connector from the PM 1000 II.
(5) Remove the attaching screws and knobs from the Hold the PM 1000 II!
PM 1000 II.
(6) Remove the unit from the instrument panel.
Doc # 6.02.15 Page 201
Rev. 2 23-51-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
B. Install the PM 1000 II Intercom
Detail Steps/Work Items Key Items/References
(1) Put the PM 1000 II in position in the instrument
panel.
(2) Install the attaching screws and knobs.
(3) Connect the connector to the PM 1000 II.
(4) Install the instrument panel cover. Refer to Section 25-10.
(5) Connect the airplane battery. Refer to Section 24-31.
(6) Do a function test of the PM 1000 II. Refer to Paragraph 3.
Page 202 Doc # 6.02.15
15 Apr 2013 23-51-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
3. Test the PM 1000 II Intercom
Detail Steps/Work Items Key Items/References
(1) Make sure all the head-sets are connected.
(2) Select the mode switch to ALL.
(3) Turn the VOLUME control to switch the unit ON.
(4) Do a test for communication between the pilot,
co-pilot and passenger head-sets.
(5) Test the function of the VOLUME control.
(6) Test the function of the SQUELCH control.
(7) Set the mode switch to ISO. Make sure that there is no intercom
between the pilot, co-pilot and
passenger head-sets.
(8) Pull the AUDIO circuit-breaker. Make sure that radio transmission and
reception is possible from the pilot's
head-set.
(9) Set the mode switch to CREW. Make sure that the pilot and co-pilot can
communicate and transmit on the
airplane radio. Make sure that the
passengers can communicate with
themselves but not to the pilot or
co-pilot.
Doc # 6.02.15 Page 203
Rev. 2 23-51-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 204 Doc # 6.02.15
15 Apr 2013 23-51-00 Rev. 2
DA 40 NG AMM Communications
AIRCRAFT
Section 23-60
Static Discharging
1. General
The static discharging system has two main parts, the electrical bonding system and the surface static
discharging system. Refer to Section 51-80 for the electrical bonding system. Section 51-80 also
describes the resistance measurements for the static discharge wicks.
The build-up of static electricity can affect the quality of radio communications on all COM and NAV
equipment. It can also affect the quality of all NAV indications.
2. Description and Operation
The static discharging system removes the electro-static charge which collects on the airplane
surfaces. The composite structure of the DA 40 NG does not let electricity flow through it. The airplane
surfaces are covered with a special conductive filler through which the electricity flows to the static
discharge wick.
Location and quantity of the static discharge wicks are given in the following table.
Location Quantity
LH wing tip, trailing edge. 1
RH wing tip, trailing edge. 1
LH horizontal tail tip, trailing edge. 1
RH horizontal tail tip, trailing edge. 1
Rudder, trailing edge, bottom. 1
Doc # 6.02.15 Page 1
Rev. 2 23-60-00 15 Apr 2013
Communications DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 23-60-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
CHAPTER 24
ELECTRICAL POWER
Doc # 6.02.15 Page 1
Rev. 2 24-TITLE 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 24-TITLE Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 24
ELECTRICAL POWER
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. 28 VDC System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Section 24-30
DC Generation
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Trouble Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Replace the Alternator Fuse if OÄM 40-321, OÄM 40-329, OÄM 40-330 Are Not
Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Replace the Alternator Fuse if OÄM 40-321, OÄM 40-329 or OÄM 40-330 Is
Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Section 24-31
Battery System
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Main Battery Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. ECU Backup Battery Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Doc # 6.02.15 Page 1
Rev. 2 24-CONTENTS 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Disconnect/Connect the Battery for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 203
5. Remove/Install the Battery Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
6. Battery Relay Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Section 24-32
Emergency Battery System
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Emergency Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 24-33
Additional Alternator
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Page 2 Doc # 6.02.15
15 Apr 2013 24-CONTENTS Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the AUX POWER Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Remove/Install the Additional Alternator Regulator . . . . . . . . . . . . . . . . . . . . . . 203
Section 24-40
External Power
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the External Power Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Section 24-60
DC Electrical Load Distribution
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Doc # 6.02.15 Page 3
Rev. 2 24-CONTENTS 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Avionics Master Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Remove/Install a Circuit-Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5. Remove /Install an Instrument Panel Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6. Remove /Install the ENGINE Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Page 4 Doc # 6.02.15
15 Apr 2013 24-CONTENTS Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
CHAPTER 24
ELECTRICAL POWER
1. General
The DA 40 NG has a 28 VDC electrical system. This Chapter describes the complete system from the
power supplies to the circuit-breakers or other interface with the consumers.
This Chapter has only simplified schematic diagrams and location diagrams. Refer to Chapter 92 for
the wiring diagrams. Refer to the related Chapter for data about systems. For example, refer to
Chapter 80 for data about the starter system.
For Trouble-Shooting and Maintenance Practices for this system, refer to these Sections:
) Section 24-30. Electrical power generation.
) Section 24-31. Battery system.
) Section 24-32. Emergency battery system.
) Section 24-33. Additional alternator (if OÄM 40-314 is installed).
) Section 24-40. External power.
) Section 24-60. Power distribution.
Note: Equipment which is certified for installation in the DA 40 NG is listed in Section 6.5
of the Airplane Flight Manual. Such equipment may be installed in accordance with
the Airplane Maintenance Manual.
Any equipment which is not listed in Section 6.5 of the Airplane Flight Manual is
called "Additional Equipment". The installation of Additional Equipment is a
modification which must be handled in accordance with national regulations or a
Service Bulletin.
Doc # 6.02.15 Page 1
Rev. 2 24-00-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
A
Avionic V INSTRUMENT PANEL ENGINE COMPARTMENT
I
Relay O
AV. BUS
N
25 I
C
B
U
To Avionic S
Alternator Starter
Switch
Current
B Sensor
Power A
Relay T
PWR T
E
60 R Aux Power To Alt. Reg.
H
5A
Y Plug Field
M 5A
O To Starter Relay
A B + T
50A
I U To Battery
N S - B
U
5A
B 2 S
U Starter
S
Relay To Starter
START Engine Electric Relay Coil
10
Master Master 100A
OFF 100A
To Battery Relay
ON E
80A
C
U
B
U
20A
S
Essential Tie
MAIN Relay
TIE
30 To Battery
Relay Coil
Engine E
OFF Master C
ON
OFF U
5A
ESS ON B
TIE Essential Bus Engine
B
Switch U Master
30 OFF
S
10A
E To Alt. Reg. Enable
S ON
S
E Avionic EECU Backup
N Master
T MASTER Relay 10A
OFF
I CONTROL To Avionic Relay 32A
A ON
L 2
ECU Backup
B Battery
U
S
FUSELAGE
LEGEND
MAIN
TIE Circuit-Breaker with Name and Rating
30 (Name as on the Placard)
5A
Fuse with Rating
Figure 1: Electrical System Schematic Diagram
Page 2 Doc # 6.02.15
15 Apr 2013 24-00-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
ENGINE COMPARTMENT
FUSE PANEL B
A
T
50A
T
B
U
5A
S
80A
20A
Power
Relay E
C
PWR
Current U
60 Sensor
5A
B
M U
A 100A S
I
N
B
U Starter Alternator
S
Relay
START Engine Electric Starter
10
Master Master
OFF
ON
Field
Enable
Ground
Aux Alt. Reg.
Ess Tie Power
MAIN Relay Plug H
TIE O
5A
30
+ T
- B
U
5A
S Battery
OFF
ON
Relay Main
Battery
ESS
TIE
Essential
A
30 Bus V
Avionic
E Relay I Engine Master E
5A
O OFF C
S AV. BUS 5A
N U
S I ON Starter
E 25 Relay
N
C B Engine
T B
Master
I B OFF
U U
A S
10A
L MASTER S
ON
OFF
CONTROL
B ON
U 2 EECU Backup 100A
S Avionic Relay 10A
Master 32A
INSTRUMENT PANEL
ECU Backup
Battery
LEGEND
MAIN
TIE Circuit-Breaker with Name and Rating
30 (Name as on the Placard)
5A FUSELAGE
Fuse with Rating
Figure 2: Electrical System Schematic Diagram
(if Conventional Cockpit (OÄM 40-321) is installed)
Doc # 6.02.15 Page 3
Rev. 2 24-00-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
A ENGINE COMPARTMENT
Avionic V
I
Relay O
FUSE PANEL B
AV. BUS A
N
T
25 I
T
C 50A
B
B
U
U
S
To Avionic S 5A
Switch 2
80A
20A
Power
Relay E
C
PWR
Current U
60 Sensor
5A
B
M U
A 100A S
I
N
B
U Starter Alternator
S
Relay
START Engine Electric Starter
10
Master Master
OFF
ON
Field
Enable
Ground
Aux Alt. Reg.
Ess Tie Power
MAIN Relay Plug H
TIE O
5A
30
+ T
- B
U
5A
S Battery
OFF
ON
Relay Main
Battery
ESS
TIE
Essential
30 Bus
E
Engine Master E
5A
S
OFF
5A C
S U Starter
ON
E To Avionic Relay Relay
N B Engine
T MASTER Master
I CONTROL OFF B OFF
A ON
U 10A
L 2 S
ON
Avionic
B Master
U EECU Backup 100A
S Relay 10A
INSTRUMENT PANEL 32A
ECU Backup
Battery
LEGEND
MAIN
TIE Circuit-Breaker with Name and Rating
30 (Name as on the Placard)
5A FUSELAGE
Fuse with Rating
Figure 3: Electrical System Schematic Diagram (if OÄM 40-329 or OÄM 40-330 is installed)
Page 4 Doc # 6.02.15
15 Apr 2013 24-00-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
%
%
% INSTRUMENT PANEL ENGINE COMPARTMENT
Avionic
% Relay A
AV. BUS V Alternator
% 25
I
O Starter
% N
I
C Current
% 5A To Sensor
B
% Avionic U
Switch S B
% Power 50A
A
T
T Excitation
% PWR
Relay
Supply
B
Lamp
% 60 U
5A
S Ground
M
% A 5A 2 Usense
I
% N
80A
100A
B
% U Starter E
S C
% Relay U
START Engine Electric
Master Master
% 10
OFF
B
U
20A S
% ON
5A
Battery
% 4
5A Relay Main
H Battery
Ess Tie
% MAIN Relay
TB3 O
Aux T
% TIE
Power B
30 Plug U
% S
5A
% OFF E Starter
C Relay
%
ON
U
% ESS
TIE
B
Essential
B
% 30 Bus U
S
% E
S To Avionic
S Relay EECU Backup
% E
Relay
32A
N MASTER 10A
% T CONTROL OFF
I ON ECU
A 2 Backup
% L Avionic Battery
Master
% B
U
5A
EPU
S TB1 Relay
% 1
50A
EPU
% 2
Plug
%
LEGEND
% MAIN
TIE Circuit-Breaker with Name and Rating
% 30 (Name as on the Placard)
% 5A
Fuse with Rating FUSELAGE
%
%
% Figure 4: Electrical Schematic Diagram (if MÄM 40-551 is installed)
Doc # 6.02.15 Page 5
Rev. 2 24-00-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
2. 28 VDC System Description and Operation
Figure 1 shows the electrical system schematic diagram, if the G1000 system with GFC 700 autopilot
is installed.
Figure 2 shows the electrical system schematic diagram, if the conventional cockpit (OÄM 40-321
is installed).
Figure 3 shows the electrical system schematic diagram, if the G1000 system with KAP 140 autopilot
(OÄM 40-329) or without autopilot (OÄM 40-330) is installed.
% Figure 4 shows the electrical system schematic diagram, if the alternator regulator E4A-91-200-000
% (MÄM 40-551) is installed.
A. Power Supplies
(1) Main Battery
The main battery is located in the rear fuselage on the LH side. It is a 24 V, 13.6 Ah sealed
battery. It connects to the instrument panel ground point, the lightning protection system, the hot
battery bus and the battery relay.
(2) Alternator
The alternator is located at the bottom, left rear of the engine. A flat multi-V belt with automatic
tensioner turns the alternator. The alternator is connected to an external regulator, located
under the pilot’s seat. The output connects to the ECU bus bar via a 100 A fuse. The field can
be energized directly by the ECU backup battery if the main battery fails.
(3) Engine Control Unit (ECU) Backup Battery
The ECU backup battery is located in the rear fuselage. It consists of two 12 V, 7.2 Ah sealed
batteries, connected in series. The ECU backup battery connects directly to the ECU B bus.
The ECU backup battery is also used as alternator excitation battery.
(4) External Power Connector
The external power connector is located on the left side of the rear fuselage, near the relay
junction box. The external power connector connects to the external power relay in the relay
junction box on the baggage compartment frame.
) The control pin connects to the relay coil through a diode to prevent reverse connection.
) The + pin connects to the relay main input connection.
) The - pin connects to ground.
Page 6 Doc # 6.02.15
15 Apr 2013 24-00-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
B. Power Supply Control
(1) Battery Relay
The battery relay is located in the relay junction box on the baggage compartment frame. The
output connects directly to the relay junction box bus bar. The coil + of the battery relay is tied
to the battery + connection to the relay. The ELECTRIC MASTER key switch provides the coil
ground when set to the ON or START position.
(2) External Power Relay
The external power relay is located in the relay junction box on the baggage compartment
frame. The output connects directly to the relay junction box bus bar.
If 28 VDC external power is connected, the +28 VDC on the control pin energizes the relay. The
relay connects the external power to the relay junction box bus bar.
(3) Bus Structure
All buses are flat metal strips connecting rows of circuit-breakers. The circuit-breakers are
located on the instrument panel on the right side.
(4) Relay Junction Box Bus
The relay junction box bus is located in the relay junction box on the baggage compartment
frame. It is a flat metal strip connecting these relays:
) The external power relay.
) The battery relay.
) The starter relay.
The bus has three outputs:
) The battery bus in the instrument panel.
) The glow plugs.
) The engine starter motor solenoid.
Doc # 6.02.15 Page 7
Rev. 2 24-00-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
(5) ECU Bus
The ECU bus is located at the circuit breakers. The ECU bus has power when the any one of
the following are connected to the ECU bus:
) The main battery.
) External power.
) The alternator.
The ECU bus provides power for Engine Control Unit A (ECU A) and ECU B and their fuel
pumps. Circuit-breakers protect each circuit.
The ECU B and its fuel pump is connected to the ECU bus via a diode and a fuse. The ECU
backup battery is also connected to ECU B and its fuel pump.
(6) Main Bus
The main bus provides power for the consumers. Each consumer has a circuit breaker to
protect the circuit. The main bus also connects to the switch contact of:
) The starter relay.
A circuit-breaker protects the supply to the relay.
(7) Power Relay
The power relay connects the battery bus in the instrument panel to the main bus. The essential
bus switch controls the power relay.
(8) Essential Tie Relay
In the usual (de-energized) condition, the essential tie relay connects the main bus to the
essential bus.
In the emergency (energized) condition, the essential tie relay connects the battery bus in the
instrument panel to the essential bus.
The essential bus switch controls the essential tie relay.
Page 8 Doc # 6.02.15
15 Apr 2013 24-00-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
(9) Essential Bus Switch (Marked ESS BUS)
The ESS BUS switch is located in the switch panel at the bottom left of the instrument panel.
In the OFF position, the ESS BUS switch gives a ground to the power relay coil. The relay
closes and connects the battery bus in the instrument panel to the main bus. This is the usual
position when all systems are operating correctly.
In the ON position, the ESS BUS switch disconnects the ground from the power relay coil. The
power relay opens and disconnects the main bus from the power supply (the battery bus). It also
gives a ground to the coil of the essential tie relay. The relay energizes to break the connection
between the main bus and the essential bus. At the same time, it connects the battery bus to
the essential bus.
There is a light emitting diode in the essential bus switch. If there is power on the battery bus,
and the ELECTRIC MASTER key switch is set to ON or START, the light emitting diode comes
ON.
(10) Starter Relay
The starter relay contacts and coil connect to the main bus. A 10 A circuit-breaker protects the
circuit.
When the ENGINE MASTER switch set to ON and the ELECTRIC MASTER key switch is set
to START, they give a ground to the relay coil. The relay connects the main bus to the starter
solenoid (part of the starter). The solenoid engages the starter and operates a heavy-current
contactor to connect the relay junction box bus to the starter.
(11) Avionics Master Relay
The avionics master relay connects the main bus (if G1000 system is installed) or the essential
bus (if the conventional cockpit is installed) to the avionics bus. The AVIONIC MASTER switch
controls the relay.
(12) AVIONIC MASTER Switch
With the AVIONIC MASTER switch set to OFF:
) The avionic master relay is energized to disconnect the avionics bus from the main bus.
With the AVIONIC MASTER switch set to ON:
) The avionic master relay is de-energized to connect the avionics bus to the main bus.
Doc # 6.02.15 Page 9
Rev. 2 24-00-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
(13) ENGINE MASTER Switch
The ENGINE MASTER switch is located on the left, center of the instrument panel switch panel.
It has four sets of contacts. When set to ON, each set of contacts connects one input to one
output as follows:
) ECU A power supply to ECU A.
) ECU B power supply to ECU B. The ECU backup relay is energized.
) ECU backup battery to the alternator regulator enable connection.
) ELECTRIC MASTER key switch START connection to the starter relay.
Page 10 Doc # 6.02.15
15 Apr 2013 24-00-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Section 24-30
DC Generation
1. General
The DC generation system for the DA 40 NG has these components:
) Alternator.
) Alternator current sensor.
) Alternator fuse.
) Voltage regulator.
) Alternator excitation battery (ECU backup battery).
This Section gives you only the simplified description, Trouble-Shooting and Maintenance Practices
for the generating system. Refer to Section 24-00 for the full system description and operation.
Doc # 6.02.15 Page 1
Rev. 2 24-30-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
INSTRUMENT PANEL ENGINE COMPARTMENT
F
I
R
E
W
A
B
Power A L
T
Relay T
L
PWR Current
E
60 R Sensor
5A
Y
M Alternator
A B
50A
I U
N S
5A
B 2
U
S
START E
10 100A
C To Hot To Alt. Reg.
U
Electric Bus 5A
Master B
U R Battery
S E Relay Main Battery
80A
L 24V / 13.6Ah
A
Y
Essential Tie J
U
MAIN Relay N
TIE C 5A
T
30 I
O
100A N
B
OFF O
ON X
B
ESS U
E TIE Essential Bus S
S Switch
S 30
E
N
T
I FUSELAGE
A
L
B
U
S
LEGEND
MAIN
TIE Circuit-Breaker with Name and Rating
30 (Name as on the Placard)
5A
Fuse with Rating
Figure 1: Electrical Generation System Simplified Schematic Diagram
Page 2 Doc # 6.02.15
15 Apr 2013 24-30-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
ENGINE COMPARTMENT
FUSE PANEL B
A
T
50A
T
B
U
5A
S
80A
Power
Relay E
C
PWR
Current U
60 Sensor
5A
B
U
100A S
M Alternator
A
I
N Electric
Master
B
U
S Field
Enable
Ground
Ess Tie Alt. Reg.
MAIN Relay H
TIE O
T
30
B
U
5A
S Battery
OFF
Relay
ON Main
Battery
ESS
TIE
Essential
30 Bus
E 5A
S
S 100A
E
N
T
INSTRUMENT PANEL
I
A
L
B
U FUSELAGE
S
LEGEND
MAIN
TIE Circuit-Breaker with Name and Rating
30 (Name as on the Placard)
5A
Fuse with Rating
Figure 2: Electrical Generation System Simplified Schematic Diagram
if Conventional Cockpit (OÄM 40-321), OÄM 40-329 or OÄM 40-330 Is Installed
Doc # 6.02.15 Page 3
Rev. 2 24-30-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
2. Description and Operation
Figure 1 shows the generation system simplified schematic diagram if the G1000 system with
GFC 700 autopilot is installed.
Figure 2 shows the generation system simplified schematic diagram if the conventional cockpit
(OÄM 40-321), G1000 system with KAP 140 autopilot (OÄM 40-329) or G1000 system without
autopilot (OÄM 40-330) is installed.
A. Alternator
The alternator is supplied as part of the engine. It is a 28 VDC machine with a maximum output of
70 A. It attaches to the rear left of the engine. A multi-V flat belt turns the alternator. An automatic
system adjusts the belt tension.
The alternator has an external voltage regulator.
There is no approved maintenance possible on the alternator.
B. Alternator Excitation Battery (ECU Backup Battery)
The ECU backup battery is also used as alternator excitation battery. It is located in the rear
fuselage, behind the first ring spar.
The ENGINE MASTER switch controls the circuit to the alternator regulator.
C. Alternator Current Sensor
An alternator current sensor is located in the instrument panel or in the engine compartment.
D. Alternator Fuse
A 100 A fuse is located in the instrument panel or in the engine compartment between the
alternator cable and the ECU bus.
E. Alternator Regulator
The alternator regulator is located under the pilot’s seat. It measures the alternator output voltage
and controls the current through the alternator field coils via a pulse-width modulated signal. To
keep the output voltage stable in all load and speed situations, the alternator field signal is
modulated accordingly.
Page 4 Doc # 6.02.15
15 Apr 2013 24-30-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Trouble Shooting
1. General
The table below lists the defects you could have with the generating system. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair given
in the Repair column.
Trouble Possible Cause Repair
Alternator warning light Alternator defective. Refer to the engine
illuminated. manufacturer.
Alternator regulator defective. Refer to the engine
manufacturer.
Doc # 6.02.15 Page 101
Rev. 2 24-30-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 24-30-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Maintenance Practices
1. General
This Section gives you the data to remove/install and adjust the components of the 28 VDC electrical
generation system on the airplane. Refer to the component manufacturers' manuals for more data and
shop data.
2. Electrical Safety
The DA 40 NG has a low voltage DC electrical system. When correctly maintained it is safe to work
on. The battery can supply heavy current through low resistance circuits (for example, if you ground
the positive output with a wrench by accident).
Always follow the usual safety practices for working on electrical equipment. Allow only qualified
persons to maintain the electrical system.
CAUTION: DISCONNECT THE BATTERY BEFORE DOING MAINTENANCE ON
THE ELECTRICAL SYSTEM. MAKE SURE THAT YOU DISCONNECT
THE NEGATIVE LEAD FIRST.
CAUTION: AFTER DOING ELECTRICAL MAINTENANCE ALWAYS DO A
CONFIDENCE TEST OF THE SYSTEM WITH A 24 VOLT POWER
SUPPLY THAT HAS OVER-CURRENT PROTECTION. DO THIS
BEFORE CONNECTING THE BATTERY.
CAUTION: USE ONLY DA 40 NG SPARE PARTS APPROVED BY THE
MANUFACTURER.
Doc # 6.02.15 Page 201
Rev. 2 24-30-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
3. Replace the Alternator Fuse if OÄM 40-321, OÄM 40-329, OÄM 40-330 Are Not Installed
Detail Steps/Work Items Key Items/References
(1) Disconnect the airplane main battery:
S Disconnect the negative cable from the
battery.
S Disconnect the positive cable from the
battery.
(2) Remove the instrument panel cover.
(3) Release the 100 A alternator fuse. Dispose of the old fuse.
(4) Install a new 100 A fuse.
(5) Install the instrument panel cover.
(6) Do an engine ground test. The ammeter must show an electrical
load.
Page 202 Doc # 6.02.15
15 Apr 2013 24-30-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
4. Replace the Alternator Fuse if OÄM 40-321, OÄM 40-329 or OÄM 40-330 Is Installed
Detail Steps/Work Items Key Items/References
(1) Disconnect the airplane main battery:
S Disconnect the negative cable from the
battery.
S Disconnect the positive cable from the
battery.
(2) Remove the engine cowlings. Refer to Section 71-10.
(3) Remove the cover of the fuse panel in the engine
compartment.
(4) Release the 100 A alternator fuse. Dispose of the old fuse.
(5) Install a new 100 A fuse.
(6) Install the cover of the fuse panel in the engine
compartment.
(7) Install the engine cowlings. Refer to Section 71-10.
(8) Do an engine ground test. The ammeter must show an electrical
load.
Doc # 6.02.15 Page 203
Rev. 2 24-30-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 204 Doc # 6.02.15
15 Apr 2013 24-30-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Section 24-31
Battery System
1. General
This Section tells you about the battery systems for DA 40 NG airplanes. See Sections 24-00 and
24-32 for the description and operation of the battery in the electrical generation system.
The airplane has three batteries:
) A main battery located in the rear fuselage behind the baggage compartment frame. This battery
provides the usual airplane electrical services.
) An ECU backup battery located in the rear fuselage behind the first ring frame. The ECU backup
battery connects directly to the ECU backup relay. This battery provides power to the ECU B and
its fuel pump if all other power supplies fail.
) If the G1000 system is installed, an emergency battery located on the instrument panel. Refer to
Section 24-32 for information about this battery.
2. Main Battery Description and Operation
The main battery is a 24 V, 13.6 Ah sealed battery. A tray in the fuselage holds the base of the battery.
A strap holds the battery in place. The positive and negative cables attach to terminals at the top of
the battery. The usual rubber caps protect the connections.
When the alternator voltage is greater than the battery voltage, the alternator charges the battery.
When the alternator is operating, the digital voltmeter shows the alternator voltage. When the alternator
is off-line, the digital voltmeter shows the battery voltage.
The battery supplies current to the battery bus through the battery relay. The battery relay is in the
relay junction box which is located on the baggage compartment frame adjacent to the battery. There
is no circuit-protection.
The battery also supplies the hot battery bus. A 5 Ampère fuse protects the hot battery system.
The main battery is maintenance free.
Doc # 6.02.15 Page 1
Rev. 2 24-31-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Positive
Terminal
Battery
Negative
Terminal
Hold-Down Strap
Figure 1: Main Battery Installation
Page 2 Doc # 6.02.15
15 Apr 2013 24-31-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
3. ECU Backup Battery Description and Operation
The ECU backup battery consists of two 12 V, 7.2 Ah sealed units connected in series. A tray behind
the first ring spar holds the battery. The positive and negative cables attach to terminals at the top of
the battery.
When the ECU B bus voltage is greater than the battery voltage, the bus charges the battery.
The battery supplies current to the ECU B and its fuel pump through the ECU backup relay. The relay
is on the instrument panel shelf. A 32 A fuse protects the circuit.
It also supplies power to the alternator regulator via a 10 A fuse and the ENGINE MASTER switch.
Doc # 6.02.15 Page 3
Rev. 2 24-31-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 24-31-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the battery system. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair given
in the Repair column.
Trouble Possible Cause Repair
Main battery voltage low. Battery capacity low. Do a capacity test. If
necessary, replace the battery.
Alternator output low. Trouble-Shoot the alternator,
refer to Section 24-31.
Main battery will not connect to Battery relay defective. Replace the battery relay.
the battery bus.
ELECTRIC MASTER key Replace the ELECTRIC
switch defective. MASTER key switch.
Battery system wiring Do a test of the battery system
defective. wiring. Refer to Chapter 92 for
the wiring diagrams.
Main battery will not connect to 5 A fuse failed. Replace the 5 A fuse. If the
the hot battery bus. fuse fails again, do a test for a
short circuit between the hot
battery bus and ground. Repair
or replace the defective
component.
Ammeter shows zero at all Defective ammeter. Replace the engine/airframe
times. unit (if G1000 is installed) or
SED (if installed).
Defective ammeter transducer.
Replace the transducer.
Voltmeter shows zero. Defective voltmeter. Replace the engine/airframe
unit (if G1000 is installed) or
SED (if installed).
Defective wiring in the
voltmeter system. Do a test of the wiring. Refer to
Chapter 92 for the wiring
diagrams.
Doc # 6.02.15 Page 101
Rev. 2 24-31-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 24-31-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Maintenance Practices
1. General
Keep the battery clean. Remove grease and other contaminants from the battery case. Remove dirt
from the area of the terminals. Protect the terminals and cable lugs with Dow Corning compound 4
(DC4).
If you do not use the airplane regularly you must remove the battery for charging.
CAUTION: INSTALL ONLY A BATTERY WHICH IS APPROVED BY THE AIRPLANE
MANUFACTURER.
2. Safety Precautions
Obey the maintenance instructions of the battery manufacturer.
Always disconnect the battery when you do work on the electrical system. Disconnect the negative
cable first. Connect the negative cable last.
3. Remove/Install the Battery
A. Remove the Battery from the Airplane
Detail Steps/Work Items Key Items/References
(1) Remove the baggage extension and baggage Refer to Section 25-10.
tray.
(2) Remove the battery retaining clamp:
S Remove the bolt, nut and 2 washers from
clamp.
(3) Disconnect the negative cable from the battery.
(4) Disconnect the positive cable from the battery.
(5) Remove the battery from the airplane.
Doc # 6.02.15 Page 201
Rev. 2 24-31-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
B. Install the Battery in the Airplane
Detail Steps/Work Items Key Items/References
(1) Make sure that the battery is clean and dry.
(2) Move the battery into position in the battery
mount.
CAUTION: MAKE SURE THAT YOU CONNECT THE CABLES TO THE
CORRECT TERMINALS. INCORRECT CONNECTION CAN DAMAGE
THE ELECTRICAL AND AVIONIC SYSTEMS.
(3) Connect the positive cable to the battery. Apply Dow Corning compound (DC4) to
the battery terminal and the cable lug.
(4) Connect the negative cable to the battery. Apply Dow Corning compound (DC4) to
the battery terminal and the cable lug.
(5) Install the battery retaining clamp:
S Put the battery retaining clamp into position Make sure that the clamp is seated
over the battery. correctly.
S Install the bolt, 2 washers and nut onto the
clamp.
(6) Install the baggage extension and baggage tray. Refer to Section 25-10.
Page 202 Doc # 6.02.15
15 Apr 2013 24-31-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
4. Disconnect/Connect the Battery for Maintenance
A. Disconnect the Battery for Maintenance
Detail Steps/Work Items Key Items/References
(1) Remove the baggage extension and baggage Refer to Section 25-10.
tray.
(2) Disconnect the negative cable from the battery.
(3) Disconnect the positive cable from the battery.
B. Connect the Battery after Maintenance
Detail Steps/Work Items Key Items/References
CAUTION: MAKE SURE THAT YOU CONNECT THE CABLES TO THE
CORRECT TERMINALS. INCORRECT CONNECTION CAN DAMAGE
THE ELECTRICAL AND AVIONIC SYSTEMS.
(1) Connect the positive cable to the battery. Apply Dow Corning compound (DC4) to
the battery terminal and the cable lug.
(2) Connect the negative cable to the battery. Apply Dow Corning compound (DC4) to
the battery terminal and the cable lug.
(3) Install the baggage extension and baggage tray. Refer to Section 25-10.
Doc # 6.02.15 Page 203
Rev. 2 24-31-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
5. Remove/Install the Battery Relay
A. Remove the Battery Relay
Detail Steps/Work Items Key Items/References
(1) Remove the baggage extension and baggage Refer to Section 25-10.
tray.
(2) Disconnect the main battery:
S Disconnect the negative cable from the
battery.
S Disconnect the positive cable from the
battery.
(3) Disconnect the ECU backup battery:
S Disconnect the negative cable from the
battery.
S Disconnect the positive cable from the
battery.
(4) Remove the bolts and washers attaching the bus
bar and cables to the relay.
(5) Disconnect the electrical cables of the battery
relay from the terminal block.
(6) Move the relay clear of the airplane.
Page 204 Doc # 6.02.15
15 Apr 2013 24-31-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
B. Install the Battery Relay
Detail Steps/Work Items Key Items/References
(1) Put the relay in position in the relay box and Check for correct polarity.
connect the control cables to the terminal block.
(2) Connect the battery positive cable and the Refer to Chapter 92 for the wiring
4 smaller cables to the battery relay: diagrams.
S Move the 2 smaller cables on the forward
side into position and install the bolt and
washer that attaches the cables to the relay
through all 2 cables and into the relay
mounting.
S Move the battery positive cable and the
2 smaller cables on the aft side into position
and install the bolt and washer that attaches
the cables to the relay through all 3 cables
and into the relay mounting.
(3) Connect the cables to the main battery: Apply Dow Corning compound (DC4) to
the battery terminal and the cable lug.
S Connect the positive cable to the battery.
S Connect the negative cable to the battery.
(4) Connect the cables to the ECU backup battery:
S Connect the positive cable to the battery.
S Connect the negative cable to the battery.
(5) Install the baggage extension and baggage tray. Refer to Section 25-10.
(6) Do a test for correct operation of the battery Refer to Paragraph 6.
relay.
Doc # 6.02.15 Page 205
Rev. 2 24-31-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
6. Battery Relay Functional Test
Detail Steps/Work Items Key Items/References
(1) Set the ELECTRIC MASTER key switch to ON. The voltmeter must indicate the battery
voltage.
(2) Set the ELECTRIC MASTER key switch to OFF.
Page 206 Doc # 6.02.15
15 Apr 2013 24-31-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Section 24-32
Emergency Battery System
1. General
This Section tells you about the emergency battery system for DA 40 NG airplanes (if G1000 is
installed). Regular maintenance of the emergency battery system is necessary.
Refer to Chapter 92 for the wiring diagrams.
2. Description
The emergency battery system consists of:
) An emergency battery pack.
) A sealed EMERGENCY switch.
The emergency battery pack consists of 10 lithium manganese batteries, 3 V, 1,300 mAh. Refer to the
Equipment List in Section 6.5 of the Airplane Flight Manual for the approved battery type.
The emergency battery pack is mounted behind the instrument panel, on the co-pilot's side.
When all other sources of electrical power fail during flight, the EMERGENCY switch on the left side
of the instrument panel is set to ON to use the emergency battery. It supplies the attitude gyro
(horizon) and the flood light with power for at least 1 hour.
Doc # 6.02.15 Page 1
Rev. 2 24-32-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Doc # 6.02.15
Page 2
15 Apr 2013 24-32-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the emergency battery system. If you have the
trouble detailed in the Trouble column read across to the Possible Cause column. Then do the repair
given in the Repair column.
Trouble Possible Cause Repair
Batteries leaking. Batteries expired. Replace battery pack. Clean all
items that are contaminated.
Voltage on the back side of the Batteries expired. Replace battery pack.
emergency switch less than
Batteries have been used. Replace battery pack.
30 Volts.
Emergency battery system Repair the emergency battery
wiring defective. system wiring.
Doc # 6.02.15 Page 101
Rev. 2 24-32-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Doc # 6.02.15
Page 102
15 Apr 2013 24-32-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to replace the emergency battery pack. It also tells you how to test the
emergency battery system.
Refer to Chapter 92 for the wiring diagrams.
2. Remove/Install the Emergency Battery Pack
A. Remove the Emergency Battery Pack
Detail Steps/Work Items Key Items/References
(1) Remove the instrument panel cover. Refer to Section 25-10.
(2) Disconnect the electrical plug of the battery Refer to Figure 1.
pack.
(3) Remove the GEA 71 of its mounting rack.
(4) Remove the two screws and nuts of the Hold the battery pack.
battery pack.
(5) Remove the battery pack clear of the airplane.
CAUTION: THE BATTERY PACKS CANNOT BE RE CHARGED. DO NOT TRY TO
RECHARGE THE BATTERY PACKS. IF YOU TRY TO RECHARGE THE
BATTERY PACKS, THEY CAN EXPLODE OR LEAK.
CAUTION: DISPOSE OF THE BATTERY PACKS PROPERLY (ASK YOUR
BATTERY DEALER FOR ADVISE). BATTERIES CONTAIN POISONS
WHICH HARM THE ENVIRONMENT. DO NOT THROW THE USED
BATTERY PACKS INTO THE GARBAGE. DO NOT EXPOSE BATTERIES
TO FIRE. DO NOT DISMANTLE BATTERY PACKS.
Doc # 6.02.15 Page 201
Rev. 2 24-32-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Nut
Washer
Safety Cover
Artificial Horizon
Horizon Emergency Switch
Emergency
Power Pack
Dry Cells (x10)
Figure 1: Emergency Battery Pack
Doc # 6.02.15
Page 202
15 Apr 2013 24-32-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
B. Install the Battery Pack
CAUTION: USE ONLY NEW BATTERY PACKS. REFER TO THE EQUIPMENT LIST
IN THE AIRPLANE FLIGHT MANUAL, SECTION 6.5, FOR THE
CORRECT BATTERY TYPE.
CAUTION: DO NOT SHORT CIRCUIT THE BATTERY PACK.
Detail Steps/Work Items Key Items/References
(1) Measure the voltage of the battery pack. On the connector for the electrical plug.
If the voltage is less than 30 V, then the
batteries are used, or at least one
battery was installed incorrectly. Use a
new battery pack.
(2) Put the battery pack in place in the instrument
panel on the co-pilot's side.
(3) Install the two screws and nuts of the battery
pack.
(4) Connect the electrical plug of the battery pack. Ensure correct polarity.
(5) Install the GEA 71.
(6) Measure the voltage on the back side of the If the voltage is below 30 V, it is
EMERGENCY HORIZON switch. probable that the wiring is defective.
Repair wiring.
(7) Install the instrument panel cover. Refer to Section 25-10.
Doc # 6.02.15 Page 203
Rev. 2 24-32-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Doc # 6.02.15
Page 204
15 Apr 2013 24-32-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Section 24-33
Additional Alternator
1. General
If OÄM 40-314 is carried out, an additional alternator is installed. The additional alternator generates
electrical DC - power for optional airplane equipment. The additional alternator and its consumers form
an additional electrical system which is not connected to the airplanes standard electrical system.
The additional alternator system has the following components:
) Alternator.
) Alternator fuse.
) Voltage regulator.
) Excitation battery.
) AUX POWER switch.
Doc # 6.02.15 Page 1
Rev. 2 24-33-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Figure 1: Additional Alternator Electrical System Schematic Diagram
Doc # 6.02.15
Page 2
15 Apr 2013 24-33-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
2. Description and Operation
Figure 1 shows the additional alternator electrical system schematic diagram.
A. Additional Alternator
The additional alternator is mounted to the engine gearbox and to the forward RH engine mounting
arm. The alternator is driven via a v-belt and generates up to 100 A at 28 V. The alternator has an
external voltage regulator.
There is no scheduled maintenance for the additional alternator. If the additional alternator fails,
it must be replaced.
B. Additional Alternator Excitation Battery
A separately installed small battery is used for the excitation of the additional alternator.
C. Alternator Fuse
A 100 A fuse is located in the engine compartment.
D. Additional Alternator Regulator
The alternator regulator is located in the engine compartment. It measures the alternator output
voltage and controls the current through the alternator field coils via a pulse-width modulated signal.
To keep the output voltage stable at all load and speed conditions, the alternator field signal is
modulated accordingly.
The AUX POWER switch controls the circuit to the alternator regulator.
Doc # 6.02.15 Page 3
Rev. 2 24-33-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Doc # 6.02.15
Page 4
15 Apr 2013 24-33-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Trouble Shooting
1. General
The table below lists the defects you could have in the additional alternator electrical system. If you
have the trouble detailed in the Trouble column read across to the Possible Cause column. Then do
the repair in the Repair column.
Trouble Possible Cause Repair
Alternator provides no electrical Alternator defective. Replace alternator.
power.
Voltage regulator defective. Replace voltage regulator.
Alternator fuse open. Replace fuse.
Alternator control fuse open. Replace fuse.
Doc # 6.02.15 Page 101
Rev. 2 24-33-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Doc # 6.02.15
Page 102
15 Apr 2013 24-33-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Maintenance Practices
1. General
This Section provides instructions how to remove/install and adjust the components of the additional
28 VDC electrical generating system. Refer to the component manufacturers' manuals for more
detailed information and instructions.
2. Electrical Safety
The additional electrical system is a low voltage DC system. When correctly maintained it is safe to
work on.
Always follow the usual safety practices for working on electrical equipment. Allow only qualified
persons to maintain the electrical system.
Maintenance carried out must be of good workmanship strictly considering the guidelines of
AC 43-13.1B. It is important that maintenance is carried out in accordance with the best available
techniques and properly trained maintenance personnel, in order to eliminate possible failures.
CAUTION: AFTER DOING ELECTRICAL MAINTENANCE ALWAYS DO A
CONFIDENCE TEST OF THE SYSTEM WITH A 24 VOLT POWER
SUPPLY THAT HAS OVER-CURRENT PROTECTION. DO THIS
BEFORE CONNECTING THE BATTERY.
CAUTION: USE ONLY DA 40 NG SPARE PARTS APPROVED BY THE
MANUFACTURER.
Doc # 6.02.15 Page 201
Rev. 2 24-33-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
3. Remove/Install the AUX POWER Switch
A. Remove the AUX POWER Switch
Detail Steps/Work Items Key Items/References
(1) Remove the center console. Refer to Section 25-10.
(2) Unplug the electrical connector of the AUX
POWER switch.
(3) Remove the nut and washer of the AUX POWER
switch.
(4) Move the AUX POWER switch clear of the center
console.
B. Install the AUX POWER Switch
Detail Steps/Work Items Key Items/References
(1) Position the AUX POWER switch in place in the
center console.
(2) Insert the washer and the nut of the AUX
POWER switch. Tighten the nut.
(3) Install the electrical connectors on the AUX
POWER switch.
(4) Install the center console. Refer to Section 25-10.
Doc # 6.02.15
Page 202
15 Apr 2013 24-33-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
4. Remove/Install the Additional Alternator Regulator
A. Remove the Voltage Regulator
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE ADDITIONAL ALTERNATOR REGULATOR. IF THE
ENGINE IS TURNED, THE PROPELLER CAN CAUSE INJURY OR
DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Remove the engine cowling. Refer to Section 71-10.
(3) Disconnect the voltage regulator wiring harness. Refer to Figure 4.
(4) Remove the two attachment bolts of the
regulator.
(5) Move the voltage regulator clear of the airplane.
Doc # 6.02.15 Page 203
Rev. 2 24-33-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
B. Install the Voltage Regulator
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE ADDITIONAL ALTERNATOR REGULATOR. IF THE
ENGINE IS TURNED, THE PROPELLER CAN CAUSE INJURY OR
DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Position the alternator regulator on the regulator Refer to Figure 4.
mounting bracket.
(3) Install the 2 bolts which attache the alternator
regulator on the regulator mounting bracket.
(4) Connect the electrical wiring harness to the Refer to Section 24-33.
alternator regulator.
(5) Install the engine cowlings. Refer to Section 71-10.
(6) Do an engine run-up. Do a test for correct Refer to Section 71-00.
operation of the regulator.
Doc # 6.02.15
Page 204
15 Apr 2013 24-33-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Section 24-40
External Power
1. General
The DA 40 NG has an external power socket located on the left side of the fuselage, near the relay
junction box. It is a standard 28 Volt DC power socket. When you connect external power to the
external power socket, the external power control relay is energized and the external power comes
on-line.
2. Description
Figure 1 shows a simple schematic diagram of the external power system. The external power system
has these components:
A. 28 Volt Socket
The 28 VDC power socket is located on the left side of the fuselage, near the relay junction box.
The socket has 3 pins:
) A large negative pin.
) A large positive pin.
) A small positive pin.
A diode connected between the external power relay solenoid and the small positive pin protects
the system of reverse polarity.
B. External Power Relay
The external power relay is located in the relay junction box mounted on the baggage compartment
frame. Heavy duty cable connects the large positive pin to the input terminal of the relay. Another
heavy duty cable connects the large negative pin to the negative pole on the main battery.
The small positive pin connects to the solenoid of the external power relay via the diode.
Doc # 6.02.15 Page 1
Rev. 2 24-40-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
FUSELAGE
5A
To Hot Bus
Battery
Relay Main Battery
24V / 13.6Ah
R
E
L 5A
A
Y
J
U Starter
N Relay
C
T
I
O
N
Starter
B
O
X
B
U EPU
S
Relay
EPU Plug
Figure 1: External Power System Schematic Diagram
Page 2 Doc # 6.02.15
15 Apr 2013 24-40-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
3. Operation
When you connect a 24 to 28 V DC power supply to the external power socket these things happen:
) Current can flow from the small positive pin to the solenoid, the solenoid operates and closes the
relay.
) Current can flow from the large positive pin through the external power relay to the battery bus
system.
) The large negative pin is connected to ground.
If the polarity of the power supply is incorrect, then the diode will prevent current from flowing through
the solenoid. The solenoid will not operate and current cannot flow through the external power relay
to the bus system.
Doc # 6.02.15 Page 3
Rev. 2 24-40-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 24-40-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the external power system. If you have the
trouble detailed in the Trouble column read across to the Possible Cause column. Then do the repair
given in the Repair column.
Trouble Possible Cause Repair
External power will not come No external power. Make sure that the external
on line. power plug is securely in the
socket.
Make sure that the external
power is operating correctly.
External power relay is Do a test of the external power
defective. relay, if necessary, replace the
external power relay.
Doc # 6.02.15 Page 101
Rev. 2 24-40-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 24-40-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to remove/install the external power relay. Refer to the component
manufacturers manuals for more data and shop data.
2. Electrical Safety
The DA 40 NG has a low voltage DC electrical system. When correctly maintained it is safe to work
on. The battery can supply heavy current through low resistance circuits (for example, if you ground
the positive output with a wrench by accident).
Always follow the usual safety practices for working on electrical equipment. Allow only qualified
persons to maintain the electrical system.
CAUTION: DISCONNECT THE BATTERY BEFORE DOING MAINTENANCE ON
THE ELECTRICAL SYSTEM. MAKE SURE THAT YOU DISCONNECT
THE NEGATIVE LEAD FIRST.
CAUTION: AFTER DOING ELECTRICAL MAINTENANCE ALWAYS DO A
CONFIDENCE TEST OF THE SYSTEM WITH A 24 VOLT POWER
SUPPLY THAT HAS OVER-CURRENT PROTECTION. DO THIS
BEFORE CONNECTING THE BATTERY.
CAUTION: USE ONLY DA 40 NG SPARE PARTS APPROVED BY THE
MANUFACTURER.
Doc # 6.02.15 Page 201
Rev. 2 24-40-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
3. Remove/Install the External Power Relay
A. Remove the External Power Relay
Detail Steps/Work Items Key Items/References
(1) Remove the baggage extension and baggage Refer to Section 25-10.
tray.
(2) Disconnect the battery:
S Disconnect the negative cable from the
battery.
S Disconnect the positive cable from the
battery.
(3) Disconnect the electrical cables of the external
power relay from the terminal block.
(4) Remove the bolts and washers which attach the
bus bar and cables to the external power relay.
(5) Move the relay clear of the airplane.
Page 202 Doc # 6.02.15
15 Apr 2013 24-40-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
B. Install the External Power Relay
Detail Steps/Work Items Key Items/References
(1) Put the relay in position in the relay junction box Check for correct polarity.
and connect the control cables to the terminal
block.
(2) Connect the cable to the external power relay: Refer to Chapter 92 for the wiring
diagrams.
S Move the cable into position at the external
power relay.
S Install the bolts and washers that attach the
cable to the relay through the cable and into
the relay mounting.
(3) Connect the positive cable to the battery. Apply Dow Corning compound (DC4) to
the battery terminal and the cable lug.
(4) Connect the negative cable to the battery. Apply Dow Corning compound (DC4) to
the battery terminal and the cable lug.
(5) Install the baggage compartment and baggage Refer to Section 25-10.
tray.
Doc # 6.02.15 Page 203
Rev. 2 24-40-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 204 Doc # 6.02.15
15 Apr 2013 24-40-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Section 24-60
DC Electrical Load Distribution
1. General
This Section tells you about the system which supplies DC electrical power for other systems. The DC
electrical load distribution system has these components:
) Main bus.
) Relay junction box bus.
) ECU bus.
) Avionic bus.
) Essential bus.
) Hot battery bus.
) Battery relay.
) Power relay.
) Avionics master relay.
) Essential tie relay.
) Switches.
) Circuit-breakers.
) Fuses.
Figure 1 shows the electrical system bus structure diagram of the electrical distribution system.
Figure 2 shows the instrument panel layout with the Garmin G1000 system installed.
Figure 3 shows the electrical system bus structure diagram of the electrical distribution system, if the
conventional cockpit (OÄM 40-321) is installed.
Figure 4 shows the instrument panel layout if the conventional cockpit (OÄM 40-321) is installed.
Figure 5 shows the generation system simplified schematic diagram, if the G1000 system with
KAP 140 autopilot (OÄM 40-329) or G1000 system without autopilot (OÄM 40-330) is installed.
This Section gives you the Trouble-Shooting and Maintenance Practices for the electrical distribution
system. Refer to Section 24-00 for the full system description and operation.
Doc # 6.02.15 Page 1
Rev. 2 24-60-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
A
Avionic V INSTRUMENT PANEL ENGINE COMPARTMENT
I
Relay O
AV. BUS
N
25 I
C
B
U
To Avionic S
Alternator
Switch
Current
B Sensor
Power A
Relay T
PWR T
E
60 R To Alt. Reg.
5A
Y
M
A B
50A
I U
N S
5A
B 2
U
S
100A
E
C
80A U
B
U
20A
S
Essential Tie
MAIN Relay
TIE
30
FUSELAGE
Engine E
OFF Master C
ON
OFF U
5A
ESS ON B
TIE Essential Bus Engine
B
Switch U Master
30 OFF
S
10A
E To Alt. Reg. Enable
S ON
S
E Avionic EECU Backup
N Master
T MASTER Relay 10A
OFF
I CONTROL To Avionic Relay 32A
A ON
L 2
ECU Backup
B Battery
U
S
LEGEND
MAIN
TIE Circuit-Breaker with Name and Rating
30 (Name as on the Placard)
5A
Fuse with Rating
Figure 1: Electrical System Bus Structure Diagram
Page 2 Doc # 6.02.15
15 Apr 2013 24-60-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
A B C D E
Man ou ver ing speed:
Limitations for GFC 700 Autopilot System:
VA =111 KIAS ( ab ove 1036 u p to 1200 kg / a bo ve 228 4 up to 26 46 lb)
D o not use A P i f “ A lte rn at e S tati c” is o pe n.
VA =94 KIAS ( 780 t o 1 03 6 k g / 1720 to 2284lb) Ess Bus C ondu c t A P an d trim ch ec k p rio r t o ea ch fli ght (se e A FM) .
This air pla ne ma y only be o pe rat ed in acc or dance with the Air plane Fligh t not for Aut opilot OFF d ur ing t ak e -of f and lan di n g.
Man ua l. I t ca n b e op er ated in the "Normal" and " Utility " c ate go rie s in
non- icin g c on ditio ns. Pr ovided th at national opera tio nal require me nt s normal Max imum sp ee d f or au top ilot op era ti on is 1 65 KI AS .
ar e me t and th e a pp ropr iat e e quipment is ins talle d, this air plane is ap- operation Min im u m s p ee d fo r a ut opil ot op era tio n is 70 KI AS.
pr ov ed for t he following k inds of oper at ion: day VFR, nig ht VFR an d See AFM Min im u m alt itud e f or au top ilo t o perat ion:
IFR. All ae robatics maneuv er s in clud ing sp inn ing ar e prohib ite d. For C ru is e , C limb, D es c e nt an d M an eu v e rin g: 8 00 f eet AG L
furth er ope ration al limita tio ns ref er to th e Air plane Flig ht Manual.
App roa ch : 2 00 fe et AG L
No smok ing
FG H I J K L M N
SWITCHES: EECU BUS
FUEL FUEL
EECU A EECU B EECU A EECU B PUMP A PUMP B
A - LANDING 20 20
B - TAXI ESSENTIAL BUS
C - POSITION HORIZON AHRS ADC COM1 GPS/NAV1
D - STROBE 3 5 5 5 5
E - HORIZON EMERGENCY
F - ECU VOTER
G - FUEL PUMPS
5 5 5 10 3
H - ECU TEST
I - ENGINE MASTER MASTER
J - ESSENTIAL BUS CONTROL
K - AVIONIC MASTER 5 5 2 30 30
L - ELECTRIC MASTER MAIN BUS
AVIONICS BUS
M - FUEL TRANSFER
N - PITOT 60 5 5 5 25 5 5 5 3
3 10 5 3 5 5 2 3
Figure 2: Electrical Switches and Circuit-Breakers
Doc # 6.02.15 Page 3
Rev. 2 24-60-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
ENGINE COMPARTMENT
FUSE PANEL B
A
T
50A
T
B
U
5A
S
80A
20A
Power
Relay E
C
PWR
Current U
60 Sensor
5A
B
M U
A 100A S
I
N
B
U Alternator
S
Field
Enable
Ground
Ess Tie Alt. Reg.
MAIN Relay
TIE
30
OFF
ON
ESS
TIE
Essential
30 Bus A
Avionic V Engine Master
E E
I
S Relay O
OFF
5A C
S AV. BUS U
N ON
E I
N
25
C
B Engine
T Master
I B OFF
B
A U 10A
U
L MASTER S
S ON
OFF
CONTROL
B ON
U 2 EECU Backup
S Avionic Relay 10A
Master 32A
INSTRUMENT PANEL ECU Backup
Battery
LEGEND
MAIN
TIE Circuit-Breaker with Name and Rating
30 (Name as on the Placard)
5A FUSELAGE
Fuse with Rating
Figure 3: Electrical System Bus Structure Diagram,
if Conventional Cockpit (OÄM 40-321) Is Installed
Page 4 Doc # 6.02.15
15 Apr 2013 24-60-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
P W R /X MT PM1000II
PILO T CO -PIL OT
IS O
AL L
H 160
20
9
0
1
O FF
VOLU ME SQUEL CH VO LU ME SQUEL CH
INSTRUMENT AIRSPEED 40 10 20
10
8 ALT 2
140 CALI BRATED
TO
ON 10 20 ,000 FEET
120 20 10
KNOTS 60 20
7 3
100
OFF 80 6 4 OP
FLOOD 5 LH RH
OT 0 ,9 ba r 6 ,5
CT 14
F U EL PR ES S
14 0
ON FLOW -GAL/hr
9 1 O.A.T. VO LTS
G ON
FUEL
PUMPS
OFF
DC
ELE C
21
24
27 10
2 3 00
- 30
l/ mi n
°C
RPM - 30
14 0 GT - 30
°C 120
°C 1 05
%
1 00
10
FT
60
L
VOLTAGE/V
2 4 ,1 32
60
R
FT
10
8 ALT
CALI BRATED
TO
20,0 00 FEET
2
UT LT
OFF 5
UP
15
5 °C
-2 5 CURRENT/A - 2 5
°C 5
7 3 FT ET
15 18
VOTER ECU
30
VE R TIC A L SP EE D SELECT CONTROL
ECU TEST LOAD 70
6 4
F
100 FE ET PE R M IN U TE
20 W ATE R LEV
% 0 0 5
33 0
GAL
AUTO TU R N C O OR D IN ATO R 20
12
ECU B L R DOWN
9 3 5 15
2 M IN 6 10
N O P ITC H
IN FO RM ATIO N
P U L L S Q UE L C H TX
VOL
ELECT RIC ESS. AVIONIC FUEL T RANS OFF
PITOT LANDING TAXI POSITION STROBE MASTER BUS MASTER
ENGINE ON
G TX 32 8
MAX
ON ST
ON MASTER I DE N T FUNC CR SR 110 KIAS
7000 FLIGHT TIME
F
AR
AL T
OF
ALT
ST
T
01:23:20 MIN
OFF
START CLR
BY
V FR STOP 98 KIAS
OFF
0 1 2 3 4 5 6 7 8 9
A R TE X
E LT
EM ER G EN C Y US E O NL Y
ON
A RM
MIC EECU A EECU B FUEL FUEL PWR MAIN FAN/OAT T& B DG INST. LT TAXI/MAP POSITION STROBE START XFER AUDIO COM1 NAV1 XPDR AV. BUS FLAPS HOR IZON ANNUN INST. 1 PITOT LANDING FLO OD ESS MASTER
T E S T /R E S E T
PUMP A PUMP B TIE PUMP P R ES S ON
TIE CON TROL
W A IT 1 S E C O N D 28 VDC ACCESSORY PWR.
ECU BUS MAIN BUS PR ESS A RM
AVIONIC BUS ESSENTIAL BUS
GROUND OPS. ONLY 2A MAX
N A B C D L J K M I
20 20 7.5 7.5 60 30 3 3 3 5 5 5 5 10 5
MIC EECU A EECU B FUEL FUEL PWR MAIN FAN/OAT T&B DG INST. LT TAXI/MAP POSITION STROBE START XFER
PUMP A PUMP B TIE PUMP
ECU BUS MAIN BUS
1 5 2 5 25 5 3 3 5 10 5 3 30 2
AUDIO COM1 NAV1 XPDR AV. BUS FLAPS HORIZON ANNUN INST. 1 PITOT LANDING FLOOD ESS MASTER
28 VDC ACCESSORY PWR. TIE CONTROL
AVIONIC BUS ESSENTIAL BUS
GROUND OPS. ONLY 2A MAX
SWITCHES:
A - LANDING
B - TAXI
C - POSITION
D - STROBE
F - ECU SWAP
G - FUEL PUMPS
H - ECU VOTER
I - ENGINE MASTER
J - ESSENTIAL BUS
K - AVIONIC MASTER
L - ELECTRIC MASTER
M - FUEL TRANSFER
N - PITOT
Figure 4: Electrical Switches and Circuit-Breakers
if Conventional Cockpit (OÄM 40-321) Is Installed
Doc # 6.02.15 Page 5
Rev. 2 24-60-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
A ENGINE COMPARTMENT
Avionic V
I
Relay O
FUSE PANEL B
AV. BUS A
N
T
25 I
T
C 50A
B
B
U
U
S
To Avionic S 5A
Switch 2
80A
20A
Power
Relay E
C
PWR
Current U
60 Sensor
5A
B
M U
A 100A S
I
N
B
U Alternator
S
Field
Enable
Ground
Ess Tie Alt. Reg.
MAIN Relay
TIE
30
OFF
ON
ESS
TIE
Essential
30 Bus
E
Engine Master E
S
OFF
5A C
S U
ON
E To Avionic Relay
N B Engine
T MASTER Master
I CONTROL OFF B OFF
A ON
U 10A
L 2 S
ON
Avionic
B Master
U EECU Backup
S Relay 10A
INSTRUMENT PANEL 32A
ECU Backup
Battery
LEGEND
MAIN
TIE Circuit-Breaker with Name and Rating
30 (Name as on the Placard)
5A FUSELAGE
Fuse with Rating
Figure 5: Electrical System Bus Structure Diagram, if OÄM 40-329 or OÄM 40-330 Is Installed
Page 6 Doc # 6.02.15
15 Apr 2013 24-60-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Trouble-Shooting
1. General
Make sure that the alternator is supplying power and that there is 28 VDC on the main bus. Refer to
Section 24-32. For faults on a piece of equipment, or a system, refer to the applicable Chapter. For
example, for no oil pressure indication, see Chapter 77 - Engine Indicating. The table below lists the
defects you could have with the DC load distribution system. If you have the trouble detailed in the
Trouble column, read across to the Possible Cause column. Then do the repair given in the Repair
column.
Trouble Possible Cause Repair
There is 28 VDC on the main AVIONIC MASTER switch set Set the AVIONIC MASTER
bus (if G1000 is installed) or to OFF. switch to ON.
essential bus (if OÄM 40-321
AV. BUS circuit-breaker not Set the AV. BUS circuit
is installed but not on the
set. breaker.
avionic bus.
Avionics master relay Replace the avionics master
defective. relay.
A failure of the cables which Do a continuity test of the
connect the main bus to the cables. Refer to Chapter 92 for
avionics bus. the wiring diagrams.
Repair/replace defective
cables.
There is 28 VDC on the main MAIN TIE circuit-breaker not Set the MAIN TIE circuit
bus but not on the essential set. breaker.
bus with the essential bus
ESS TIE circuit breaker not Set the ESS TIE circuit
switch set to OFF.
set. breaker.
Essential tie relay defective. Replace the essential tie relay.
A failure of the cables which Do a continuity test of the
connect the main bus to the cables. Refer to Chapter 92 for
essential tie relay and the wiring diagrams.
essential bus. Repair/replace defective
cables.
Doc # 6.02.15 Page 101
Rev. 2 24-60-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
Trouble Possible Cause Repair
There is 28 VDC on the battery Power relay defective. Replace the power relay.
bus but not an the main bus
5 A power relay fuse failed. Replace the power relay fuse.
with the essential bus switch
set to OFF. A failure of the cables which Do a continuity test of the
connect the battery bus to the cables. Refer to Chapter 92 for
power relay and main bus. the wiring diagrams.
Repair/replace defective
cables.
A failure of the cables which Do a continuity test of the
connect the power relay coil to cables. Refer to Chapter 92 for
the essential bus switch. the wiring diagrams.
Repair/replace defective
cables.
ESSENTIAL BUS switch Replace the ESSENTIAL BUS
defective. switch.
Page 102 Doc # 6.02.15
15 Apr 2013 24-60-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to remove/install components of the DC load distribution system. Refer to
the component manufacturers' manuals for more data and shop data.
2. Electrical Safety
The DA 40 NG has a low voltage DC electrical system. When correctly maintained it is safe to work
on. The battery can supply heavy current through low resistance circuits (for example, if you ground
the positive output with a wrench by accident).
Always follow the usual safety practices for working on electrical equipment. Allow only qualified
persons to maintain the electrical system.
CAUTION: DISCONNECT THE BATTERY BEFORE DOING MAINTENANCE ON
THE ELECTRICAL SYSTEM. MAKE SURE THAT YOU DISCONNECT
THE NEGATIVE LEAD FIRST.
CAUTION: AFTER DOING ELECTRICAL MAINTENANCE ALWAYS DO A
CONFIDENCE TEST OF THE SYSTEM WITH A 24 VOLT POWER
SUPPLY THAT HAS OVER-CURRENT PROTECTION. DO THIS
BEFORE CONNECTING THE BATTERY.
CAUTION: USE ONLY DA 40 NG SPARE PARTS APPROVED BY THE
MANUFACTURER.
Doc # 6.02.15 Page 201
Rev. 2 24-60-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
3. Remove/Install the Avionics Master Relay
A. Remove the Avionics Master Relay
Detail Steps/Work Items Key Items/References
(1) Disconnect the battery for maintenance. Refer to Section 24-31.
(2) Remove the instrument panel cover. Refer to Section 25-10.
(3) Disconnect the electrical cables from the relay.
(4) Remove the bolts which attach the relay to the
instrument panel floor.
(5) Move the relay clear of the airplane.
B. Install the Avionics Master Relay
Detail Steps/Work Items Key Items/References
(1) Put the relay in position on the instrument floor.
(2) Install the bolts which attach the relay to the
instrument panel floor.
(3) Connect the cables to the relay. Refer to Chapter 92 for the Wiring
Diagrams.
(4) Install the instrument panel cover. Refer to Section 25-10.
(5) Connect the battery. Refer to Section 24-31. Connect the
positive cable first.
(6) Do a test of the relay:
S Set the ELECTRIC MASTER key switch to
ON.
S Set the AVIONIC MASTER switch to ON. The equipment connected to the avionic
bus must operate.
S Set the AVIONIC MASTER switch to OFF.
S Set the ELECTRIC MASTER key switch to
OFF.
Page 202 Doc # 6.02.15
15 Apr 2013 24-60-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
4. Remove/Install a Circuit-Breaker
A. Remove a Circuit-Breaker
Detail Steps/Work Items Key Items/References
(1) Remove the baggage extension and baggage Refer to Section 25-10.
tray.
(2) Disconnect the main battery: Refer to Section 24-31.
S Disconnect the negative cable from the
battery.
S Disconnect the positive cable from the
battery.
(3) Disconnect the ECU backup battery: Refer to Section 24-31.
S Disconnect the negative cable from the
battery.
S Disconnect the positive cable from the
battery.
(4) Remove the instrument panel cover. Refer to Section 25-10.
(5) Remove the nuts and washers which attach the Do this for all circuit-breakers attached
circuit-breakers to the instrument panel. to the same bus bar.
(6) Remove the screw which connects the circuit-
breaker to the copper bus bar.
(7) Disconnect the wires from the circuit-breaker.
(8) Shift back the copper bus bar together with the
remaining circuit-breakers.
(9) Remove the circuit-breaker from the instrument
panel.
Doc # 6.02.15 Page 203
Rev. 2 24-60-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
B. Install a Circuit-Breaker
Detail Steps/Work Items Key Items/References
(1) Put the circuit-breaker in position in the
instrument panel.
(2) Move the copper bus bar forward together with
the remaining circuit-breakers.
(3) Connect the wires to the circuit breaker. Refer to Chapter 92 for the Wiring
Diagrams.
(4) Install the screw which attaches the circuit-
breaker to the copper bus bar.
(5) Install the nuts and washers which attach the
circuit-breakers to the instrument panel.
(6) Install the instrument panel cover. Refer to Section 25-10.
(7) Connect the main battery. Refer to Section 24-31. Connect the
positive cable first.
(8) Connect the ECU backup battery. Refer to Section 24-31. Connect the
positive cable first.
(9) Install the baggage extension and baggage tray. Refer to Section 25-10.
(10) Do a functional test of the circuit-breaker:
S Set the ELECTRIC MASTER key switch to
ON.
S Operate the electrical system related to the Apply the full electrical load to the
circuit-breaker you will test. system.
S Pull the circuit-breaker. The system must stop operating. Make
sure there is no power to the system.
S Close the circuit-breaker.
S Set the ELECTRIC MASTER key switch to
OFF.
Page 204 Doc # 6.02.15
15 Apr 2013 24-60-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
5. Remove /Install an Instrument Panel Switch
This procedure applies to the following switches:
) PITOT.
) LANDING, TAXI, POSITION and STROBE lights.
) ESS. BUS.
) AVIONIC MASTER.
) FUEL TRANS ».
A. Remove an Instrument Panel Switch
Detail Steps/Work Items Key Items/References
(1) Remove the baggage extension and baggage Refer to Section 25-10.
tray.
(2) Disconnect the battery: Refer to Section 24-31.
S Disconnect the negative cable from the
battery.
S Disconnect the positive cable from the
battery.
(3) Remove the instrument panel cover. Refer to Section 25-10.
(4) Disconnect the electrical cables from the switch
that you will remove.
(5) Remove the switch from the instrument panel:
S Press the locking clips at the side of the With your fingers from the back of the
switch to release the switch from the instrument panel.
instrument panel.
S Move the switch backwards through the
instrument panel and clear of the airplane.
Doc # 6.02.15 Page 205
Rev. 2 24-60-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
B. Install an Instrument Panel Switch
Detail Steps/Work Items Key Items/References
(1) Hold the spring clips on the switch compressed From the front of the instrument panel.
and put the switch in position in the instrument Make sure that the clips have expanded
panel. and that the switch is correctly located.
(2) Connect the electrical cables to the switch. Refer to Chapter 92 for the Wiring
Diagrams.
(3) Install the instrument panel cover. Refer to Section 25-10.
(4) Connect the main battery. Refer to Section 24-31. Connect the
positive cable first.
(5) Install the baggage extension and baggage tray. Refer to Section 25-10.
(6) Do a functional test of the switch:
S Set the ELECTRIC MASTER key switch to
ON.
S Set the switch that you have installed to ON. The system must operate correctly.
S Set the switch that you have installed to OFF. The system must switch off.
S Set the ELECTRIC MASTER key switch to
OFF.
Page 206 Doc # 6.02.15
15 Apr 2013 24-60-00 Rev. 2
DA 40 NG AMM Electrical Power
AIRCRAFT
6. Remove /Install the ENGINE Switch
A. Remove the ENGINE Switch
Detail Steps/Work Items Key Items/References
(1) Remove the baggage extension and baggage Refer to Section 25-10.
tray.
(2) Disconnect the battery: Refer to Section 24-31.
S Disconnect the negative cable from the
battery.
S Disconnect the positive cable from the
battery.
(3) Disconnect the ECU backup battery: Refer to Section 24-31.
S Disconnect the negative cable from the
battery.
S Disconnect the positive cable from the
battery.
(4) Remove the instrument panel cover. Refer to Section 25-10.
(5) Remove the nut and washers that attach the
switch.
(6) Move the switch towards the firewall. To give access to the electrical cable
connection on the switch.
(7) Disconnect the electrical cables from the
ENGINE MASTER switch.
(8) Remove the switch from the instrument panel.
Doc # 6.02.15 Page 207
Rev. 2 24-60-00 15 Apr 2013
Electrical Power DA 40 NG AMM
AIRCRAFT
B. Install the ENGINE Switch
Detail Steps/Work Items Key Items/References
(1) Put the switch in position adjacent to the switch
electrical cables.
(2) Connect the electrical cables to the switch. Refer to Chapter 92 for the Wiring
Diagrams.
(3) Push the switch into position in the instrument
panel.
(4) Install the washer and nut to the switch.
(5) Install the instrument panel cover. Refer to Section 25-10.
(6) Connect the main battery. Refer to Section 24-31. Connect the
positive cable first.
(7) Connect the ECU backup battery. Refer to Section 24-31. Connect the
positive cable first.
(8) Install the baggage extension and baggage tray. Refer to Section 25-10.
(9) Do an engine ground run-up. All engine systems and the alternator
must operate correctly.
Page 208 Doc # 6.02.15
15 Apr 2013 24-60-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
CHAPTER 25
EQUIPMENT/FURNISHINGS
Doc # 6.02.15 Page 1
Rev. 2 25-TITLE 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 25-TITLE Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 25
EQUIPMENT/FURNISHINGS - GENERAL
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 25-10
Flight Compartment
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Pilot’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install a Pilot's Seat Access Panel (if installed) . . . . . . . . . . . . . . . . . . 203
4. Remove/Install the Access Panel of the Passenger Seat (if installed) . . . . . . . . 204
5. Remove/Install the Access Panel in the Baggage Extension . . . . . . . . . . . . . . . 205
6. Remove/Install the Baggage Extension and Baggage Tray . . . . . . . . . . . . . . . . 206
7. Remove/Install the Short Baggage Extension and Baggage Tray (OÄM 40-331 is
installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8. Remove/Install the Passenger Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
9. Remove/Install a Safety Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
10. Remove/Install the Instrument Panel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
11. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Doc # 6.02.15 Page 1
Rev. 2 25-CONTENTS 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
Section 25-60
Emergency
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Replace the ELT Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5. Remove/Install the RCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6. ELT Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Page 2 Doc # 6.02.15
15 Apr 2013 25-CONTENTS Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
CHAPTER 25
EQUIPMENT/FURNISHINGS - GENERAL
1. General
This Chapter tells you about the equipment and furnishing in the flight compartment. Section 25-10
includes the cabin trim panels, pilots' seats, passenger’s seat and safety belts. Section 25-60 gives
the data for the Emergency Location Transmitter (ELT).
Note: Equipment which is certified for installation in the DA 40 NG is listed in Section 6.5
of the Airplane Flight Manual. Such equipment may be installed in accordance with
the Airplane Maintenance Manual.
Any equipment which is not listed in Section 6.5 of the Airplane Flight Manual is
called "Additional Equipment". The installation of Additional Equipment is a
modification which must be handled in accordance with national regulations or a
Service Bulletin.
Doc # 6.02.15 Page 1
Rev. 2 25-00-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 25-00-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
Section 25-10
Flight Compartment
1. General
The flight compartment contains fixed seats for two pilots and two passengers. Each seat has a safety
belt. The fuselage shell has fabric wall panels. Carpets cover the floor areas and baggage
compartment floor. Map pockets are located on the cockpit side by each pilot.
The extended baggage compartment consists of the standard baggage compartment behind the rear
seats and the optional baggage extension mounted in the rear bulkhead.
GFRP moldings make the instrument panel cover and the center console. See Section 25-60 for data
about the ELT.
2. Description and Operation
A. Pilots' Seats
Figure 1 shows the pilot's seat installation. Each pilot’s seat is a GFRP/Carbon/Kevlar molding.
Rivets attach a metal plate to the bottom of the seat pan at the back. Two bolts go through the
seat pan and the metal plate to hold the lap straps of the safety belt. These bolts also hold
metal anchor plates which attach to anchor nuts in the large cut-out in the front main bulkhead.
The front of the seat pan curves down to locate over the rear wall of the floor panel. Two bolts
with washer plates attach the front of the seat to the floor panel.
A padded seat cushion covers the GFRP/Carbon/Kevlar molding. Press-studs attach the
forward part of the seat cushion to the seat pan. A flexible gaiter attaches to the seat pan with
press-studs. The control stick passes through the gaiter. A velcro seals the top of the gaiter to
the stick.
Doc # 6.02.15 Page 1
Rev. 2 25-10-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
Gaiter for
Control Stick
Bolt
Washer
Anchor Plate
Press Studs for
Seat Cushion Washer
Bolt
Inner Crash
Element
Front Main
Bulkhead
Outer Crash
Rear Face of the Element
Floor Panel
Figure 1: Pilot’s Seat Installation
Page 2 Doc # 6.02.15
15 Apr 2013 25-10-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
Bolt
Washer Bolt
Washer
Bolt
Washer
Crash
Element
Anchor Plate
Rear Main Bulkhead
Figure 2: Passenger Seat Installation
Doc # 6.02.15 Page 3
Rev. 2 25-10-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
B. Passenger Seat
Figure 2 shows the passenger seat installation. The passenger seat has three main parts. It has
a double seat pan which is the full width of the cockpit. The rear part of the seat pan also makes
the baggage compartment floor. The passenger seat also has two seat-backs which attach to the
seat pan with hinges. A latch pin at the left side of each seat-back locks the seat-back in the upright
position. You can lift the latch to fold the seat-back forward for access to the baggage compartment.
A padded seat cushion covers the GFRP/Carbon/Kevlar molding. Press-studs attach the forward
part of the seat cushion to the seat pan. Padded cushions also cover the seat-backs.
Rivets attach a metal plate under each half of the seat pan at the back. Two bolts go through each
half of the seat pan and the metal plate to hold the lap straps of the safety belt. Three bolts with
washer plates on each side of the seat pan go through the seat pan and metal plate to anchor nuts
in metal anchor plates. The anchor plates are bolted to the fuselage structure. Two bolts with
washer plates attach the front of the seat pan to ribs on top of the rear main bulkhead. Five bolts
with washer plates attach the rear of the seat pan to the top face of the baggage compartment
frame.
C. Crash Elements
Each seat rests on crash elements. Each crash element has layers of carbon fiber composite and
a special rigid foam bonded together. The crash elements compress under the high loads which
occur in accidents. They reduce the injury to the pilot or passenger in an accident.
The rear of each pilot’s seat rests on two crash elements. They are located just outboard of the
safety belt attachments. The passenger seat pan rests on two crash elements. They are located
under the anchor plates on each side.
Page 4 Doc # 6.02.15
15 Apr 2013 25-10-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
Figure 3: Safety Belt Installation
Doc # 6.02.15 Page 5
Rev. 2 25-10-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
D. Safety Belts
Figure 3 shows the safety belt installation. Each seat has a fixed lap belt and an inertia sensitive
shoulder strap. The lap belt has two straps. The outboard strap has an adjuster to tighten the belt
in use. It also has a tongue to engage the buckle on the inboard belt. The inboard strap has a fixed
length. The buckle has a button at the outboard end to release the tongue of the outboard lap strap.
Push the tongue into the end of the buckle to lock them together.
Bolts with washer plates and self-locking nuts attach each lap strap to the seat pan. You must
remove the seat to remove the lap belt.
The shoulder strap attaches to an inertia reel. The inertia reel has a latch which senses
acceleration. With the airplane flying straight and level, the inertia reel lets the shoulder strap pull
out against a light spring. If the airplane is accelerated (for example in turbulence), the latch stops
the shoulder strap from pulling out.
The inertia reel for the pilot’s safety belt is located on the fuselage wall behind the pilot’s seat. The
strap passes up through a guide attached to the roll-bar just above the pilot’s shoulder and down
to the tongue on the outboard lap strap. The end fitting on the shoulder strap hooks onto a stud on
the tongue.
The inertia reel for the rear passenger's safety belt is located above and to the rear of the
passengers. It is on the fuselage top-inner surface.
E. Fabric Wall Panels
Fabric wall panels bond to the inside of the fuselage shell. Each front panel has a map pocket.
F. Instrument Panel Cover
A GFRP cover goes over the instrument panel. Screws attach the cover to the instrument panel.
The instrument panel cover has a defrost manifold. Two hoses connect the defrost manifold to the
cabin heating system. The manifold supplies warm air to the front of the canopy to prevent misting.
G. Center Console Panel
A GFRP panel goes between the rear wall of the floor panel and the front face of the front main
bulkhead. The center console panel covers the trim mechanism. It also seals the gap between the
pilots' seats.
Page 6 Doc # 6.02.15
15 Apr 2013 25-10-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
H. Baggage Extension and Baggage Tray
Baggage extension and baggage tray are optional equipment.
The baggage extension has a door that may be hinged up to keep items from sliding aft or hinged
down to carry long items. The baggage extension also has a removable panel in the bottom to allow
access for inspection of the rear fuselage area.
The baggage tray may be installed in the bottom of the standard baggage compartment. The lid
of the baggage tray and the bottom of the baggage extension form a flat loading surface. The lid
has mounting provisions for the tow bar. The space under the lid may be used to carry small items
such as the gust lock and the fuel quantity measuring device.
If OÄM 40-331 is installed, a short baggage extension is installed.
Doc # 6.02.15 Page 7
Rev. 2 25-10-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 8 Doc # 6.02.15
15 Apr 2013 25-10-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove/install the seats, the safety belts and other
furnishings. See Section 25-60 for data about the ELT.
2. Remove/Install a Pilot’s Seat
Note: Some maintenance procedures described in this AMM require the removal of a
front seat. However, if the maintenance hole in the seat gives sufficient access to
the system beneath it, it is acceptable to leave the seat in place and remove only
the maintenance access panel. Refer to Paragraph 3.
A. Remove a Pilot’s Seat
Detail Steps/Work Items Key Items/References
(1) Release the velcro at the top of the gaiter for the Refer to Figure 1.
control stick.
(2) Release the press-studs at the front of the seat Move the cushion back far enough to
cushion. give access to the attaching bolts for
the seat.
(3) Remove the 2 bolts with washer plates which From the passenger compartment
attach the anchor plates to the front main behind the pilot’s seat.
bulkhead.
(4) Remove the 2 bolts with washer plates which
attach the front of the seat to the rear wall of the
floor panel.
(5) Remove the lap belt from the seat.
(6) Lift the seat forward and up out of the cockpit. Take care that the stick gaiter does not
catch on the top of the stick.
Doc # 6.02.15 Page 201
Rev. 2 25-10-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
B. Install a Pilot’s Seat
Detail Steps/Work Items Key Items/References
(1) Examine the crash elements. Look specially for Refer to Figure 1.
delamination and buckling.
(2) Do a check for unwanted items in the area below For example: tools.
the seat.
(3) Put the seat in position so that the anchor plates Make sure that the stick gaiter does not
go through the large hole in the front main catch on the stick top.
bulkhead.
(4) Install the bolts with washer plates which attach Torque: 6.4 Nm (4.7 lbf.ft.).
the seat to the floor panel.
(5) Install the bolts with washer plates which attach From the passenger compartment
the anchor plates to the front main bulkhead. behind the pilot’s seat.
Torque: 16 Nm (11.8 lbf.ft.).
(6) Fasten the press-studs which attach the seat
cushion.
(7) Tighten the velcro at the top of the stick gaiter. Make sure that the aileron and elevator
controls are free to move throughout
their range.
Page 202 Doc # 6.02.15
15 Apr 2013 25-10-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
3. Remove/Install a Pilot's Seat Access Panel (if installed)
A. Remove a Pilot's Seat Access Panel
Detail Steps/Work Items Key Items/References
(1) Remove the cloth coating from the seat.
(2) Remove the 12 (10) bolts which attach the
access panel to the seat.
(3) Move the access panel clear of the airplane.
B. Install a Pilot's Seat Access Panel
Detail Steps/Work Items Key Items/References
(1) Move the access panel in place in the seat.
(2) Install the 12 (10) bolts which attach the access
panel to the seat.
(3) Fasten the cloth coating on the seat.
Doc # 6.02.15 Page 203
Rev. 2 25-10-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
4. Remove/Install the Access Panel of the Passenger Seat (if installed)
A. Remove the Passenger Seat Access Panel
Detail Steps/Work Items Key Items/References
(1) Remove the cloth coating from the passenger
seat.
(2) Remove the 12 fixing bolts of the access panel.
(3) Remove the access panel.
B. Install the Passenger Seat Access Panel
Detail Steps/Work Items Key Items/References
(1) Put the access panel in place on the passenger
seat.
(2) Install the access panel with the12 fixing bolts.
(3) Fasten the cloth coating on the passenger seat.
Page 204 Doc # 6.02.15
15 Apr 2013 25-10-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
5. Remove/Install the Access Panel in the Baggage Extension
A. Remove the Access Panel in the Baggage Extension
Detail Steps/Work Items Key Items/References
(1) Fold rear seat-backs forward.
(2) Peel back each side of baggage extension carpet Carpet is held with velcro.
to expose 1/4-turn fasteners.
(3) Release the four 1/4-turn fasteners holding the
access panel to the baggage extension.
(4) Release latch holding baggage tray lid (if fitted).
(5) Remove access panel from baggage extension.
B. Install the Access Panel in the Baggage Extension
Detail Steps/Work Items Key Items/References
(1) Do a check for unwanted items in the area below For example: tools.
the access panel.
(2) Put access panel in position in baggage Make sure that baggage tray lid latch
extension. fits to baggage tray, if fitted.
(3) Engage latch which holds baggage tray lid (if
fitted).
(4) Fasten the four 1/4-turn fasteners on the baggage Latch baggage tray lid, if fitted.
extension.
(5) Fasten baggage extension carpet.
Doc # 6.02.15 Page 205
Rev. 2 25-10-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
6. Remove/Install the Baggage Extension and Baggage Tray
A. Remove the Baggage Extension and Baggage Tray
Detail Steps/Work Items Key Items/References
(1) Remove access panel. Refer to Paragraph 4A.
(2) Release 4 screws with washers which attach the
front of the baggage tray (if fitted) to the rear
seats.
(3) Release the 2 screws with washers which attach
the rear of the tray (if fitted) to the baggage
bulkhead.
(4) Remove the upholstery pieces which cover the Attached with velcro.
sides of the baggage bulkhead.
(5) Release the four 1/4-turn fasteners which attach
the baggage extension to the baggage bulkhead.
(6) Remove the baggage extension from the airplane. Do not damage the upholstery.
B. Install the Baggage Extension and Baggage Tray
Detail Steps/Work Items Key Items/References
(1) Do a check for unwanted items in the area below For example: tools.
the baggage extension.
(2) Put the baggage extension in place in the Do not damage the upholstery.
baggage bulkhead.
(3) Fasten the four 1/4-turn fasteners which attach
the baggage extension to the baggage bulkhead.
(4) Install the upholstery pieces which cover the sides Attached with velcro.
of the baggage bulkhead.
(5) Put the baggage tray (if fitted) in place on the
baggage floor.
(6) Fasten the 4 screws with washers that attach the Torque: 3.6 Nm (2.7 lbf.ft.).
front of the baggage tray to the rear seat base.
(7) Fasten the 2 screws with washers that attach the Torque: 3.6 Nm (2.7 lbf.ft.).
rear of the baggage tray to the baggage bulkhead.
(8) Install the access panel. Refer to Paragraph 4A.
Page 206 Doc # 6.02.15
15 Apr 2013 25-10-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
7. Remove/Install the Short Baggage Extension and Baggage Tray (OÄM 40-331 is installed)
A. Remove the Short Baggage Extension and Baggage Tray
Detail Steps/Work Items Key Items/References
(1) Remove access panel. Refer to Paragraph 4A.
(2) Release 4 screws with washers which attach the
front of the baggage tray to the rear seats.
(3) Release the 2 screws with washers which attach
the rear of the tray to the baggage bulkhead.
(4) Remove the upholstery pieces which cover the Attached with velcro.
sides of the baggage bulkhead.
(5) Open the baggage tray and unplug the electrical
connectors of the cabin fan (if installed).
(6) Release the seven 1/4-turn fasteners which attach
the short baggage extension to the baggage
bulkhead.
(7) Remove the short baggage extension from the Do not damage the upholstery.
airplane.
Doc # 6.02.15 Page 207
Rev. 2 25-10-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
8. Remove/Install the Passenger Seat
A. Remove the Passenger Seat
Detail Steps/Work Items Key Items/References
(1) Release the press-studs at the front of the seat Refer to Figure 2. Move the cushion
cushion. back far enough to give access to the
attaching bolts for the seat.
(2) Remove the 6 bolts with washer plates which
attach the seat pan to the anchor plates.
(3) Remove the 2 bolts with washer plates which
attach the front of the seat pan to the rib on top of
the rear main bulkhead.
(4) Fold the seat-backs forward. Lift the release catch at the left side of
each seat-back.
(5) Remove the 5 bolts with washer plates which
attach the rear of the seat pan to the baggage
compartment frame.
(6) Remove the two seat belt attach points in center
section of the seat.
(7) Lift the seat forward and up out of the cockpit.
Page 208 Doc # 6.02.15
15 Apr 2013 25-10-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
B. Install the Passenger Seat
Detail Steps/Work Items Key Items/References
(1) Examine the crash elements. Look specially for Refer to Figure 2.
delamination and buckling.
(2) Do a check for unwanted items in the area below For example: tools.
the seat.
(3) Put the seat in position in the fuselage with the Lift the release catch at the left side of
seat-backs folded forward. each seat-back.
(4) Attach seat belt fastener to center section of seat.
(5) Install the 5 bolts with washer plates which attach Torque: 6.4 Nm (4.7 lbf.ft.).
the rear of the seat pan to the baggage
compartment frame.
(6) Install the 6 bolts with washer plates which attach Torque: 16 Nm (11.8 lbf.ft.).
the seat pan to the anchor plates.
(7) Install the 2 bolts with washer plates which attach Torque: 6.4 Nm (4.7 lbf.ft.).
the front of the seat pan to the rib on top of the
rear main bulkhead.
(8) Fasten the press-studs which hold the seat
cushion.
Doc # 6.02.15 Page 209
Rev. 2 25-10-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
9. Remove/Install a Safety Belt
This procedure applies to the pilots' seats and the passenger seat.
A. Remove a Safety Belt
Detail Steps/Work Items Key Items/References
(1) Remove the seat. Refer to Paragraph 2 or 3.
(2) Remove the self-locking nuts, washer plates and Refer to Figure 3.
bolts which attach the straps to the seat.
For the pilots' seats only:
S Make a note of the position of the
anchor plates which these bolts
also hold.
(3) Move the straps through the holes in the seat pan
and remove them.
(4) Release the bolt and washer which attach the
inertia reel and its cover to the structure.
(5) Release the bolt, washer plate and spring washer For the pilots' seats only:
which attach the guide to the roll-bar.
S Make a note of the position of the
washers.
(6) Remove the shoulder strap.
Page 210 Doc # 6.02.15
15 Apr 2013 25-10-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
B. Install a Safety Belt
Detail Steps/Work Items Key Items/References
(1) Install the bolt and washer which attach the inertia Refer to Figure 3.
reel and its cover to the structure.
(2) Install the bolt, washer plate and spring washer For the pilots' seats only.
which attach the guide to the roll-bar.
(3) Put the lap straps through the holes in the seat The buckle goes to the inboard side of
pan. the pilots' seats (front) and the outboard
side of the passenger seat (rear).
(4) Put the lap straps between the seat pan and the
metal plate. Install the bolts with washer plates
from the top of the seat pan.
(5) Put the anchor plates in position on the bolts. For the pilots' seats only.
(6) Install washer plates and self-locking nuts on the Torque: 16 Nm (11.8 lbf.ft.).
bolts.
(7) Install the seat. Refer to Paragraph 2 or 3.
Doc # 6.02.15 Page 211
Rev. 2 25-10-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
10. Remove/Install the Instrument Panel Cover
A. Remove the Instrument Panel Cover
Detail Steps/Work Items Key Items/References
(1) Remove the screws which attach the instrument
panel cover to the instrument panel and the
fuselage.
(2) Lift the cover far enough to give access to the
defrost hoses.
(3) Loosen the hose clamps on the defrost hoses.
Remove the hoses from the cover.
(4) Lift the cover clear of the airplane.
B. Install the Instrument Panel Cover
Detail Steps/Work Items Key Items/References
(1) Do a check for unwanted items in the area For example: tools.
between the firewall and the instrument panel.
(2) Put the instrument panel cover in position just
above the instrument panel.
(3) Connect the defrost hoses to the cover.
(4) Tighten the hose clamps on the defrost hoses.
(5) Lower the cover into position on the instrument
panel.
(6) Install the attaching screws.
Page 212 Doc # 6.02.15
15 Apr 2013 25-10-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
11. Cleaning
A. Seats
The seat cushions are made from a fire-resistant material. Clean the cushions with a vacuum
cleaner. Use a mild soap solution to remove stains. Make sure that the area is well ventilated after
cleaning to remove all moisture.
B. Safety Belts
Use a mild soap solution to remove stains from the safety belts.
Doc # 6.02.15 Page 213
Rev. 2 25-10-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 214 Doc # 6.02.15
15 Apr 2013 25-10-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
Section 25-60
Emergency
1. General
This Section tells you about the optional Emergency Location Transmitter (ELT) Artex ME 406. It also
tells you about the Remote Control switch (RCS) for the Artex ME 406. Refer to the manufacturer's
Operator’s Manual for more data.
2. Description
A. ELT Equipment
(1) Location
The ME 406 is located in the rear fuselage, below the aft baggage compartment. A velcro strap
attached to a mounting bracket holds the ME 406 in position. The ELT antenna is mounted on
a bracket in the aft fuselage, above the ELT. A Remote Control switch (RCS) is mounted on the
instrument panel, right side.
(2) Signal Transmission
The ME 406 transmit signals automatically after a crash on the emergency frequencies of 121.5
% and 406 Megahertz (MHz). Every 50 seconds the transmitter transmits a signal on the 406 MHz
frequency to a satellite. The signal to the satellite contains the serial number of the ELT
transmitter or the airplane ID, a country code and a unique identity code. The satellite will also
give the emergency services a more accurate location for the airplane.
(3) Functional Test
Do regular functional tests (see the Maintenance Practices in this Section).
Doc # 6.02.15 Page 1
Rev. 2 25-60-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
B. ELT Batteries
The ELT has its own battery pack to supply electrical power. When the ELT is ON and transmitting
the batteries will keep the ELT transmitting until battery power is gone on the 121.5 MHz frequency
% and for up to 24 hours on the 406 MHz frequency.
It is important to monitor the battery expiry dates for the battery pack. The expiry date for the battery
pack is shown on the identity plate for the transmitter. The battery pack must be replaced:
) After use in an emergency.
) After the transmitter has been accidentally switched ON for an unknown period of time.
) After 1 hour of accumulated use (testing).
) On or before the battery pack expiry date.
You must do regular functional tests. Refer to the Maintenance Practices in this Section.
Page 2 Doc # 6.02.15
15 Apr 2013 25-60-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
Panel Mounted Switch
LED Indicator
ARTEX
ELT
EMERGENCY USE ONLY
ON
ARM Remote Switch
TEST/RESET
PRESS ON
WAIT 1 SECOND
PRESS ARM
ELT Unit (Front View)
Main Switch LED Indicator
Antenna Connector
Electric Connector
Figure 1: ELT Artex ME 406
Doc # 6.02.15 Page 3
Rev. 2 25-60-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
3. Operation
A. ELT
The ELT has a switch with these two positions:
) ON.
) OFF/ARM.
The ON position is for ground test. When the airplane is in use the switch must be in the ARM
position.
(1) Emergency Operation
If the airplane crashes, then the accelerometer senses the crash. The accelerometer sets the
transmitter to ON. The transmitter transmits the international distress frequency and on
% 406 MHz. The battery in the ELT supplies power to the transmitter. The battery can operate the
ELT for at least 50 hours.
(2) Test
If you switch the RCS to ON, then the following occurs:
) A LED flashes in the RCS and the ELT unit.
) If you set the radio to 121.5 MHz, you can hear the audio sweep tone from the ELT.
B. Remote Control Switch (RCS)
The RCS is installed on the right side of the instrument panel and has a red LED to indicate the
activation of the ELT. When it is switched to ON it does a test of the ELT. When you switch it back
to ARM the switch stops the test of the ELT. The red LED flashes when you test the ELT. If a
problem has been detected the LED provides a coded signal following the initial 1 second pulse.
Page 4 Doc # 6.02.15
15 Apr 2013 25-60-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
Trouble-Shooting
1. General
If you find the trouble given in the Trouble column, do the Repair in column 3.
Trouble Possible Cause Repair
ELT does not operate on test. ELT batteries discharged. Replace the ELT batteries.
ELT defective. If the ELT batteries are
serviceable, then replace the
ELT.
Doc # 6.02.15 Page 101
Rev. 2 25-60-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 25-60-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to remove and install the ELT and the RCS. It tells you how to test the ELT
in the airplane. It also tells you how replace the batteries in the ELT. This Section also gives you the
periodic maintenance necessary to maintain the ELT equipment in a serviceable condition.
See the ELT manufacturer's Operator’s Manual for more data.
2. Remove/Install the ELT
A. Remove the ELT
Detail Steps/Work Items Key Items/References
(1) Remove the trim/cover from the front face of the Pull the rear seat-backs forward.
baggage compartment frame.
(2) Loosen the thumb screws on the end cap.
Pull the end cap away from the ELT unit.
Move the protective top cover up and backward
and remove.
(3) Disconnect the co-axial cable for the antenna at At the ELT.
the ELT BNC connector and all other cables.
(4) Release the velcro strap which hold the ELT in its
mounting and remove the ELT from the airplane.
WARNING: IF THE ELT IS MOVED TO A DIFFERENT AIRPLANE THAN WHICH
IT WAS ORIGINALLY REGISTERED WITH, THE ELT MUST BE
RE-REGISTERED AND THE PRODUCT LABEL RE-MARKED TO
INDICATE THE NEW PROGRAMMING AND/OR NEW COUNTRY OF
REGISTRY.
Doc # 6.02.15 Page 201
Rev. 2 25-60-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
Figure 2: Artex ME 406 ELT Installation
Page 202 Doc # 6.02.15
15 Apr 2013 25-60-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
B. Install the ELT
Detail Steps/Work Items Key Items/References
WARNING: IF THE ELT IS MOVED TO A DIFFERENT AIRPLANE THAN WHICH
IT WAS ORIGINALLY REGISTERED WITH, THE ELT MUST BE
RE-REGISTERED AND THE PRODUCT LABEL RE-MARKED TO
INDICATE THE NEW PROGRAMMING AND/OR NEW COUNTRY OF
REGISTRY.
(1) Move the ELT into position into its mounting. At an angle so that the locking ears at
the end opposite the direction-of-flight
arrow fit into the mounting tray locking
slots.
(2) Close and secure the velcro straps which hold
the ELT.
(3) Feed the coax cable through the hole in the end
cap and connect it to the ELT.
Fit the top cover onto the ELT unit. Ensure that the slots at the end of the
cover fit over the locking ears on the
Position the end cap and connector assembly
ELT prior to fitting cover onto the
onto the ELT and tighten the thumbscrews
connector end.
securely.
(4) Do a test for the correct operation of the ELT. Refer to Paragraph 3.
(5) Install the trim/cover to the front face of the
baggage compartment frame.
Doc # 6.02.15 Page 203
Rev. 2 25-60-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
3. ELT Functional Test
Note: Do this test only during the first 5 minutes of each hour. If you are at a location with
a control tower or other monitoring facility, tell them before you do the test.
Note: For maintenance done to FAR 91 (airplanes registered in the USA) an additional
functional test of the ELT is required. Refer to FAA Action Notice 8150.3 for more
data.
CAUTION: DO NOT ALLOW THE TEST DURATION TO EXCEED 5 SECONDS. THE
% ELT WILL TRANSMIT A 406 MHZ SIGNAL AFTER THE ELT IS ACTIVE
% FOR APPROXIMATELY 50 SECONDS. THE SATELLITE SYSTEM
CONSIDERS THIS TRANSMISSION TO BE A VALID DISTRESS
SIGNAL.
Detail Steps/Work Items Key Items/References
(1) Set the ELECTRIC MASTER key switch to ON.
(2) Set the AVIONIC MASTER switch to ON.
(3) Set the radio to receive on 121.5 MHz.
(4) Set the Remote Control switch to ON.
(5) Monitor the radio for 3 ELT sweep tones.
(6) Set the Remote Control switch to ARM. Pay special attention to the LED activity
upon entering the ARM (OFF)
condition.
If a problem is detected, the LED
provides a coded signal following the
initial 1 second pulse. Refer to the ELT
manufacturer's Operator’s Manual for
coded signals.
(7) Set the AVIONIC MASTER switch to OFF.
(8) Set the ELECTRIC MASTER key switch to OFF.
Page 204 Doc # 6.02.15
15 Apr 2013 25-60-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
4. Replace the ELT Batteries
You must only use a battery pack that is supplied by the equipment manufacturer.
Note: The battery pack contains components that are sensitive to static electricity. You
must take electro-static discharge precautions before doing work on the battery
pack.
Note: The battery pack is connected to the ELT by a short electrical cable assembly. You
must take care not to strain this cable when you separate the battery pack from the
ELT.
Detail Steps/Work Items Key Items/References
(1) Remove the ELT from the airplane ELT Refer to Paragraph 2.
mounting.
% Refer to the Artex Installation and Maintenance Manual for ME 406, Doc. No. 570-1600.
(2) Install the ELT in the airplane mounting and Refer to Paragraph 2.
attach the Battery Pack Replacement Date label
to the top surface of the ELT protective cover
where it can be easily seen.
(3) Record the details of the ELT battery pack
replacement date in the airplane log-book.
(4) Do a functional test of the ELT. Refer to Paragraph 3.
Doc # 6.02.15 Page 205
Rev. 2 25-60-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
5. Remove/Install the RCS
A. Remove the RCS
Detail Steps/Work Items Key Items/References
(1) Remove the instrument panel cover. Refer to Section 25-10.
(2) Disconnect the electrical cable from the rear of At the in-line connector.
the RCS.
(3) Remove the 4 screws which attach the RCS to
the instrument panel.
(4) Move the RCS forward and clear of the airplane.
B. Install the RCS
Detail Steps/Work Items Key Items/References
(1) Move the RCS into position in the instrument
panel.
(2) Install the 4 screws which attach the RCS to the
instrument panel.
(3) Connect the electrical cable to the rear of the At the in-line connector.
RCS.
(4) Install the instrument panel cover. Refer to Section 25-10.
(5) Do a functional test of the ELT system. Refer to Paragraph 3.
Page 206 Doc # 6.02.15
15 Apr 2013 25-60-00 Rev. 2
DA 40 NG AMM Equipment/Furnishings
AIRCRAFT
6. ELT Periodic Inspection
The ELT installation must be inspected at least once every 12 months to maintain serviceability.
Detail Steps/Work Items Key Items/References
(1) Examine the ELT and the ELT mounting tray,
look specially for:
S Security of the fasteners.
S Security of all mechanical assemblies.
(2) Examine the co-axial cable from the ELT to the
antenna. Look specially for:
S Cuts or abrasions to the outer sheath of the
co-axial cable.
(3) Disconnect the co-axial cable from the antenna
and the ELT.
Examine the connectors at each end of the
co-axial cable, the antenna and the ELT for
corrosion or damage.
Reconnect the co-axial cable.
(4) Examine the cable which connects the ELT to the
RCS. Look specially for:
S Cuts or abrasions to the outer sheath of the
cable.
(5) Read the expiry date of the system battery and Refer to Paragraph 4.
replace the battery if necessary.
Doc # 6.02.15 Page 207
Rev. 2 25-60-00 15 Apr 2013
Equipment/Furnishings DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 208 Doc # 6.02.15
15 Apr 2013 25-60-00 Rev. 2
DA 40 NG AMM Fire Protection
AIRCRAFT
CHAPTER 26
FIRE PROTECTION
Doc # 6.02.15 Page 1
Rev. 2 26-TITLE 15 Apr 2013
Fire Protection DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 26-TITLE Rev. 2
DA 40 NG AMM Fire Protection
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 26
FIRE PROTECTION - GENERAL
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Doc # 6.02.15 Page 1
Rev. 2 26-CONTENTS 15 Apr 2013
Fire Protection DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 26-CONTENTS Rev. 2
DA 40 NG AMM Fire Protection
AIRCRAFT
CHAPTER 26
FIRE PROTECTION - GENERAL
1. General
This Chapter tells you only about the fire extinguisher installed in the airplane. See the fire extinguisher
manufacturer's manual for more data about the extinguisher.
Note: Equipment which is certified for installation in the DA 40 NG is listed in Section 6.5
of the Airplane Flight Manual. Such equipment may be installed in accordance with
the Airplane Maintenance Manual.
Any equipment which is not listed in Section 6.5 of the Airplane Flight Manual is
called "Additional Equipment". The installation of Additional Equipment is a
modification which must be handled in accordance with national regulations or a
Service Bulletin.
2. Description
Figure 1 shows the installation of the fire extinguisher in the airplane. The fire extinguisher is located
behind the co-pilot's seat. Screws attach the extinguisher mounting bracket to the closing rib between
the front and the rear main bulkhead. The extinguisher uses a liquid gas which is non-toxic and does
not have a residue.
The only on-airplane maintenance is:
) Monitor the pressure indicator. It must show in the green sector.
) Make sure that the seal wire is not broken.
) Make sure that the extinguisher is correctly held in the mounting.
If the seal wire is broken, remove the extinguisher for weighing. Weight data is given on the label
attached to the extinguisher body.
You must replace the extinguisher (or return it to the manufacturer for repair):
) When the weight is incorrect.
) When the pressure is too low.
) When the extinguisher has been used.
) If the extinguisher is damaged.
) At the ‘Next Overhaul Date’ that is given on the label attached to the extinguisher body.
Doc # 6.02.15 Page 1
Rev. 2 26-00-00 15 Apr 2013
Fire Protection DA 40 NG AMM
AIRCRAFT
Release Lever
Safety Guard Pressure
Gauge Carry Handle
Seal Wire
Container
Nozzle
Screw
Washer
Nut Extinguisher
Mount
Figure 1: Fire Extinguisher Installation
Page 2 Doc # 6.02.15
15 Apr 2013 26-00-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
CHAPTER 27
FLIGHT CONTROLS
Doc # 6.02.15 Page 1
Rev. 2 27-TITLE 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 27-TITLE Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 27
FLIGHT CONTROLS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Push-Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Control Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Push-Rod Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install Bellcranks and Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Section 27-10
Flight Controls - Ailerons and Tabs
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Aileron Control System Test for Correct Range of Movement . . . . . . . . . . . . . . 202
3. Aileron Control System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Aileron Push-Rod Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5. Aileron Bellcrank and Lever Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Doc # 6.02.15 Page 1
Rev. 2 27-CONTENTS 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Section 27-20
Flight Controls - Rudder
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Rudder Control System Test for Correct Range of Movement . . . . . . . . . . . . . . 201
3. Rudder Control System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Remove/Install Rudder Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5. Rudder Control Cable and Yoke Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Section 27-30
Flight Controls - Elevator
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Elevator Control System Test for Correct Range of Movement . . . . . . . . . . . . . 201
3. Elevator Control System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Elevator Push-Rod Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5. Elevator Bellcrank and Lever Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Page 2 Doc # 6.02.15
15 Apr 2013 27-CONTENTS Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Section 27-38
Flight Controls - Elevator Trim
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Elevator Trim Control System Test for Correct Range of Movement . . . . . . . . . 201
3. Elevator Trim Control System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Section 27-39
Stall Warning System
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Stall Warning Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Procedure to Remove Water from the Stall Warning System . . . . . . . . . . . . . . . 203
4. Stall Warning Horn Classification Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Doc # 6.02.15 Page 3
Rev. 2 27-CONTENTS 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Section 27-50
Flight Controls - Flaps
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. Fail-Safe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Flap Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3. Test the Flap Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Adjust the Flap Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5. Flap Push-Rod Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
6. Flap Bellcrank and Lever Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Page 4 Doc # 6.02.15
15 Apr 2013 27-CONTENTS Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
CHAPTER 27
FLIGHT CONTROLS
1. General
This Section tells you about the operation and the adjustment of the flight controls. It also tells you
about the assembly of the flight controls. Refer to the related Section for the data on a specified
system.
This Section tells you how standard parts are used to make the flight controls for each system.
Note: Equipment which is certified for installation in the DA 40 NG is listed in Section 6.5
of the Airplane Flight Manual. Such equipment may be installed in accordance with
the Airplane Maintenance Manual.
Any equipment which is not listed in Section 6.5 of the Airplane Flight Manual is
called "Additional Equipment". The installation of Additional Equipment is a
modification which must be handled in accordance with national regulations or a
Service Bulletin.
2. Description
The DA 40 NG has the usual flight controls. An elevator attached to the horizontal stabilizer gives
longitudinal control. Ailerons attached to the trailing edge of each wing give lateral control. The rudder
attached to the vertical stabilizer gives yaw control. Flaps attached to the trailing edge of each wing
give extra lift for landing and for take-off.
The DA 40 NG has a control stick for each pilot. The pilot can set the elevator trim with a control wheel
in the center console.
Each pilot has a rudder pedal assembly. The assembly attaches to the cockpit floor. The pilot can
adjust the position of the rudder pedals with an adjuster handle on the rudder pedal assembly.
The pilot moves each primary control through a system of push-rods and bellcranks. Cables operate
the rudder. An electric actuator operates the flaps.
Doc # 6.02.15 Page 1
Rev. 2 27-00-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Fixed Fork-End Fitting
Welded into Place
Control Rod
Threaded End Fitting
Welded into Place
Safety Test Hole
Toothed Washer
Jam-Nut
Eye-End Fitting
with Spherical Bearing
Figure 1: Standard Push-Rod
Page 2 Doc # 6.02.15
15 Apr 2013 27-00-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
3. Push-Rods
The push-rods used in the DA 40 NG have standard end fittings. Also most rods use a standard
diameter tube. Only the length of the rods is special. Some rods have one fixed fork end and one
adjustable eye-end fitting. Other rods have two adjustable eye-end fittings.
Figure 1 shows an example of a standard push-rod. The rod has one adjustable end fitting. The end
fitting has an eye-end with a threaded shaft. The eye-end has a spherical bearing. A jam-nut on the
threaded shaft locks the eye-end in position. A toothed washer locks the nut. You can turn the eye-end
to adjust the length of the rod.
A steel tube connects the end fittings. A threaded insert is welded into the steel tube to take the
eye-end. A safety hole is drilled in the end of the steel tube with the adjustable end fitting. The safety
hole shows you if the installation of the eye-end to the insert in the steel tube is correct. If you can push
the safety wire through the hole to the other side, the eye-end installation is not correct. But, if you
cannot push the safety wire through the hole, the eye-end installation is correct.
A fixed fork-end is welded to the steel tube.
Refer to Maintenance Practices in this Section for the procedures for adjusting push-rods.
4. Control Rigging
The flight controls of the DA 40 NG have been designed to make correct rigging as easy as possible.
All levers and bellcranks have holes for rigging pins. The rigging pins lock the levers in the neutral
position.
Doc # 6.02.15 Page 3
Rev. 2 27-00-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 27-00-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to do procedures (such as push-rod adjustment) which
apply to all of the control systems.
2. Push-Rod Adjustment
WARNING: IF YOU DO AN ADJUSTMENT OF A PUSH-ROD, YOU MUST MAKE
SURE THAT THE PUSH-ROD IS STILL IN SAFETY. IF YOU DO NOT DO
THIS, THE PUSH-ROD CAN DISCONNECT. THIS CAN CAUSE DEATH
OR INJURY TO PERSONS.
Detail Steps/Work Items Key Items/References
(1) Release the bolt attaching the push-rod to the At the end with an adjustable end fitting.
lever or bellcrank.
(2) Loosen the jam-nut on the adjustable end fitting. Refer to Figure 1.
(3) Turn the eye-end to adjust the length of the rod. Turn clockwise to make the rod shorter.
Turn counter-clockwise to make the rod
longer.
(4) Do a test for safety of the eye-end. Push a piece The wire must not go through the hole
of lock-wire through the safety test hole. and out the other side.
(5) Tighten the jam-nut. Torque: 16 Nm (11.8 lbf.ft.).
(6) Put the end-fitting in position in the lever or
bellcrank.
(7) Install the bolt, washer and self-locking nut. Torque: 6.4 Nm (4.7 lbf.ft.). You must
always use a new self-locking nut.
(8) Do an inspection of the control that you have
adjusted.
S If necessary for your Airworthiness Authority,
do a second inspection of the control.
Doc # 6.02.15 Page 201
Rev. 2 27-00-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
3. Remove/Install Bellcranks and Levers
The DA 40 NG has standard attachments for bellcranks and levers in the flight control systems. Refer
to the tables at the end of each Section for access data. Refer to the Figures in the related Section for
the correct orientation.
A. Remove a Bellcrank or Lever
Detail Steps/Work Items Key Items/References
(1) Release the bolts attaching the push-rods to the
lever or bellcrank.
(2) Remove the pivot bolt from the lever or bellcrank.
(3) If necessary, remove the mounting bracket: Where you have access to both sides of
the attachment, bolts with washers and
S Remove the attaching bolts and washers.
nuts are used. In all other cases,
anchor-nuts are used.
B. Install a Bellcrank or Lever
Detail Steps/Work Items Key Items/References
(1) Put the mounting bracket in position. If removed.
Note: You must always use new self-locking nuts when installing control levers or
bellcranks. Do not use a self-locking nut more than once.
(2) Install the attaching bolts, washers and nuts. Torque: 6.4 Nm (4.7 lbf.ft.).
(3) Put the bellcrank or lever in position in the Make sure that the bushes and spacer
mounting bracket. are in position.
(4) Install the pivot bolt, washer and nut. Torque: 6.4 Nm (4.7 lbf.ft.).
(5) Install the bolts, washers and self-locking nuts Torque: 6.4 Nm (4.7 lbf.ft.).
which attach the push-rods.
(6) Do a test of the control system. Refer to the related Section.
(7) Do an inspection of the control that you have
installed or adjusted.
S If necessary for your Airworthiness Authority,
do a second inspection of the control.
Page 202 Doc # 6.02.15
15 Apr 2013 27-00-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Section 27-10
Flight Controls - Ailerons and Tabs
1. General
The DA 40 NG has two control sticks that operate the ailerons. The aileron control system uses
push-rods and bellcranks.
Figure 1 shows the aileron controls in the fuselage. Figure 2 shows the aileron controls in the wing.
Doc # 6.02.15 Page 1
Rev. 2 27-10-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Push Rod to Flap Torsion Tube
Right Wing
Balance Springs
Push Rod to
Left Wing
Rigging
Pin Hole
Rear Bellcrank
Push Rod from
Idler Lever
Rear Bulkhead
Front Bulkhead
Control
Bulkhead
Left Stick
Idler Lever Rigging
Rigging
Push Rod to Pin Hole Pin Hole
Right Stick
Front Bellcrank Push Rod to
Idler Lever
Push Rod to
Left Stick
Adjustable Aileron Stop
Rigging
Pin Hole
Torque Tube Assy
Rigging
Pin Hole
Control Stick Mounting Block
Figure 1: Aileron Controls in the Fuselage
Page 2 Doc # 6.02.15
15 Apr 2013 27-10-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
2. Description
The DA 40 NG has a control stick for each pilot for the aileron and elevator controls. Aileron push-rods
connect to the bottom of the control sticks. The push-rods connect to the aileron front bellcrank at the
control bulkhead. The front bellcrank at the control bulkhead connects to a short push-rod under the
center console.
The push-rod under the center console connects to an idler lever attached to the front main bulkhead.
A push-rod connects the idler lever to the rear aileron bellcrank on the rear face of the rear main
bulkhead.
The rear bellcrank connects to the two push-rods in the center section. Each rod connects to a long
push-rod in the wing.
Each long push-rod has three push-rod guides. The first push-rod guide attaches to the root rib. The
second attaches to the flap-control rib. A small rib holds the third push-rod guide. The two long
push-rods connect to the two aileron bellcranks, one in each wing.
Short push-rods connect the aileron bellcranks to the aileron horns. You can adjust the short push-rods
to move the range up or down.
The aileron stop which limits the stick movement to the right side (right aileron up, left aileron down)
is located left of the pilot's control stick (refer to Figure 1). The aileron stop which limits the stick
movement to the left side (left aileron up, right aileron down) is located right of the co-pilot's control
stick. Each aileron stop consists of a nut which is welded to the torque tube assembly, a bolt which is
held by that nut, and a jam-nut which secures the bolt.
Additional, non-adjustable stops are located in front of the leading edge of the LH and RH aileron.
Each stop consists of a GFRP block with rubber coating, bonded to the inside of the upper wing skin.
When the aileron is deflected fully downward, the aileron paddle is deflected fully upward and contacts
the stop.
Doc # 6.02.15 Page 3
Rev. 2 27-10-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Push Rod to
Right Wing Rigging Pin Hole
Push Rod to
Left Wing Wing Root Rib
Aileron Bellcrank 2
Guide Rollers
Guide Rollers
Flap Control Rib
Guide Rollers
Support Bracket Aileron
Rigging Pin Hole
Aileron Horn
Aileron Control Rib
Left Aileron Bellcrank LEFT SYSTEM SHOWN,
RIGHT SYSTEM OPPOSITE
Figure 2: Aileron Controls in the Wings
Page 4 Doc # 6.02.15
15 Apr 2013 27-10-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
3. Operation
If you move the control sticks to the left:
) The push-rods connected to the stick move to the right.
) The front bellcrank moves the push-rod below the center console to the rear.
) The push-rod below the center console moves the idler lever and second short push-rod to the
rear.
) The second short push-rod moves the rear bellcrank so that the long push-rods in the wing move
to the left.
) The left aileron bellcrank in the left wing moves the short push-rod attached to the left aileron horn
to the rear.
) The left aileron moves up.
) The push-rod in the right wing also moves to the left. It pulls the aileron bellcrank in the wing which
moves the push-rod attached to the right aileron horn forward.
) The right aileron moves down.
If you move the control sticks to the right:
) The left aileron moves down.
) The right aileron moves up.
Doc # 6.02.15 Page 5
Rev. 2 27-10-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 6 Doc # 6.02.15
15 Apr 2013 27-10-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have in the aileron control system. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair in the
Repair column.
Trouble Possible Cause Repair
Airplane moves about its Aileron push-rods need Adjust the aileron push-rods.
longitudinal axis in flight. adjusting.
Aileron controls stiff/catch. Bearings defective. Replace the defective eye-end.
Control rod guides defective. Replace the guides.
Push-rod bent. Replace the push-rod.
Doc # 6.02.15 Page 101
Rev. 2 27-10-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 27-10-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to do tests on the aileron control system. They also tell you
how to adjust the aileron control system. Refer to Paragraphs 4 and 5 for removal, installation and
access data on the push-rods and bellcranks. Refer to Section 57-60 to remove/install the ailerons.
WARNING: WHEN YOU DO WORK ON THE AIRPLANE CONTROLS, YOU MUST
MAKE SURE THE AREA AROUND THE CONTROLS/CONTROL
SURFACES ARE CLEAR OF PERSONNEL AND EQUIPMENT. IF YOU
DO NOT DO THIS, INJURY TO PERSONNEL AND DAMAGE TO
CONTROL SURFACES CAN OCCUR.
WARNING: WHEN YOU COMPLETE WORK ON THE CONTROLS, MAKE SURE
THAT YOU REMOVE ALL LOOSE ITEMS OR TOOLS FROM THAT
AREA. LOOSE ITEMS OR TOOLS CAN PREVENT FULL MOVEMENT OF
THE AIRPLANE CONTROLS. THIS CAN CAUSE DEATH OR INJURY TO
PERSONS.
Doc # 6.02.15 Page 201
Rev. 2 27-10-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
2. Aileron Control System Test for Correct Range of Movement
A. Equipment
Item Quantity Part Number
Control stick rigging pins. 2 -
Ruler. 1 Commercial.
B. Aileron Control Test Procedure
Note: Use a ruler to make all measurements at the aileron control surfaces. Make the
measurement between the top surface of the aileron, and the top surface of the
wing tip.
Detail Steps/Work Items Key Items/References
(1) Make a copy of the Control Surfaces Adjustment Refer to Section 06-00.
Report.
Use it to record the measurements.
(2) Remove the left pilot’s seat. Refer to Section 25-10.
(3) Install the control stick rigging pins: Refer to Figure 1.
S At the bottom of the left stick. To lock aileron movement.
S Through the left mounting bracket into the To lock elevator movement.
torque tube.
(4) Measure the distance between the trailing edge Record these measurements.
of each aileron and the trailing edge of the wing
The left aileron must align with the right
tip.
aileron.
(5) Remove the rigging pins from the following:
S The bottom of each control stick.
S The left stick mounting bracket.
Page 202 Doc # 6.02.15
15 Apr 2013 27-10-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Detail Steps/Work Items Key Items/References
WARNING: WHEN YOU DO WORK ON THE AIRPLANE CONTROLS, YOU MUST
MAKE SURE THE AREAS AROUND THE CONTROLS/CONTROL
SURFACES ARE CLEAR OF PERSONS/EQUIPMENT. IF YOU DO
NOT DO THIS, INJURY TO PERSONNEL AND DAMAGE TO
CONTROL SURFACES CAN OCCUR.
(6) Move the control stick fully to the left and hold it
against the stop.
(7) Measure the distance between the trailing edge Record the measurement.
of the left aileron and the trailing edge of the wing
The distance must be as shown in the
tip.
Control Surfaces Adjustment Report.
(8) Measure the distance between the trailing edge Record the measurement.
of the right aileron and the trailing edge of the
The distance must be as shown in the
wing tip.
Control Surfaces Adjustment Report.
(9) Move the control stick fully to the right and hold it
against the stop.
(10) Measure the angle between the trailing edge of Record the measurement.
the right aileron and the trailing edge of the wing
The distance must be as shown in the
tip.
Control Surfaces Adjustment Report.
(11) Measure the angle between the trailing edge of Record the measurement.
the left aileron and the trailing edge of the wing
The distance must be as shown in the
tip.
Control Surfaces Adjustment Report.
(12) Install the left pilot’s seat. Refer to Section 25-10.
Doc # 6.02.15 Page 203
Rev. 2 27-10-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
3. Aileron Control System Adjustments
If you cannot get the correct range of movement of the aileron control system, use this procedure to
adjust the system. Gust travel refers to the amount of travel remaining at the control surface with the
control stick held against the cockpit stop.
WARNING: IF YOU DO AN ADJUSTMENT OF A PUSH-ROD, YOU MUST MAKE
SURE THAT THE PUSH-ROD IS STILL IN SAFETY. IF YOU DO NOT DO
THIS, THE PUSH-ROD CAN DISCONNECT. THIS CAN CAUSE DEATH
OR INJURY TO PERSONS.
Item Quantity Part Number
Rigging pins. 3 -
Ruler. 1 Commercial.
A. Aileron Adjustment Procedure
Detail Steps/Work Items Key Items/References
(1) Remove these items for access:
S Pilots’ seats. Refer to Section 25-10.
S Passenger seat.
S Push-rod access panels under the center Refer to Section 52-40.
section.
S Aileron bellcrank access panels under each
wing.
(2) Install rigging pins in the following: Refer to Figures 1 and 2.
S The bottom of each control stick. To lock the stick to the torque tube.
S The left stick mounting bracket. To lock the elevator movement.
S The front bellcrank. On the control bulkhead.
S The idler lever. On the front main bulkhead.
S The rear bellcrank. On the rear main bulkhead.
S The left aileron bellcrank. In the wing.
S The right aileron bellcrank. In the wing.
Page 204 Doc # 6.02.15
15 Apr 2013 27-10-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Detail Steps/Work Items Key Items/References
Note: Keep the aileron rigging pins in position until you have completed the
adjustments. You can do the procedure with 3 rigging pins. Lock each lever or
bellcrank in sequence.
(3) If you cannot put a rigging pin into a lever or Refer to Section 27-00 for the push-rod
bellcrank, adjust the push-rods as necessary. adjustment procedure.
(4) Measure the distance between the trailing edge Record these measurements.
of each aileron and the trailing edge of the wing
The left aileron must align with the right
tip.
aileron.
(5) Remove the rigging pins from the following: Refer to Figures 1 and 2.
S The bottom of each control stick.
S The left stick mounting bracket.
S The front bellcrank. On the control bulkhead.
S The idler lever. On the front main bulkhead.
S The rear bellcrank. On the rear main bulkhead.
S The left aileron bellcrank. In the wing.
S The right aileron bellcrank. In the wing.
(6) Do the Aileron Control Test Procedure. Refer to Paragraph 2.
(7) If necessary, adjust the push-rods between the Refer to Section 27-00.
aileron bellcranks in the wing and the ailerons.
Adjust the rods to give the
measurements in the original Control
Surfaces Adjustment Report supplied
with the airplane.
Doc # 6.02.15 Page 205
Rev. 2 27-10-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(8) If necessary, adjust the aileron stop bolts in the Refer to Figure 1.
torque tube assembly:
S Release the jam-nut on the stop bolt.
S Adjust the stop bolt to give the correct range The aileron positions must be the
of movement. distances shown in the Control
Surfaces Adjustment Report.
(measured from the neutral position).
S Tighten the jam-nut on the stop bolt.
(9) Do an inspection of the controls that you have
adjusted.
S If necessary for your Airworthiness Authority,
do a second inspection of the controls.
(10) Install these items:
S Pilots’ seats. Refer to Section 25-10.
S Passenger seat.
S Push-rod access panels under the center Refer to Section 52-40.
section.
S Aileron bellcrank access panels under each
wing.
Page 206 Doc # 6.02.15
15 Apr 2013 27-10-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
4. Aileron Push-Rod Access
Aileron Push-Rod Remove/Install Access References
Between the control stick and the Pilots’ seats. Refer to Section 25-10.
bellcrank at the control bulkhead.
Between the bellcrank at the control Pilots’ seats. Refer to Section 25-10.
bulkhead and the idler lever at the
front main bulkhead.
Between the idler lever at the front Pilots’ seats. Refer to Section 25-10.
main bulkhead and the bellcrank at
Passenger seat.
the rear main bulkhead.
Between the bellcrank at the rear Passenger seat. Refer to Section 25-10.
main bulkhead. and the wing root
Center section access panels. Refer to Section 52-40.
rib.
Between the wing root rib and the Center section access panels. Refer to Section 52-40.
bellcrank in the left/right wing.
Aileron bellcrank access
panels under each wing.
Between the bellcrank in the Aileron bellcrank access Refer to Section 52-40.
left/right wing and the aileron. panels under each wing.
5. Aileron Bellcrank and Lever Access
Aileron Bellcrank/Lever Remove/Install Access References
Bellcrank at the control bulkhead. Pilots’ seats. Refer to Section 25-10.
Idler lever at the front main Pilots’ seats. Refer to Section 25-10.
bulkhead.
Bellcrank at the rear main bulkhead. Passenger seat. Refer to Section 25-10.
Bellcrank in the wing. Aileron bellcrank access Refer to Section 52-40.
panels under each wing.
Doc # 6.02.15 Page 207
Rev. 2 27-10-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 208 Doc # 6.02.15
15 Apr 2013 27-10-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Section 27-20
Flight Controls - Rudder
1. General
The DA 40 NG has the usual rudder control system. Each pilot has a rudder pedal assembly. The pilot
can adjust the pedal position. Control cables connect the pedal assembly to the rudder. A fixed trim
tab gives a small amount of adjustment to the rudder trim. You can only adjust the fixed trim tab on the
ground.
Doc # 6.02.15 Page 1
Rev. 2 27-20-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Rudder Lower Mounting-Bracket
Rudder Pedestal
Turnbuckles
Teflon Tubes which
Guide Cockpit Cables
Pulley
Fuselage Cables
with Guide Tubes
Yoke
Control Bulkhead
Co-Pilot's Rudder
Pedal Assembly Outboard Control Cable
Inboard Control Cable
Figure 1: Rudder Control System
Page 2 Doc # 6.02.15
15 Apr 2013 27-20-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
2. Description
The DA 40 NG has a set of rudder control pedals for each pilot. The pedal assembly can be adjusted.
Figures 1, 3, and 4 show you the rudder control system. Figure 2 shows you the rudder pedal
assembly.
The system has these parts:
) A rudder pedal assembly for each pilot at the front of the cockpit. The forward part of each pedal
connects to a brake master cylinder (refer to Section 32-40).
) An adjuster handle for each pilot, attached to the aft face of the rudder pedal assembly.
) A yoke (a “T”-shaped lever) assembly in the fuselage below the center console. The yoke attaches
to the bottom of the control bulkhead and to the fuselage shell.
) A rudder pedestal at the rear of the fuselage. The rudder lower mounting-bracket is attached to the
rudder leading edge. It connects the rudder to the rudder pedestal.
) Cable assemblies.
Six bolts attach each rudder pedal assembly to the cockpit floor. Each rudder pedal assembly has two
pedals. Each pedal has a lever and a foot pad. The pedal has an "S" shaped tube. The lower part of
the "S" shaped tube aligns with the pivot of the pedal. The upper part of the "S" shaped tube aligns
with the foot pad of the pedal.
Four control cables ('cockpit cables') go from the firewall to enter the bottom of each "S" shaped tube.
A multi-hole fitting at the firewall gives adjustment for each cable. Each cable goes through an “S”
shaped tube and comes out at the top. Each cable goes from the pedal assembly to the yoke.
Each outboard control cable goes through a Teflon tube in the aft face of the floor panel. Each
outboard control cable goes inboard through a guide pulley on the control bulkhead. The cables
connect each outer pedal to the front arm of the yoke. Each inboard control cable goes through a
Teflon tube in the aft face of the floor panel. The cables connect each inner pedal to the side arms of
the yoke.
Two cable assemblies ('fuselage cables') attach to the rear of the yoke. Each cable assembly has a
short front cable and a long rear cable. All cables go through Teflon tubes. A turnbuckle connects the
front and rear cables. The turnbuckle can adjust the tension in the fuselage cables and the neutral
position of the rudder. The two fuselage cables go through Teflon tubes in the rear fuselage. The
cables attach to the rudder lower mounting-bracket. The cables cross over each other in the rear
fuselage.
Doc # 6.02.15 Page 3
Rev. 2 27-20-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Right Rudder Pedal
Brake Pedals
'S' Tube for
Control Cables Adjuster Handle
Brake Reservoir
(Co-Pilot only)
Brake Master Cylinder
Aft Attachment
Tension Springs to Floor Panel
Left Rudder Pedal
Adjuster Return Springs
'S' Tube for
Control Cables
Front Attachment Adjuster Cable
to Floor Panel
Rudder Control Cable
Roll-Pins
Multi-Hole Bracket
Sledge Tubes Adjuster Latch (Attachment for Cables)
Figure 2: Rudder Pedal Assembly
Page 4 Doc # 6.02.15
15 Apr 2013 27-20-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
The rudder stop which limits the rudder deflection to the left side is located left of the rudder lower
hinge (refer to Figure 4). The rudder stop which limits the rudder deflection to the right side is located
right of the rudder lower hinge. Each rudder stop consists of a nut which is welded to the rudder lower
mounting-bracket, a bolt which is held by that nut, and a jam-nut which secures the bolt.
3. Operation
If you move the left rudder pedal forward:
) The top of the "S" shaped tube moves forward.
) The "S" shaped tube pulls the left cockpit cable.
) The left cockpit cable moves the yoke counter-clockwise (seen from above).
) The yoke pulls the fuselage cable attached to its right arm forward. This cable connects to the left
of the rudder.
) The fuselage cable moves the rudder to the left.
) The rudder movement pulls the other fuselage cable aft. This cable connects to the left of the yoke.
) The fuselage cable moves aft with the left side of the yoke.
) The left side of the yoke pulls both of the right cockpit cables aft. And the cables pull the "S" shaped
tubes on the right rudder pedals aft.
If you move the right rudder pedal forward each part moves in the opposite sense. The rudder moves
to the right and pulls the left pedals aft.
You can adjust the position of the rudder pedals. When you pull on the adjuster handle, the latch
disengages from the bottom sledge tube. If you pull further, the pedal assembly moves along the
sledge tubes towards you. Release the handle, then push with your feet on both pedals. The latch will
lock.
If you push with both feet while you pull the handle, the pedal assembly moves along the sledge tubes
away from you. Release the handle, then push with your feet on both pedals. The latch will lock.
When you adjust the position of the pedals, the control cables move through the "S" shaped tubes.
Doc # 6.02.15 Page 5
Rev. 2 27-20-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
%
%
%
%
Bush
%
Left Inboard Cable Spacer
%
% Alternative Version Rigging
Pin Hole
%
%
% Control Bulkhead Mounting Bracket
%
% Fuselage Cables
Right Inboard Cable
%
% Control
Bulkhead Yoke Bush
%
Right Outboard Cable
% Left Inboard Cable
% Spacer
% Pulley
% Safety Plate Oetiker Clamp
% Left Outboard Plastic Washer
Cable
% Teflon Tube
%
% Pulley Assembly Yoke
Assembly Floor
% Panel
%
%
%
%
%
%
% Teflon Tube
%
% Co-Pilot's Rudder
Pedal Assembly Floor Panel
%
Outboard Control Cable
% Pilot's Rudder
Inboard Control Cable
% Pedal Assembly
Figure 3: Rudder Controls Installation in the Cockpit
Page 6 Doc # 6.02.15
15 Apr 2013 27-20-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have in the rudder control system. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair in the
Repair column.
Trouble Possible Cause Repair
Airplane moves about its yaw Rudder control cables need Adjust the rudder control
axis in flight. adjusting. cables.
Fixed trim tab needs adjusting. Adjust the fixed trim tab.
Rudder controls stiff/catch. Bearings defective. Replace the defective bearing.
Cables chafing in guide tubes. Replace the cables and guide
tubes.
Doc # 6.02.15 Page 101
Rev. 2 27-20-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
%
%
%
%
%
%
%
%
Rudder Lower
% Mounting Bracket
%
% Rudder Pedestal
% Spacer
% A
% Fuselage Cables Bush
% with Guide Tubes
% A Rudder Stop Bolt
% A
%
%
%
% Turnbuckles
Locking Clamps
%
%
%
%
% A
% A
%
Bush Fuselage Cables
% with Guide Tubes
%
Teflon Tube
% Plastic
Spacer Washer
%
% A
% Frame
% Oetiker
Clamp
%
Yoke Assembly on
% Control Bulkhead
%
Figure 4: Rudder Controls Installation in the Rear Fuselage
Page 102 Doc # 6.02.15
15 Apr 2013 27-20-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to do test procedures on the rudder control system. They
also tell you how to adjust the rudder control system. Refer to Section 55-40 to remove/install the
rudder.
WARNING: WHEN YOU DO WORK ON THE AIRPLANE CONTROLS, YOU MUST
MAKE SURE THAT THE AREAS AROUND THE CONTROLS/CONTROL
SURFACES ARE CLEAR OF PERSONS/EQUIPMENT. IF YOU DO NOT
DO THIS, INJURY TO PERSONS AND DAMAGE TO CONTROL
SURFACES CAN OCCUR.
WARNING: WHEN YOU COMPLETE WORK ON THE CONTROLS, MAKE SURE
THAT YOU REMOVE ALL LOOSE ITEMS/TOOLS FROM THAT AREA.
LOOSE ITEMS/TOOLS CAN PREVENT FULL MOVEMENT OF THE
AIRPLANE CONTROLS. THIS CAN CAUSE DEATH OR INJURY TO
PERSONS.
2. Rudder Control System Test for Correct Range of Movement
A. Equipment
Item Quantity Part Number
Ruler or deflection gauge. 1 Commercial.
Doc # 6.02.15 Page 201
Rev. 2 27-20-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
B. Rudder Control Test Procedure
Refer to Figure 1.
Detail Steps/Work Items Key Items/References
(1) Make a copy of the Control Surfaces Adjustment Refer to Section 06-00.
Report.
Use it to record the measurements.
(2) Set both rudder pedals fully forward.
WARNING: WHEN YOU DO WORK ON THE AIRPLANE CONTROLS, YOU MUST
MAKE SURE THE AREAS AROUND THE CONTROLS/CONTROL
SURFACES ARE CLEAR OF PERSONS/EQUIPMENT. IF YOU DO
NOT DO THIS, INJURY TO PERSONNEL AND DAMAGE TO
CONTROL SURFACES CAN OCCUR.
(3) Set the rudder pedals central. The left pedal must align with the right
pedal.
Make sure the rudder is in the neutral
position shown in the Control Surfaces
Adjustment Report for the airplane.
(4) Set the rudder pedals to fully left. The rudder must hit the stops at the
rudder pedestal.
The rudder position must be the
distance to the left shown in the Control
Surfaces Adjustment Report for the
airplane. (Measured from the neutral
position).
(5) Set the rudder pedals to fully right. The rudder must hit the stops at the
rudder pedestal.
The rudder position must be the
distance to the right shown in the
Control Surfaces Adjustment Report for
the airplane. (Measured from the
neutral position).
(6) Make sure the left and right rudder pedals are free
to move when they are set in all of the adjustable
positions.
Page 202 Doc # 6.02.15
15 Apr 2013 27-20-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
3. Rudder Control System Adjustments
If you cannot get the correct range of movement of the rudder control system, use this procedure to
adjust the system.
A. Equipment
Item Quantity Part Number
Cable tension gauge. 1 Commercial.
Ruler or deflection gauge. 1 Commercial.
B. Rudder Adjustment Procedure
Detail Steps/Work Items Key Items/References
(1) Remove these items for access: Section 25-10.
S The pilots’ seats.
S The passenger seat.
(2) Set both rudder pedals fully forward.
(3) Set the rudder pedals central. Make sure the rudder is in the neutral
position. The left pedal must align with
the right pedal.
(4) If necessary, adjust the length of the cables Refer to Figure 4.
between the yoke and the rudder lower mounting
bracket.
S Remove the lock-wire from the turnbuckles. Below the passenger seat.
S Adjust the turnbuckles to set the rudder to
neutral.
S Do a test for correct cable tension. Refer to the Adjustment Report.
S Tighten the turnbuckles and install the
lock-wire.
Doc # 6.02.15 Page 203
Rev. 2 27-20-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(5) Set the rudder pedals to fully left. The rudder must hit the stops at the
rudder pedestal.
The rudder position must be the
distance to the left shown in the Control
Surfaces Adjustment Report. (Measured
from the neutral position).
(6) If necessary, adjust the rudder stop bolt on the
left side of the rudder lower mounting-bracket:
S Release the jam-nut on the left stop bolt. The rudder position must be the
distance to the left shown in the Control
S Adjust the stop bolt to give the correct range
Surfaces Adjustment. (Measured from
of movement.
the neutral position).
S Tighten the jam-nut on the stop bolt.
(7) Set the rudder pedals to fully right. The rudder must hit the stops at the
rudder pedestal.
The rudder position must be the
distance to the right shown in the
Control Surfaces Adjustment Report.
(Measured from the neutral position).
(8) If necessary, adjust the rudder stop bolt on the
right side of the rudder lower mounting-bracket:
S Release the jam-nut on the right stop bolt.
S Adjust the stop bolt to give the correct range The rudder position must be the
of movement. distance to the right shown in the
Control Surfaces Adjustment Report.
S Tighten the jam-nut on the stop bolt.
(Measured from the neutral position).
(9) Do a test for the correct range of rudder Refer to Paragraph 2.
movement.
(10) Do an inspection of all the controls that you have
adjusted.
S If necessary for your Airworthiness Authority,
do a second inspection of the controls.
Page 204 Doc # 6.02.15
15 Apr 2013 27-20-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Detail Steps/Work Items Key Items/References
(11) Install these items: Refer to Section 25-10.
S The pilots’ seats.
S The passenger seat.
4. Remove/Install Rudder Control Cables
A. Equipment
Item Quantity Part Number
Cable tension gauge. 1 Commercial.
Swaging tool. 1 Commercial.
Nicopress oval & stop sleeve gauge ('go-no-go gauge') 1
for 1/8 inch sleeves.
B. Remove the Cockpit Rudder Control Cables (from the Firewall to the Yoke)
Detail Steps/Work Items Key Items/References
(1) Remove these items for access: Section 25-10.
S The pilots’ seats.
(2) Remove the cable between the firewall and the Refer to Figures 2 and 3.
yoke:
S Remove the nut, washer, bolt and spacer that
attach the cable to the multi-hole bracket at
the firewall.
S Remove the nut, washer, bolt, bush and
spacer that attach the cable to the yoke.
S Cut the eye-end from the old cable at the
firewall end.
S Remove the old cable.
Doc # 6.02.15 Page 205
Rev. 2 27-20-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
C. Install the Rudder Control Cables (from the Firewall to the Yoke)
Detail Steps/Work Items Key Items/References
WARNING: ONLY TRAINED AND AUTHORIZED PERSONS SHOULD INSTALL
CABLE EYE-ENDS. IF THE EYE-ENDS ARE NOT INSTALLED
CORRECTLY, THE RUDDER CONTROLS CAN FAIL. THIS CAN
CAUSE DEATH OR INJURY TO PERSONNEL.
Note: Install eye-ends in accordance with FAA AC 43.13-1B, Chapter 7, Section 8.
Note: To make the work easier, install an eye-end on one end of the cable before you
install it in the airplane.
(1) Install one new eye-end to the cable before you Use cables to specification LN9374 or
install it in the airplane: ISO 2020 or MIL-DTL-83420.
S Inspect the cable eye-end for correct Use Locoloc thimbles and Nico-Press
assembly. clamps appropriate to the installed
3.2 mm (1/8 inch) diameter steel cables.
Inspect cable swage with go-no-go
S If necessary for your Airworthiness
gauge for 1/8 inch Nicopress oval sleeve
Authority, send a sample for proof test.
in accordance with FAA AC 43.13-1B,
Chapter 7, Section 8.
(2) Push the control cable through the Teflon tubes Refer to Figure 3.
from the rear.
(3) Make sure the cable is in the correct position on
the pulley (for the outer cables only).
(4) Push the cable position through the "S" tube on
the rudder pedal assembly.
(5) Install a new eye-end to the cable at the firewall Use Locoloc thimbles and Nico-Press
end: clamps appropriate to the installed
3.2 mm (1/8 inch) diameter steel cables.
S Inspect the cable eye-end for correct Inspect cable swage with go-no-go
assembly. gauge for 1/8 inch Nicopress oval sleeve
in accordance with FAA AC 43.13-1B,
S If necessary for your Airworthiness Authority,
Chapter 7, Section 8.
send a sample for proof test.
Page 206 Doc # 6.02.15
15 Apr 2013 27-20-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Detail Steps/Work Items Key Items/References
(6) Install the cable to the yoke:
S Install the bolt, bush and spacer that attach
the cable to the yoke.
S Install a washer and self-locking nut. Torque to 6.4 Nm (4.7 lbf.ft.). Use a new
self-locking nut.
(7) Install the cable to the bracket at the firewall: Adjust the position of the bolt in the
multi-hole bracket to give the correct
S Install the bolt and spacer that attach the
rudder pedal position. The rudder pedal
cable to the bracket.
lever must be vertical when the rudder is
neutral.
Torque to 6.4 Nm (4.7 lbf.ft.). Use a new
S Install a washer and self-locking nut.
self-locking nut.
(8) Do a test for the correct range of rudder Refer to Paragraph 2.
movement. If necessary, adjust the rudder Refer to Paragraph 3.
controls.
(9) Do an inspection of all the controls that you
have adjusted.
S If necessary for your Airworthiness
Authority, do a second inspection of the
controls.
(10) Install these items: Refer to Section 25-10.
S The pilots’ seats.
S The passenger seat.
Doc # 6.02.15 Page 207
Rev. 2 27-20-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
D. Remove the Fuselage Rudder Control Cables (from the Yoke to the Rudder)
Detail Steps/Work Items Key Items/References
(1) Remove these items for access: Refer to Section 25-10.
S The pilots’ seats.
S The passenger seat.
(2) Remove the cable between the yoke and the Refer to Figure 4.
turnbuckle:
S Remove the nut, washer, bolt, bush and
spacer that attach the cable to the yoke.
S Cut the eye-end from the old cable at the
yoke.
S Remove the old cable aft.
S Cut the eye-end from the turnbuckle.
(3) Remove the cable between the turnbuckle and
the rudder:
S Remove the nut, washer, bolt, bush and
spacer that attach the cable to the rudder
lower mounting-bracket.
S Cut the eye-end from the old cable at the
rudder end.
S Remove the old cable forward.
S Cut the eye-end from the turnbuckle.
Page 208 Doc # 6.02.15
15 Apr 2013 27-20-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
E. Install the Fuselage Rudder Control Cables (from the Yoke to the Rudder)
Detail Steps/Work Items Key Items/References
WARNING: ONLY TRAINED AND AUTHORIZED PERSONS SHOULD INSTALL
CABLE EYE-ENDS. IF THE EYE-ENDS ARE NOT INSTALLED
CORRECTLY, THE RUDDER CONTROLS CAN FAIL. THIS CAN
CAUSE DEATH OR INJURY TO PERSONNEL.
Note: Install eye-ends in accordance with FAA AC 43.13-1B, Chapter 7, Section 8.
Note: To make the work easier, install an eye-end on one end of each cable before
you install them in the airplane.
(1) Install a new eye-end to the front cable at the Use cables to specification LN9374 or
yoke end before you install it in the airplane: ISO 2020 or MIL-DTL-83420.
S Inspect the cable eye-end for correct Use Locoloc thimbles and Nico-Press
assembly. clamps appropriate to the installed
3.2 mm (1/8 inch) diameter steel
cables.
S If necessary for your Airworthiness Authority, Inspect cable swage with go-no-go
send a sample for proof test. gauge for 1/8 inch Nicopress oval
sleeve in accordance with FAA AC
43.13-1B, Chapter 7, Section 8.
(2) Push the control cable through the Teflon tube Refer to Figure 4.
from the front. Through the front and rear main
bulkheads.
(3) Install a new eye-end to the cable at the Use Locoloc thimbles and Nico-Press
turnbuckle end: clamps appropriate to the installed
3.2 mm (1/8 inch) diameter steel cables
to specification LN9374.
S Inspect the cable eye-end for correct Inspect cable swage with go-no-go
assembly. gauge for 1/8 inch Nicopress oval
sleeve in accordance with FAA AC
S If necessary for your Airworthiness Authority,
43.13-1B, Chapter 7, Section 8.
send a sample for proof test.
Doc # 6.02.15 Page 209
Rev. 2 27-20-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(4) Install a new eye-end to the rear cable before you Use cables to specification LN9374 or
install it in the airplane: ISO 2020 or MIL-DTL-83420.
S Inspect the cable eye-end for correct Use Locoloc thimbles and Nico-Press
assembly. clamps appropriate to the installed
3.2 mm (1/8 inch) diameter steel cables
to specification LN9374.
S If necessary for your Airworthiness Authority, Inspect cable swage with go-no-go
send a sample for proof test. gauge for 1/8 inch Nicopress oval
sleeve in accordance with FAA AC
43.13-1B, Chapter 7, Section 8.
(5) Push the control cable through the Teflon tubes From the baggage frame to the rudder.
from the front.
(6) Install a new eye-end to the cable at the rudder Use Locoloc thimbles and Nico-Press
end: clamps appropriate to the installed
3.2 mm (1/8 inch) diameter steel cables
to specification LN9374.
S Inspect the cable eye-end for correct Inspect cable swage with go-no-go
assembly. gauge for 1/8 inch Nicopress oval
sleeve in accordance with FAA AC
S If necessary for your Airworthiness Authority,
43.13-1B, Chapter 7, Section 8.
send a sample for proof test.
(7) Install the cable to the rudder lower mounting- Refer to Figure 4.
bracket:
S Install the bolt, bush and spacer that attach
the cable to the rudder.
S Install a washer and self-locking nut. Torque to 6.4 Nm (4.7 lbf.ft.). Use a
new self-locking nut.
(8) Install the cable to the yoke: Refer to Figure 4.
S Install the bolt, bush and spacer that attach
the cable to the yoke.
S Install a washer and self-locking nut. Torque to 6.4 Nm (4.7 lbf.ft.). Use a
new self-locking nut.
(9) Adjust both left and right rudder cable Refer to Paragraph 3.
turnbuckles to give the correct tension.
Page 210 Doc # 6.02.15
15 Apr 2013 27-20-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Detail Steps/Work Items Key Items/References
(10) Do a test for the correct range of rudder Refer to Paragraph 2.
movement.
(11) Do an inspection of all the controls that you have
adjusted.
S If necessary for your Airworthiness Authority,
do a second inspection of the controls.
(12) Install these items: Refer to Section 25-10.
S The pilots’ seats.
S The passenger seat.
5. Rudder Control Cable and Yoke Access
Rudder Cable/Yoke Remove/Install Access References
Cockpit cables between the firewall Pilots’ seats. Refer to Section 25-10.
and the yoke.
Rear fuselage cables between the Pilots’ seats. Refer to Section 25-10.
yoke and the rudder.
Passenger seat.
Rudder. Refer to Section 55-40.
Yoke. Pilots’ seats. Refer to Section 25-10.
Doc # 6.02.15 Page 211
Rev. 2 27-20-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 212 Doc # 6.02.15
15 Apr 2013 27-20-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Section 27-30
Flight Controls - Elevator
1. General
The DA 40 NG has the usual elevator control system. An elevator attached to the horizontal stabilizer
gives longitudinal control. The two control sticks operate the elevator.
2. Description
Figure 1 shows the elevator controls in the cockpit. Figure 2 shows the elevator controls in the rear
fuselage.
Each pilot has a control stick that attaches to a torque tube assembly. The torque tube assembly has
a lever which attaches to a short push-rod. The short push-rod connects to an idler lever on the front
main bulkhead. The idler lever connects to a long push-rod.
The long push-rod has three guide bearings. The baggage frame, ring frame 1 and ring frame 2 have
push-rod guides. Each guide has three rollers.
The long push-rod attaches to a bellcrank at the bottom of the vertical stabilizer. The bellcrank
attaches to a vertical push-rod in the vertical stabilizer. The vertical push-rod connects to the elevator
horn.
The elevator stop for the downward movement consists of a GFRP block which is bonded to the inside
of the upper skin of the horizontal stabilizer. When the elevator is deflected fully downward, the forward
extension of the elevator horn is deflected fully upward and contacts the stop.
The elevator stop for the upward movement consists of a bolt/bush assembly which is installed in the
trim actuator mounting bracket in transverse direction (see Section 27-38, Figure 2). When the elevator
is deflected fully upward, the forward extension of the elevator horn is deflected fully downward and
contacts the stop.
You cannot adjust the elevator stops.
Doc # 6.02.15 Page 1
Rev. 2 27-30-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Front Main Bulkhead
Left Stick
Idler Lever Rigging
Pin Hole
Push Rod to
Idler Lever Rigging
Pin Hole
Elevator Lever
Torque Tube Assy
Control Stick Mounting Block
Figure 1: Elevator Control Installation in the Cockpit
Page 2 Doc # 6.02.15
15 Apr 2013 27-30-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
3. Operation
If you move the control stick forward:
) The torque tube assembly turns.
) The lever below the torque tube assembly pushes the short push-rod aft.
) The short push-rod pushes the long push-rod aft.
) The long push-rod pushes the bellcrank rearward.
) The bellcrank pushes the vertical push-rod up.
) The vertical push-rod moves the elevator horn.
) The elevator moves down.
If you move the control stick aft:
) The torque tube assembly turns.
) The short and long push-rods move forward.
) The bellcrank pulls the vertical push-rod down.
) The elevator moves up.
Doc # 6.02.15 Page 3
Rev. 2 27-30-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Earthing Strip
Balance Weight
Elevator Lever Rib
Elevator Actuating Lever
Large Washer
Collar Bush
Distance Bush
Elevator Push Rod
Elevator Bellcrank
Rigging
Pin Hole
Ring Frame 2
Ring Frame 1
Rigging
Pin Hole
Baggage Frame
Idler Lever
Elevator Push Rod
Idler Lever To Bellcrank
Figure 2: Elevator Controls Installation in the Rear Fuselage
Page 4 Doc # 6.02.15
15 Apr 2013 27-30-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have in the elevator control system. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair in the
Repair column.
Trouble Possible Cause Repair
Control vibration in the air. Too much backlash in the flight Examine the system to isolate
controls. the problem. Replace the
defective part.
Elevator controls stiff/catch. Bearings defective. Replace the defective eye-end.
Push-rod bent. Replace the push-rod.
Doc # 6.02.15 Page 101
Rev. 2 27-30-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 27-30-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to do test procedures on the elevator control system. And
they tell you how to adjust the elevator control system. Refer to Section 55-20 to remove/install the
elevator.
WARNING: WHEN YOU DO WORK ON THE AIRPLANE CONTROLS, YOU MUST
MAKE SURE THE AREAS AROUND THE CONTROLS/CONTROL
SURFACES ARE CLEAR OF PERSONS/EQUIPMENT. IF YOU DO NOT
DO THIS, INJURY TO PERSONS AND DAMAGE TO CONTROL
SURFACES CAN OCCUR.
WARNING: WHEN YOU COMPLETE WORK ON THE CONTROLS, MAKE SURE
THAT YOU REMOVE ALL LOOSE ITEMS/TOOLS FROM THAT AREA.
LOOSE ITEMS/TOOLS CAN PREVENT FULL MOVEMENT OF THE
AIRPLANE CONTROLS. THIS CAN CAUSE DEATH OR INJURY TO
PERSONS.
2. Elevator Control System Test for Correct Range of Movement
A. Equipment
Item Quantity Part Number
Rigging pin. 1 -
Ruler or deflection gauge. 1 Commercial.
Fuselage trestle. 1 Commercial.
B. Elevator Control Test Procedure
Note: If you use a deflection gauge, make sure that the airplane does not move in pitch
during the procedure. It will cause errors in the test.
Detail Steps/Work Items Key Items/References
(1) Make a copy of the Control Surfaces Adjustment Refer to Section 06-00.
Report.
Use it to record the measurements.
(2) If you will use a deflection gauge, put a trestle To prevent movement in pitch.
under the rear fuselage.
(3) Remove the left pilot’s seat. Refer to Section 25-10.
Doc # 6.02.15 Page 201
Rev. 2 27-30-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(4) Install the rigging pin through the stick mounting Refer to Figure 1.
block and the torque tube.
Note: Use a ruler or deflection gauge to make all measurements at the elevator
control surface. Make the measurement between the top surface of the trailing
edge of the horizontal stabilizer and the top surface of the elevator.
(5) Make sure that the elevator aligns with the At the stabilizer tips.
horizontal stabilizer.
(6) Measure the distance between the top surface of Record the distance.
the trailing edge of the horizontal stabilizer and
the top surface of the elevator.
(7) Remove the rigging pin from the stick mounting
block.
WARNING: WHEN YOU DO WORK ON THE AIRPLANE CONTROLS, YOU MUST
MAKE SURE THE AREAS AROUND THE CONTROLS/CONTROL
SURFACES ARE CLEAR OF PERSONS/EQUIPMENT. IF YOU DO
NOT DO THIS, INJURY TO PERSONNEL AND DAMAGE TO
CONTROL SURFACES CAN OCCUR.
(8) Move the control stick fully forward and hold it
against the stop.
(9) Measure the distance between the top surface of Record the measurement.
the trailing edge of the horizontal stabilizer and
The distance must be as shown in the
the top surface of the elevator.
Control Surfaces Adjustment Report.
(10) Move the control stick fully aft and hold it against
the stop.
(11) Measure the distance between the top surface of Record the measurement.
the trailing edge of the horizontal stabilizer and
The distance must be as shown in the
the top surface of the elevator.
Control Surfaces Adjustment Report.
(12) Install the left pilot’s seat. Refer to Section 25-10.
(13) Remove the trestle under the rear fuselage.
Page 202 Doc # 6.02.15
15 Apr 2013 27-30-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
3. Elevator Control System Adjustments
If you cannot get the correct range of movement of the elevator control system, use this procedure to
adjust the system. Gust travel refers to the amount of travel remaining at the control surface with the
control stick held against the cockpit stop.
WARNING: IF YOU DO AN ADJUSTMENT OF A PUSH-ROD, YOU MUST MAKE
SURE THAT THE PUSH-ROD IS STILL IN SAFETY. IF YOU DO NOT DO
THIS, THE PUSH-ROD CAN DISCONNECT. THIS CAN CAUSE DEATH
OR INJURY TO PERSONNEL.
A. Equipment
Item Quantity Part Number
Ruler or deflection gauge. 1 Commercial.
Rigging pins. 3 -
B. Elevator Control Adjustment Procedure
Refer to Figure 1.
Detail Steps/Work Items Key Items/References
(1) Remove these items for access:
S The pilots' seats. Refer to Section 25-10.
S The rudder. Refer to Section 55-40.
(2) Install rigging pins in the following:
S Through the stick mounting block and the On the control bulkhead.
torque tube.
S The idler lever. On the front main bulkhead.
S The rear bellcrank. On the vertical stabilizer rear web.
(3) If you cannot put a rigging pin into a lever or Refer to Section 27-00 for the push-rod
bellcrank, adjust the push-rods as necessary. adjustment procedure.
(4) Make sure that the elevator aligns with the At the stabilizer tips.
horizontal stabilizer.
Doc # 6.02.15 Page 203
Rev. 2 27-30-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(5) If the elevator does not align with the horizontal Refer to Section 27-00 for the push-rod
stabilizer, adjust the vertical push-rod at the rear adjustment procedure.
bellcrank.
(6) Remove rigging pins from the following:
S The stick mounting block. On the control bulkhead.
S The idler lever. On the front main bulkhead.
S The rear bellcrank. On the vertical stabilizer rear web.
(7) Do a test for the correct range of elevator Refer to Paragraph 2.
movement.
(8) Do an inspection of all the controls that you have
adjusted.
S If necessary for your Airworthiness Authority,
do a second inspection of the controls.
(9) Install these items:
S The pilots' seats. Refer to Section 25-10.
S The rudder. Refer to Section 55-40.
Page 204 Doc # 6.02.15
15 Apr 2013 27-30-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
4. Elevator Push-Rod Access
Elevator Push-Rod Remove/Install Access References
Between the control torque tube and Pilots’ seats. Refer to Section 25-10.
the idler lever at the front main
bulkhead.
Between the idler lever at the front Pilots’ seats. Refer to Section 25-10.
main bulkhead and the bellcrank at
Rudder. Refer to Section 55-40.
the vertical stabilizer rear web.
Between the bellcrank at the vertical Rudder. Refer to Section 55-40.
stabilizer rear web and the elevator.
5. Elevator Bellcrank and Lever Access
Elevator Bellcrank/Lever Remove/Install Access References
Idler lever at the front main Pilots’ seats. Refer to Section 25-10.
bulkhead.
Bellcrank at the vertical stabilizer Rudder. Refer to Section 27-20.
rear web.
Doc # 6.02.15 Page 205
Rev. 2 27-30-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 206 Doc # 6.02.15
15 Apr 2013 27-30-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Section 27-38
Flight Controls - Elevator Trim
1. General
The DA 40 NG has an elevator with a trim tab. The trim tab is mechanically operated. This lets you trim
the airplane for different speeds and center-of-gravity positions.
A handwheel on the center console controls the elevator trim. An indicator tells the pilot the trim
setting. A flexible cable moves the trim tab.
2. Description
The trim installation has three main parts:
) A handwheel assembly with a trim indicator.
) A flexible cable which connects the handwheel to the trim tab.
) The trim tab actuator assembly.
Figure 1 shows the elevator trim mechanism in the cockpit. Figure 2 shows the trim tab actuator
assembly.
A. Trim Handwheel Assembly
A handwheel assembly on the center console controls the elevator trim system. The assembly has
a metal mounting frame. The frame attaches to the rear of the engine control assembly and the top
of the control bulkhead.
A long bolt through the mounting frame carries the handwheel. The bolt also holds friction disks,
plain washers and spring washers against the handwheel. Two jam-nuts let you adjust the friction.
A small gear wheel attaches to the handwheel. The small gear wheel engages with a large gear
segment with internal teeth. The gear segment has a pivot bolt at the bottom of the mounting frame.
A ball-stud attaches the eye-end of a long flexible cable to the gear segment. An extension to the
mounting frame to the rear makes the anchor point for the outer sheath of the cable.
The gear segment is also the trim indicator. The top face of the segment has a white line across
it mid way between the front and back. The top face can be seen through a slot in the cover plate.
The sides of the cover plate have markings to show the trim position.
Doc # 6.02.15 Page 1
Rev. 2 27-38-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Handwheel
Right Cover Plate
Left Cover Plate
Flexible Cable
Frame Assembly
Right Frame Lock Nut TRIM HANDWHEEL ASSEMBLY
Lock Nut Friction Damper Nut
Plain Washer
Spring Washers
Lock Washer
Trim Gear Assembly
Spring Washers
Trim Indicator Mark
Plastic Friction Washers
Plastic Friction Washers
Distance Bush
Gear Segment with
Internal Teeth
Ball Stud
Bushes
Left Frame
HANDWHEEL AND
TRIM INDICATOR INSTALLATION
Pivot Bolt
Figure 1: Elevator Trim Mechanism in the Cockpit
Page 2 Doc # 6.02.15
15 Apr 2013 27-38-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
B. Flexible Cable
A long flexible cable connects the trim handwheel assembly to the trim tab. The cable goes through
holes in the front and rear main bulkheads, the baggage frame and each of the ring frames. It goes
up the front face of the front web of the vertical stabilizer and through a slot near the top. It goes
through a large hole at the top of the rear web of the vertical stabilizer to the trim tab actuator
assembly.
The cable has an inner core with threaded end fittings. Spherical end fittings at each end connect
to the gear segment and trim tab actuator assembly.
Clamp blocks hold the outer core to the mounting frame at the front and a bracket from the
horizontal stabilizer at the back.
C. Trim Tab Actuator Assembly
The trim tab is a one-piece GFRP molding. The tab has two integral levers. Two cranked actuating
levers attach to the integral levers. The left cranked actuating lever connects to the long flexible
cable. The right actuating lever connects to a friction damper.
The friction damper has a clamp-block with a hole for a rod. The rod connects to the right actuating
lever on the trim tab. You can adjust the friction of the rod in the clamp block.
Doc # 6.02.15 Page 3
Rev. 2 27-38-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
TrimTab
Right Actuating lever
Left Actuating lever
Friction Damper
Friction Clamp Block
Flexible Operating Cable Inner
Trim Actuator Mounting Bracket
Elevator Stop
Flexible Operating Cable Outer
Figure 2: Trim Tab Actuator Assembly
Page 4 Doc # 6.02.15
15 Apr 2013 27-38-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
3. Operation
When you move the top of the trim handwheel forward, these things happen:
) The small gear wheel moves the top of the gear segment forward.
) The gear segment pulls the inner core of the flexible cable forward.
) The inner core of the flexible cable pulls the left cranked actuating lever forward.
) The left cranked actuating lever pulls the trim tab lever forward to move the tab up.
) The up movement of the trim tab pushes the elevator down in flight giving nose-down trim.
When you move the top of the handwheel aft, the gear segment moves aft, the cable moves aft and
the trim tab moves down. This pushes the elevator up and gives nose-up trim.
In each case, the pilot can see the trim position from the white mark on the gear segment.
4. Emergency Operation
In the event of failure of the trim control system between the handwheel and the trim actuator lever,
the friction damper will prevent trim tab flutter.
Doc # 6.02.15 Page 5
Rev. 2 27-38-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 6 Doc # 6.02.15
15 Apr 2013 27-38-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have in the elevator trim control system. If you have the
trouble detailed in the Trouble column read across to the Possible Cause column. Then do the repair
in the Repair column.
Trouble Possible Cause Repair
Too much play in the trim Worn bearings or joints. Replace the defective items.
system.
Trim handwheel stiff to move. Flexible cable damaged. Replace the flexible cable.
Trim damper incorrectly Adjust the trim damper.
adjusted.
Doc # 6.02.15 Page 101
Rev. 2 27-38-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 27-38-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to test the elevator trim control system. They also tell you
how to adjust the system. Refer to Section 55-20 for data on how to remove and install the elevator
and trim tab.
2. Elevator Trim Control System Test for Correct Range of Movement
A. Equipment
Item Quantity Part Number
Control clamp. 1 Commercial.
Inclinometer. 1 Commercial.
Fuselage trestle. 1 Commercial.
B. Elevator Trim Control Test Procedure
Note: Make sure that the airplane does not move in pitch during the procedure. It will
cause errors in the test.
Detail Steps/Work Items Key Items/References
(1) Make a copy of the Control Surfaces Adjustment Refer to Section 06-00.
Report.
Use it to record the measurements.
(2) Put a trestle under the rear fuselage. To prevent movement in pitch.
(3) Hold the trailing edge of the elevator in line with Use a clamp at the tips.
the horizontal stabilizer
(4) Set the trim handwheel to neutral.
Note: Use an inclinometer to make all measurements at the trim tab surface. Make the
measurement at the center.
(5) Put the inclinometer on the top surface of the trim
tab. Set the inclinometer to zero.
Doc # 6.02.15 Page 201
Rev. 2 27-38-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(6) Set the trim handwheel to fully NOSE DOWN.
(7) Measure the angle of the top surface of the trim Record the angle of the top surface of
tab. the trim tab.
The angle must be as shown in the
Control Surfaces Adjustment Report.
(8) Set the trim handwheel to fully NOSE UP.
(9) Measure the angle of the top surface of the trim Record the angle of the top surface of
tab. the trim tab.
The angle must be as shown in the
Control Surfaces Adjustment Report.
(10) Remove the trestle under the rear fuselage.
3. Elevator Trim Control System Adjustments
If you cannot get the correct range of movement of the elevator trim control system, use this procedure
to adjust the system.
A. Equipment
Item Quantity Part Number
Inclinometer. 1 Commercial.
Control clamp. 1 Commercial.
Fuselage trestle. 1 Commercial.
Spring balance. 1 Commercial.
Page 202 Doc # 6.02.15
15 Apr 2013 27-38-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
B. Elevator Trim Control Adjustment Procedure
Detail Steps/Work Items Key Items/References
(1) Remove these items for access: Refer to Section 25-10.
S The pilots’ seats.
S The center console cover.
(2) Put a trestle under the rear fuselage. To prevent movement in pitch.
(3) Hold the trailing edge of the elevator in line with Use a clamp at the tips.
the horizontal stabilizer.
(4) Set the trim indicator to neutral.
(5) Adjust the flexible cable: Refer to Figure 1.
S Loosen the nuts which hold the outer sheath
of the flexible cable to the mounting frame for
the trim handwheel.
S Turn the nuts to move the outer sheath Move the outer sheath forward to move
forward of aft as necessary. the trim tab down. Move the outer
sheath aft to move the trim tab up.
S Tighten the nuts.
(6) Do a test for the correct range of movement of Refer to Paragraph 2.
the trim tab.
(7) Do an inspection of all the controls that you have
adjusted.
S If necessary for your Airworthiness Authority,
do a second inspection of the controls.
(8) Install these items: Refer to Section 25-10.
S The pilots' seats.
S The center console cover.
Doc # 6.02.15 Page 203
Rev. 2 27-38-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
C. Elevator Trim Friction Damper Adjustment Procedure
Detail Steps/Work Items Key Items/References
(1) Remove the horizontal stabilizer fairing. Refer to Section 55-10.
(2) Disconnect the right actuator lever from the
friction rod:
S Release the spring locking clip from the
ball-stud.
S Pull the end fitting away from the stud.
(3) Measure the force needed to move the damper Use a spring balance.
rod.
The friction force must be 15 - 30 N
(3.4 - 6.7 lb).
(4) If necessary, adjust the friction force:
S Tighten or loosen the clamping screw a small
amount.
(5) Do steps 3 and 4 again as necessary.
(6) Connect the right actuator lever to the friction rod:
S Push the end fitting onto the stud.
S Install the spring locking clip in the ball-stud.
(7) Do an inspection of all the controls that you have
adjusted.
S If necessary for your Airworthiness Authority,
do a second inspection of the controls.
(8) Install the horizontal stabilizer fairing. Refer to Section 55-10.
Page 204 Doc # 6.02.15
15 Apr 2013 27-38-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
D. Elevator Trim Handwheel Friction Damper Adjustment Procedure
Detail Steps/Work Items Key Items/References
(1) Remove these items for access: Refer to Section 25-10.
S The pilots’ seats.
S The center console cover.
(2) Loosen the self-locking nut on the handwheel On the right of the mounting frame.
pivot bolt.
(3) Loosen the locknut for the handwheel friction Against the right inner face of the
damper. mounting frame.
(4) Adjust the friction damper nut. Against the pack of washers and spring
washers on the pivot bolt.
(5) Measure the friction force. The friction force must be 200 N
(45 lb.).
(6) Do steps 4 and 5 as necessary.
(7) Tighten the locknut for the handwheel friction
damper.
(8) Tighten the self-locking nut on the handwheel
pivot bolt.
(9) Do an inspection of all the controls that you have
adjusted.
S If necessary for your Airworthiness Authority,
do a second inspection of the controls.
(10) Install these items: Refer to Section 25-10.
S The pilots' seats.
S The center console cover.
Doc # 6.02.15 Page 205
Rev. 2 27-38-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 206 Doc # 6.02.15
15 Apr 2013 27-38-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Section 27-39
Stall Warning System
1. General
The DA 40 NG has a simple mechanical stall warning system.
2. Description and Operation
Figure 1 shows the stall warning system if the G1000 system is installed.
Figure 2 shows the stall warning system if the conventional cockpit is installed.
The stall warning horn is located in the instrument panel. A flexible hose connects the stall warning
horn to a hole in the leading edge of the left wing. When the angle of attack of the wing is just less than
the stall angle, the airflow through the hole operates the horn. A ball-valve in the tube stops air and
water flowing from the outside into the cockpit through the stall warning system.
Doc # 6.02.15 Page 1
Rev. 2 27-39-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Ball Valve
20 mm
Attaching Nut
Flexible Tube from
Wing Leading Edge 25 mm Retaining
Ring
Cotter Pin Stall Warning Horn
Ty-wrap
Attaching Screw
Instrument Panel
Figure 1: Stall Warning System if the G1000 System Is Installed
Page 2 Doc # 6.02.15
15 Apr 2013 27-39-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Attaching Screw
Stall Warning Horn
Retaining Ring
Attaching Nut
32 ±5 mm
Hose Barb
Coupling
Ball
Cotter Pin Valve Ty-wrap
Flexible Tube Instrument Panel
20 ±2 mm
50 mm
Flexible Tube from
Wing Leading Edge
Figure 2: Stall Warning System if the Conventional Cockpit (OÄM 40-321) Is Installed
Doc # 6.02.15 Page 3
Rev. 2 27-39-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 27-39-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the stall warning system. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair given
in the Repair column.
Trouble Possible Cause Repair
Stall warning horn does not Stall warning horn defective. Replace the stall warning horn.
operate.
Water frozen in the stall Drain the water from the stall
warning system. warning system.
Stall warning operates too Stall warning horn defective. Replace the stall warning horn.
early during stall.
Doc # 6.02.15 Page 101
Rev. 2 27-39-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 27-39-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove/install the stall warning horn. They also tell you
how to drain water from the stall warning system.
2. Remove/Install the Stall Warning Horn
A. Remove the Stall Warning Horn
Detail Steps/Work Items Key Items/References
(1) Remove the instrument panel cover. Refer to Section 25-10.
(2) Disconnect the hose from the stall warning horn:
S Cut the cable tie that connects the hose to
the stall warning horn.
S Carefully pull the hose from the stall warning
horn.
S Remove the ball-valve from the end of the
hose.
(3) Remove the two screws and nuts that attach the
horn to the instrument panel.
(4) Remove the stall warning horn from the panel.
Doc # 6.02.15 Page 201
Rev. 2 27-39-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
B. Install the Stall Warning Horn
Detail Steps/Work Items Key Items/References
(1) Perform a stall warning horn classification check. Refer to Paragraph 4.
(2) Make sure to install a stall warning horn with the
same classification.
(3) Put the stall warning horn in position in the
instrument panel.
(4) Install the two screws and nuts which attach the
horn to the panel.
(5) Make sure that the hose has the cotter pin Refer to Figure 1.
installed correctly.
(6) Connect the flexible hose to the horn:
S Carefully push the ball-valve into the end of
the hose.
S Carefully push the hose onto the stall warning
horn.
S Make sure that there is a 20 mm (0.8 in)
clearance between the end of the horn and
the cotter pin.
S Install the cable tie which connects the hose
to the stall warning horn.
(7) Install the instrument panel cover. Refer to Section 25-10
(8) Do a flight check of the stall warning system. Refer to the Airplane Flight Manual.
Page 202 Doc # 6.02.15
15 Apr 2013 27-39-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
3. Procedure to Remove Water from the Stall Warning System
Detail Steps/Work Items Key Items/References
(1) Remove the left hand pilot's seat. Refer to Section 25-10.
(2) Carefully pull the stall warning hose from the
wing root connector.
(3) Lower the end of the hose and drain the water
from the system.
(4) Reconnect then stall warning hose to the
connector in the wing root.
(5) Do a flight check of the stall warning system. Refer to the Airplane Flight Manual.
4. Stall Warning Horn Classification Test
The stall warning horn is attached to a suction pump via an adjustable valve. The pressure is
measured with an altitude indicator, indicating feet. The test starts with the suction pump operating and
the adjustable valve in the closed position. The adjustable valve is opened slowly and as soon as the
stall warning horn starts whistling, the indication on the altitude indicator is read.
The altitude indicator reading classifies the tested stall warning according to the table below:
Indicated Height at the Moment
Classification
When It Begins Whistling
0 ft to 50 ft Reject
51 ft to 100 ft A
101 ft to 150 ft B
151 ft to 200 ft C
201 ft to 250 ft D
above 251 ft Reject
Note: If the result of the classification test does not match the labeling on the stall
warning horn, the stall warning horn must be replaced by a stall warning horn
classified in the same class.
Doc # 6.02.15 Page 203
Rev. 2 27-39-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 204 Doc # 6.02.15
15 Apr 2013 27-39-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Section 27-50
Flight Controls - Flaps
1. General
The DA 40 NG has flaps for landing and take-off. An electric flap actuator moves the flaps. See Section
57-50 for data about the flap structure.
A three-position toggle switch controls the flaps. The switch is in the center section or RH section of
the instrument panel.
The flap position indicator has marks for UP, T/O and LDG positions.
Doc # 6.02.15 Page 1
Rev. 2 27-50-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Torsion Tube Rear Closing Rib
Insert
Guide
Transfer Lever
Transfer Pins
Push Rod
to Right Wing Bushes Flap
Torsion Tube
Flap Actuator
Rear Closing Rib
Flap
Idler Lever
Push Rod
to Right Wing
Push Rod
To Left Wing
Flap Actuator Rear Main Bulkhead
Spacer
Rigging
Pin Hole Push Rod
to Left Wing
Figure 1: Flap Control System in the Fuselage
Page 2 Doc # 6.02.15
15 Apr 2013 27-50-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
2. Description
Figure 1 shows the flap control system in the fuselage. Figure 2 shows the flap push-rods and
bellcranks in the wing. Figure 3 shows the flap actuator installation.
A. Flap Actuator
An electric actuator operates the flaps. The electric actuator is under the left passenger seat.
A mounting bracket on the left rear closing rib attaches the actuator to the structure.
The electric actuator has an electric motor. The motor has a reduction gear which turns a spindle.
The spindle operates a push-rod. The push-rod connects to an idler lever attached to the rear main
bulkhead.
A cam attached to the push-rod operates five micro-switches. The micro-switches are part of the
flaps electronic control circuit.
B. Push-Rods and Bellcranks
The idler lever on the rear main bulkhead connects to two push-rods. The two push-rods connect
to the inboard ends of long push-rods at the wing root ribs. The long push-rods connect to the flap
bellcranks in the wings. A guide bearing holds each long rod at the root rib. Two short push-rods
attach to the flap horns.
C. Torsion Tube
A cranked torsion tube connects to the inboard end of each flap. The torsion tube has two parts.
Bolts attach the two parts of the torsion tube to each other in the fuselage.
A transfer lever attaches to the outboard end of each part of the torsion tube. The transfer lever has
two transfer pins. The transfer pins engage with bushes in the root rib of the flap.
If there is a failure of the flap mechanical system, the torsion tube transfers movement from one flap
to the other flap. It makes sure that the flaps are synchronized.
Doc # 6.02.15 Page 3
Rev. 2 27-50-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Rigging
Pin Hole
Right Flap Rib Right Flap
Right Wing
Root Rib
Guide Rollers
Push Rod from
Fuselage
Flap Idler Lever
in the Fuselage
Push Rod from
Fuselage
Guide Rollers
Left Wing
Root Rib
Rigging Left Flap
Pin Hole
Left Flap Rib
Figure 2: Flap Controls in the Wing
Page 4 Doc # 6.02.15
15 Apr 2013 27-50-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
D. Flap Electrical Control
Figure 4 shows the flap electrical control system. The main bus or, if installed, the essential bus
supplies power for the flaps. A circuit-breaker protects the circuit (10 A). See Chapter 92 for the
wiring diagram.
The flap electrical control system uses solid-state electronics. It has an electronic control unit and
a switchboard. The electronic control unit is located on the instrument panel. The switch board
attaches to the flap actuator.
The electronic control unit has a 3-position selector switch and a flap position indicator. The
selector switch can be set to:
) UP (fully up). 0º ± 1º
) T/O (take-off). 20º ± 2º
) LDG (landing). 42º ± 1º
The flap position indicator has three light-emitting diodes. The top diode lights when the flaps are
in the UP position. The middle diode lights when the flaps are in the T/O position. The bottom diode
lights when the flaps are in the LDG position.
The switch board attaches to the body of the flap actuator. The switch board has five micro
switches. It also has a solid-state logic circuit board.
The logic circuits monitor the outputs from the selector switch and the micro-switches on the switch
board. They control four power transistors. Two of the power transistors can connect the power
supply to the flap motor. The other two can connect the motor to ground.
Two screws attach each micro-switch to the switch board. You can adjust the position of the switch
board with three worm-drive clamps. The micro-switches have these functions:
) Micro-switch 1 - UP position.
) Micro-switch 2 - UP indication and T/O position moving down.
) Micro-switch 3 - T/O indication.
) Micro-switch 4 - LDG position.
) Micro-switch 5 - LDG indication T/O position moving up.
Cable harnesses with multi-pin connectors connect the components.
Doc # 6.02.15 Page 5
Rev. 2 27-50-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Actuator Control Rod
Worm-Drive Clamps
Circuit Board
Actuator Motor
Cam Adjusting Nuts
Cam
Actuator
Idler Lever
Swivel
Block
Micro-Switches
Micro-Switch Base Plate
Bush
Micro-Switch Base Plate Mounting Bracket
Rear Closing Rib
Cam
TYPICAL ATTACHMENT
OF MICRO-SWITCH
Figure 3: Flap Actuator Installation
Page 6 Doc # 6.02.15
15 Apr 2013 27-50-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
3. Operation
If you operate the flap selector switch these things happen:
) The switch energizes the related logic circuit.
) The logic circuit switches on the related transistors to supply power/ground to the flap motor.
) The flap motor turns the reduction gear and spindle. This moves the push-rod towards the new set
position.
) The push-rod turns the idler lever around its axis.
) The idler lever moves the push-rods in the fuselage and the wings.
) The push-rods move the bellcranks in the left and right wing.
) The two short push-rods move the flaps.
When the flaps come to the set position:
) The cam on the flap actuator operates the related position and indication micro-switches.
) The logic circuit switches off the related transistors to de-energize the motor.
) The flap position indicator shows the new flap position.
4. Fail-Safe Operation
The flap control system has these safety properties:
) If the LDG position micro-switch fails closed the flap actuator push-rod will continue to travel for
about 5 mm (0.2 in) until it reaches an internal stop. This prevents damage to the flaps. The FLAP
circuit-breaker opens.
) If the UP position micro-switch fails closed, the actuator push-rod contacts the end of the actuator
body after about 5 mm (0.2 in) of movement. This prevents damage to the flaps. The FLAP
circuit-breaker opens.
) If there is a mechanical failure in the controls to one flap, the torsion tube prevents asymmetric flap
movement.
Doc # 6.02.15 Page 7
Rev. 2 27-50-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Flap Selector Switch Flap Position Indicator
UP UP LED
T/O
LDG
Flaps
T/O LED
LDG LED
FLAP CONTROL UNIT IN THE INSTRUMENT PANEL
(View Looking Forward)
Closed Open UP Position
Micro-Switch
S4 S1
UP POSITION
S5 S3 S2
UP Indication and
Open Open Closed
T/O Position Moving Down
Micro-Switch
Closed Closed
S4 S1
T/O POSITION
S5 S3 S2
UP Indication and
LDG Indication and Open Closed Open T/O Position Moving Down
T/O Position Moving Up Micro-Switch
Micro-Switch
T/O Indication
Micro-Switch
LDG Position
Micro-Switch Open Closed
S4 S1
LDG POSITION
S5 S3 S2
LDG Indication and Closed Open Open
T/O Position Moving Up
Micro-Switch
MICRO-SWITCH BOARD
(View Looking Down)
Figure 4: Flap Electrical Control System
Page 8 Doc # 6.02.15
15 Apr 2013 27-50-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have in the flap control system. If you have the trouble detailed
in the Trouble column read across to the Possible Cause column. Then do the repair in the Repair
column.
Trouble Possible Cause Repair
Flaps do not operate. Circuit breaker not set. Set the flap circuit breaker.
Airplane electrical system voltage Do a test of the airplane
low. electrical system voltage.
Flap selector switch defective. Replace the flap electronic
control unit.
Flap circuit-breaker will Short to ground in the wires to the Do an insulation test between
not stay closed. electrical control unit or the each wire and ground. Repair
micro-switches. or replace defective wires.
Short to ground in the electrical Replace the electrical control
control unit. unit.
Short to ground in a micro-switch. Replace the micro-switch.
Short to ground in a wire between a Do an insulation test between
closed micro-switch and the control each wire and ground. Repair
unit. or replace defective wires.
Flap circuit-breaker opens Short to ground in a motor supply Do an insulation test between
when flap selector switch wire. each wire and ground. Repair
moved to any down or replace defective wires.
position.
Flap circuit-breaker opens Short to ground in a motor supply Do an insulation test between
when flap selector switch wire. each wire and ground. Repair
moved to any up position. or replace defective wires.
Flap circuit-breaker opens Short to ground in the wires to the Do an insulation test between
when the flaps stop at the electrical control unit from the each wire and ground. Repair
chosen position. related indication micro-switch. or replace defective wires.
Doc # 6.02.15 Page 101
Rev. 2 27-50-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Trouble Possible Cause Repair
Flap circuit-breaker opens Short to ground in the wires to the Do an insulation test between
when the flaps have electrical control unit from each wire and ground. Repair
moved only a short micro-switch 1. or replace defective wires.
distance from the UP
setting.
Flap circuit-breaker opens Short to ground in the wires to the Do an insulation test between
when the flaps have electrical control unit from each wire and ground. Repair
moved only a short micro-switch 4. or replace defective wires.
distance from the LDG
setting.
Flaps move slowly. Airplane electrical system voltage Do a test of the airplane
low. electrical system voltage.
Flap motor defective. Do a test for 14 V at the motor
with flaps selected. If there is
14 V at the motor, replace the
actuator.
Flap actuator defective. Examine the actuator. If you
find damage, then replace the
flap actuator.
Flaps do no not align with Flaps extended at too high Examine the flap system.
the wing trailing edge. airspeed. Replace damaged parts. Adjust
the system.
Flaps will not move to Micro-switch 4 defective. Replace the micro-switch.
LDG position. Flaps move
Open circuit in the micro-switch 4 Do a continuity test of the
to T/O and UP correctly.
wiring. wiring. Repair or replace the
defective wire.
Flaps will not move to UP Micro-switch 1 defective. Replace the micro-switch.
position. Flaps move to
Open circuit in the micro-switch 1 Do a continuity test of the
T/O and LDG correctly.
wiring. wiring. Repair or replace the
defective wire.
Page 102 Doc # 6.02.15
15 Apr 2013 27-50-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Trouble Possible Cause Repair
No LDG indication when Micro-switch 5 defective. Replace the micro-switch.
the flaps are in the LDG
Open circuit in the micro-switch 5 Do a continuity test of the
position. Flaps will not
wiring. wiring. Repair or replace the
move from LDG to T/O.
defective wire.
Flaps move from LDG to
UP correctly.
No UP indication when the Micro-switch 2 defective. Replace the micro-switch.
flaps are in the UP
Open circuit in the micro-switch 2 Do a continuity test of the
position. Flaps will not
wiring. wiring. Repair or replace the
move from UP to T/O.
defective wire.
Flaps move from UP to
LDG correctly.
No T/O indication when Micro-switch 3 defective. Replace the micro-switch.
the flaps are in the T/O
Open circuit in the micro-switch 3 Do a continuity test of the
position. Flaps move to all
wiring. wiring. Repair or replace the
positions correctly.
defective wire.
Flap circuit-breaker opens Micro-switch 4 defective. Replace the micro-switch.
at the end of down
movement.
Flap circuit-breaker opens Micro-switch 1 defective. Replace the micro-switch.
at the end of up
movement.
LDG LED stays on when Micro-switch 5 defective. Replace the micro-switch.
the flaps are not in the
LDG position. The other
indications operate
correctly.
UP LED stays on when Micro-switch 2 defective. Replace the micro-switch.
the flaps are not in the UP
position. The other
indications operate
correctly.
Doc # 6.02.15 Page 103
Rev. 2 27-50-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Trouble Possible Cause Repair
T/O LED stays on when Micro-switch 3 defective. Replace the micro-switch.
the flaps are not in the
T/O position. The other
indications operate
correctly.
Flaps move to LDG when Micro-switch 2 defective. Replace the micro-switch.
T/O set from UP.
Flaps move to UP when Micro-switch 5 defective. Replace the micro-switch.
T/O set from LDG.
Page 104 Doc # 6.02.15
15 Apr 2013 27-50-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove and install the components of the flap control
system. They also tell you how to test and adjust the system. See Section 57-50 for data about
removing and installing the flaps.
WARNING: WHEN YOU DO WORK ON THE AIRPLANE CONTROLS, YOU MUST
MAKE SURE THE AREAS AROUND THE CONTROLS/CONTROL
SURFACES ARE CLEAR OF PERSONS/EQUIPMENT. IF YOU DO NOT
DO THIS, INJURY TO PERSONS AND DAMAGE TO CONTROL
SURFACES CAN OCCUR.
WARNING: WHEN YOU COMPLETE WORK ON THE CONTROLS, MAKE SURE
THAT YOU REMOVE ALL LOOSE ITEMS/TOOLS FROM THAT AREA.
LOOSE ITEMS/TOOLS CAN PREVENT FULL MOVEMENT OF THE
AIRPLANE CONTROLS. THIS CAN CAUSE DEATH OR INJURY TO
PERSONS.
Doc # 6.02.15 Page 201
Rev. 2 27-50-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
2. Remove/Install the Flap Actuator
Refer to Figures 1 and 3.
A. Remove the Flap Actuator
Detail Steps/Work Items Key Items/References
(1) If possible, set the flaps to the T/O position.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the passenger seat. Refer to Section 25-10.
(4) Disconnect the electrical supply connector to the
flap motor.
(5) Disconnect the control harness plug from the
switch-board.
(6) Remove the bolt which attaches the actuator At the rear main bulkhead.
push-rod to the idler lever. Hold the flaps.
(7) Lower the flaps by hand until they stop.
(8) Remove the bolt which attaches the actuator At the left rear closing rib.
body to the mounting bracket.
(9) Remove the actuator from the airplane.
Page 202 Doc # 6.02.15
15 Apr 2013 27-50-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
B. Install the Flap Actuator
Detail Steps/Work Items Key Items/References
(1) Put the flap actuator in position in the fuselage.
(2) Install the bolt which attaches the actuator body to At the left rear closing rib.
the mounting bracket. Make sure that the bush is in position in
the actuator swivel block.
Torque: 6.4 Nm (4.7 lbf.ft.).
(3) Install the bolt which attaches the actuator push- At the rear main bulkhead. Hold the
rod to the idle lever. flaps.
Torque: 6.4 Nm (4.7 lbf.ft.).
(4) Connect the control harness plug for the
switch-board.
(5) Connect the electrical supply connector to the flap
motor.
(6) Connect the airplane main battery. Refer to Section 24-31.
(7) Do the adjustment procedure. See Paragraph 4.
(8) Do an inspection of all the controls that you have
connected.
S If necessary for your Airworthiness Authority,
do a second inspection of the controls.
(9) Install the passenger seat. Refer to Section 25-10.
Doc # 6.02.15 Page 203
Rev. 2 27-50-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
3. Test the Flap Control System
A. Equipment
Item Quantity Part Number
Inclinometer. 1 Commercial.
Spring balance. 1 Commercial.
B. Test the Flap Control System Procedure
Detail Steps/Work Items Key Items/References
(1) Make a copy of the Control Surfaces Adjustment Refer to Section 06-00.
Report.
Use it to record the measurements.
(2) Make sure that the flaps are fully UP:
S Set the ELECTRIC MASTER key switch to
ON.
S Set the flaps to T/O.
S When the flaps stop moving, set the flaps to
UP.
S When the flaps stop moving, set the
ELECTRIC MASTER key switch to OFF.
(3) Do a test for the correct pre-load in the flap UP
position:
S Put a loop of adhesive tape on the trailing
edge of the left flap opposite the up-stop.
S Pull down on the loop of tape with the spring
balance until the flap just moves from the up-
stop.
S Record the value in the Control Surfaces The value must be as shown in the
Adjustment Report. Control Surfaces Adjustment Report.
(4) If the pre-load is not correct, adjust the control rod Refer to Section 27-00.
between the bellcrank in the wing and the flap
horn. Do steps 3 and 4 again as necessary.
Page 204 Doc # 6.02.15
15 Apr 2013 27-50-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Detail Steps/Work Items Key Items/References
(5) Do steps 3 and 4 for the right flap.
(6) Zero the inclinometer to the left flap:
S Put the inclinometer on the left flap close to
the flap horn.
S Zero the inclinometer.
S Remove the inclinometer.
(7) Set the flaps to T/O:
S Set the ELECTRIC MASTER key switch to
ON.
S Set the flaps to T/O.
S When the flaps stop moving, set the
ELECTRIC MASTER key switch to OFF.
(8) Measure the angle of the left flap. Use the inclinometer.
S Record the value in the Control Surfaces The value must be as shown in the
Adjustment Report. Control Surfaces Adjustment Report.
(9) Do step 8 for the right flap.
(10) Set the flaps to LDG:
S Set the ELECTRIC MASTER key switch to
ON.
S Set the flaps to LDG.
S When the flaps stop moving, set the
ELECTRIC MASTER key switch to OFF.
(11) Measure the angle of the left flap. Use the inclinometer.
S Record the value in the Control Surfaces The value must be as shown in the
Adjustment Report. Control Surfaces Adjustment Report.
(12) Do step 11 for the right flap.
(13) Set the flaps to UP.
Doc # 6.02.15 Page 205
Rev. 2 27-50-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
4. Adjust the Flap Control System
If you cannot get the correct range of movement of the flap control system, use this procedure to adjust
the system.
A. Equipment
Item Quantity Part Number
Rigging pins. 3 -
Inclinometer. 1 Commercial.
B. Adjust The Flap Control System Procedure
Detail Steps/Work Items Key Items/References
(1) Make a copy of the Control Surfaces Adjustment Refer to Section 06-00.
Report.
Use it to record the measurements.
(2) Remove these items for access:
S The passenger seat. Refer to Section 25-10.
S The flap bellcrank access panels. Refer to Section 53-40.
(3) Disconnect the airplane main battery. Refer to Section 24-31.
(4) Remove the bolt, spacer, washer and nut which At the rear main bulkhead.
attach the actuator push-rod to the idler lever.
Hold the flaps.
(5) Put a rigging pin in the idler lever. Refer to Figure 3.
At the rear main bulkhead.
(6) Put rigging pins in the left and right flap Refer to Section 27-00.
bellcranks in the wings. If necessary, adjust the
push-rods between the idler lever and the
bellcranks.
(7) Remove the rigging pins from these items:
S The idler lever.
S The left and right flap bellcranks in the wings.
(8) Connect the airplane main battery. Refer to Section 24-31.
(9) Hold the flaps hard against the up-stops.
Page 206 Doc # 6.02.15
15 Apr 2013 27-50-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Detail Steps/Work Items Key Items/References
(10) Make sure that both flaps hit the up stops at the Refer to Section 27-00.
same time. If necessary, adjust the rod between
the bellcrank in the wing and the flap.
WARNING: DO NOT TOUCH THE ACTUATOR WHEN YOU OPERATE IT. THE
MOVING PARTS CAN CAUSE INJURY.
(11) Set the actuator to the T/O position:
S Hold the actuator clear of the structure. Use a piece of string through the eye
end.
S Set the ELECTRIC MASTER key switch to
ON.
S Set the FLAP switch to T/O.
S When the actuator stops moving, set the flap
switch to UP.
S When the actuator stops moving, set the
ELECTRIC MASTER key switch to OFF.
(12) Measure the extension of the actuator push-rod. The distance between the center of the
eye-end of the actuator rod and the
center of the actuator swivel block
mounting must be 379.7 mm (14.87 in.).
(13) If the actuator push-rod extension is not correct, Refer to Figure 3.
adjust the cam rod:
S Loosen the nuts which attach the cam rod to
the plate at the eye end.
S Turn the nuts to move the cam rod. One turn clockwise decreases the
extension by 1 mm (0.04 in.).
S Tighten the nuts. Torque: 6.4 Nm (4.7 lbf.ft.).
(14) Do steps 12 and 13 as necessary to get the
correct extension.
Doc # 6.02.15 Page 207
Rev. 2 27-50-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(15) Connect the flap actuator:
S Hold the flaps hard against the up-stops.
S If necessary, adjust the eye-end to align with
the idler lever:
S Loosen the jam-nut.
S Turn the eye-end to align with the idler
lever.
S Tighten the jam-nut. Torque: 16 Nm (11.8 lbf.ft.).
S Install the bolt, spacer, washer and nut which Torque: 6.4 Nm (4.7 lbf.ft.).
attach the eye-end to the idler lever.
(16) Do a test for the correct pre-load in the flap UP
position:
S Put a loop of adhesive tape on the trailing
edge of the left flap opposite the up-stop.
S Pull down on the loop of tape with the spring
balance until the flap just moves from the
up-stop.
S Record the value in the Control Surfaces The value must be as shown in the
Adjustment Report. Control Surfaces Adjustment Report.
(17) If the pre-load is not correct, adjust the control Refer to Section 27-00.
rod between the bellcrank in the wing and the
flap horn. Do steps 16 and 17 again as
necessary.
(18) Do steps 16 and 17 for the right flap.
(19) Do a test of the flap system. Refer to Paragraph 3.
(20) Do an inspection of all the controls that you have
adjusted.
S If necessary for your Airworthiness Authority,
do a second inspection of the controls.
Page 208 Doc # 6.02.15
15 Apr 2013 27-50-00 Rev. 2
DA 40 NG AMM Flight Controls
AIRCRAFT
Detail Steps/Work Items Key Items/References
(21) Install these items:
S The passenger seat. Refer to Section 25-10.
S The flap bellcrank access panels. Refer to Section 53-40.
5. Flap Push-Rod Access
Flap Push-Rod Remove/Install Access References
Between the idler lever at the rear Passenger seat. Refer to Section 25-10.
main bulkhead and the wing root rib.
Center section access panels. Refer to Section 52-40.
Between the wing root rib and the Center section access panels. Refer to Section 52-40.
bellcrank in the left/right wing.
Flap bellcrank access panels
under each wing.
Between the bellcrank in the Flap bellcrank access panels Refer to Section 52-40.
left/right wing and the flap. under each wing.
6. Flap Bellcrank and Lever Access
Flap Bellcrank/Lever Remove/Install Access References
Idler lever at the rear main bulkhead. Passenger seat. Refer to Section 25-10.
Bellcrank in the wing. Flap bellcrank access panels Refer to Section 52-40.
under each wing.
Doc # 6.02.15 Page 209
Rev. 2 27-50-00 15 Apr 2013
Flight Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 210 Doc # 6.02.15
15 Apr 2013 27-50-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
CHAPTER 28
FUEL SYSTEM
Doc # 6.02.15 Page 1
Rev. 2 28-TITLE 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 28-TITLE Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 28
FUEL SYSTEM
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Section 28-10
Fuel Storage System
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Fuel Tank Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Fuel Filler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Disassemble the Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Assemble/Install the Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Remove/Disassemble the Long Range Tank Assembly (if OÄM-40-130 installed)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
5. Assemble/Install the Long Range Tank Assembly (if OÄM 40-130 installed) . . 212
Section 28-20
Fuel Distribution System
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Fuel System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Fuel Transfer System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Doc # 6.02.15 Page 1
Rev. 2 28-CONTENTS 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Fuel Valve and the Gascolator . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Gascolator Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Remove/Replace/Install the Fuel Pressure Pulsation Damper (if MÄM 40-468 is
installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5. Remove/Install the Electrically Driven Fuel Pumps with Bypass Valve . . . . . . . 208
6. Remove/Install the Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
7. Disassemble/Assemble the Fuel Transfer Pump Assembly . . . . . . . . . . . . . . . . 211
8. Remove/Install the Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
9. Test the Fuel Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
10. Test the Check Valve in the Fuel Return Line . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Section 28-40
Fuel Quantity Indicating
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Low Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the High Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Remove/Install a Fuel Quantity Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Page 2 Doc # 6.02.15
15 Apr 2013 28-CONTENTS Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
CHAPTER 28
FUEL SYSTEM
1. General
This Chapter describes the DA 40 NG airplane fuel system. It does not include the fuel system for the
engine. For more data on the engine fuel system refer to the AE Operation Manual, latest revision.
The DA 40 NG has a fuel tank in each wing. Two different tank versions are provided. The total usable
fuel capacity of the fuel system is 28 US gal (106 liter) in case of the standard tank and 39 US gal
(148 liter) in case of the long range tank. One engine-mounted pump and one electrically driven fuel
pump (a second parallel electric fuel pump is installed) supply fuel to the engine. A fuel filter provides
protection to sensitive components. An electric transfer pump moves fuel from the right wing fuel tank
(aux) to the left wing fuel tank (main) as necessary.
The pilot controls the fuel transfer system with a switch which activates the electrically driven fuel
transfer pump. A fuel valve provides a backup system for fuel transfer and emergency operation. A fuel
quantity indicator shows the quantity of fuel in the fuel tanks. Refer to these Sections for more data on
these systems:
) Section 28-10. Fuel storage.
) Section 28-20. Fuel distribution.
) Section 28-40. Fuel quantity indication.
) Section 73-00. Engine fuel system.
Note: Equipment which is certified for installation in the DA 40 NG is listed in Chapter 6
of the Airplane Flight Manual. Such equipment may be installed in accordance with
the Airplane Maintenance Manual.
Any equipment which is not listed in Chapter 6 of the Airplane Flight Manual is
called "Additional Equipment". The installation of Additional Equipment is a
modification which must be handled in accordance with national regulations or a
Service Bulletin.
Doc # 6.02.15 Page 1
Rev. 2 28-00-00 15 Apr 2013
Page 2
Fuel System
15 Apr 2013
Engine
Fuel Return
Fuel Supply
Fuel Pumps Fuel Filter Firewall
Fuel Tank
Vent High Level Low Fuel Fuel Bypass Low Fuel
Fuel Sensor Sensor Valve Sensor
Fuel Check Finger Cooling
28-00-00
Fuel Fuel Quantity Fuel
Filler Probe Gascolator Cooler Valve Filter Loop Filler
AIRCRAFT
Restrictor
Relief Valve Check Valve Drain Wing RH
(Bleed Type) Wing LH Drain Check Lightning
Finger Valve Protection Fuel Tank
Filter Hose Fuel Quantity Check Valve
Fuel Tank Probe (Bleed Type)
Electric Fuel Valve
Transfer Fuselage
Pump
Figure 1: Fuel System Schematic Drawing (Standard Tank Configuration)
DA 40 NG AMM
Rev. 2
Doc # 6.02.15
Rev. 2
Doc # 6.02.15
Engine
DA 40 NG AMM
Return Line
Fuel Supply
Fuel Pumps Fuel Filter Firewall
Pressure
Relief
Valve High Fuel Fuel Bypass Low Fuel Long Range Tank
Sensor Valve Sensor Restrictor
Fuel Low Fuel
Tank Fuel Fuel Quantity Sensor Fuel Check Finger Cooling Fuel
Vent Filler Probe Gascolator Cooler Valve Filter Loop Filler
Drain
Valve
AIRCRAFT
Check
Valve Fuel Tank
Check Drain
Wing LH Drain Lightning Check Valve
Long Range Tank Valve Wing RH
Finger Protection Hose (Bleed Type)
Filter
Fuel Tank Fuel Valve Fuel Quantity
Electric Probe
Transfer Fuselage
Pump
28-00-00
Figure 2: Fuel System Schematic Drawing (Long Range Tank Configuration)
Page 3
15 Apr 2013
Fuel System
Fuel System DA 40 NG AMM
AIRCRAFT
2. Description
A. Standard Tank Configuration
Figure 1 shows the fuel system schematic of the DA 40 NG (standard tank configuration).
A tank located inboard in each wing holds the fuel. Each tank has a fuel filler assembly and a vent
connection at the outboard end. Small diameter flexible hoses connect the top outer corners of the
tank to the top of the fuel filler just below the cap. Two short hoses connect to the fuel filler. One
is a bleed type check valve. The other is a capillar (RH tank) or a relief valve (LH tank). Each wing
tank has an usable fuel capacity of 14.0 US gal (53 liter).
Each tank has a fuel drain and a finger-filter at the connection to the fuel feed line. The fuel feed
outlet of the right tank connects to the fuel valve and the transfer pump. The outlet from the
transfer pump connects to the fuel return line of the left tank.
Fuel level sensors and fuel quantity probes are installed in both fuel tanks. The right tank has a
transfer pump shut-off switch (low fuel sensor) located at the bottom inner corner. The left tank has
a transfer pump shut-off switch (high fuel sensor) located at the top outer corner. The left tank also
has a switch for the LOW FUEL (if G1000 is installed) or FUEL LOW (if White Wire annunciator
panel is installed) caution light (low fuel sensor) located at the bottom inner corner.
The fuel quantity probes go from the bottom inner corner of each tank to the top outer corner. The
fuel level changes the probe electrical properties. The fuel quantity system measures the probe
capacitance. It uses the value as an analogue of fuel quantity. The value for each tank is shown
on the MFD of the G1000 or on the SED.
A fuel temperature sensor is installed in each fuel tank. The LH and RH fuel temperatures are
indicated on the MFD of the G1000 or on the SED.
To cool down the hot return fuel a fuel cooler is installed in the return line from the right tank to the
left tank direct at the right tank.
Flexible hoses connect the fuel tanks in the wings to the fuel valve and electrically driven fuel
pumps in the center fuselage. A gascolator attaches to the fuel valve. The gascolator has a filter
and a fuel drain valve. A flexible hose connects the gascolator to the electrically driven fuel pumps.
A fuel line with a bypass valve is installed at the electrically driven fuel pumps to keep the fuel
pressure constant at the high pressure fuel pump inlet.
One engine-mounted high pressure pump supplies the fuel to the engine fuel injection system. A
return line from the engine connects to the right wing tank. A loop of pipe inside the right tank
functions as a heat exchanger to cool the return fuel. A flexible hose connects the outlet of the loop
via a fuel cooler to the left tank.
Page 4 Doc # 6.02.15
15 Apr 2013 28-00-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
B. Long Range Tank Configuration (if OÄM 40-130 installed)
Figure 2 shows the fuel system schematic of the DA 40 NG (long range tank configuration).
The airplane has two fuel tanks. Each tank is made of two fuel chambers: the inboard fuel chamber
and the outboard fuel chamber. Both fuel chambers are interconnected. The fuel chambers are
made of aluminum. Baffles in the tank prevent the fuel from moving quickly from one end of the
chamber to the other during flight.
Each wing tank has an usable capacity of 19.5 US gal (74 liter).
The tanks have supports welded in the inboard face for the fuel quantity probe, the low fuel sensor,
and the fuel temperature sensor.
A finger filter at the tank outlet prevents debris from entering the fuel system. A drain valve is
located in the lower surface of the tank. You can use the drain valve to defuel the fuel tank and for
doing fuel contamination tests.
The outer face of the inboard fuel tank chamber is connected to the inner face of the outboard fuel
tank chamber. The fuel filler opening is integrated into the outboard fuel tank chamber. A smaller
adapter on the left tank inboard fuel chamber holds a high fuel sensor.
There are also two small adapters at the top of the outer face of the outboard fuel tank chamber
for vent hoses.
On the left side one vent hose includes a pressure relief vent to protect the tank against high
pressure due to overfilling during the fuel transfer. The other hose includes a check valve to let the
air enter the tank.
On the right side one hose includes the check valve and one hose includes a capillary.
The right tank has two adapters which connect to a pipe loop inside the tank. This is the cooling
loop.
A fuel quantity probe attaches to the inboard end of each fuel tank. Refer to Section 28-40 for more
data on the fuel quantity indication system.
Two ribs hold each fuel tank chamber in position. Padded rubber strips go between the fuel tank
chamber and each rib. The filler cap is attached to the upper skin of the wing with eight screws. It
holds the tank assembly in position in spanwise direction.
Doc # 6.02.15 Page 5
Rev. 2 28-00-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
3. Operation
A. Normal Operation
Fuel flows through the finger filter of the left tank to the fuel valve. From the valve it flows through
the gascolator. The gascolator functions also as a water separator. From there the fuel flows to the
electrically driven fuel pumps and fuel filter to the engine.
The fuel pumps always supply more fuel than the fuel injection system can use. The residual fuel
flows back though the cooling loop in the right fuel tank. Heat transfers from the return fuel to the
cold fuel in the right tank. The return fuel flows from the cooling loop to the left tank via an additional
fuel cooler.
This process keeps the fuel warm in both tanks when the airplane operates in cold conditions.
As the engine uses fuel, the fuel level in the left tank decreases. A vent system allows to equalize
tank and outside pressure. This prevents the tank pressure from decreasing to less than
atmospheric pressure, and allows the fuel pumps to continue to take fuel from the tank.
B. Fuel Transfer
As the engine uses fuel, the fuel level in the left tank decreases. The fuel level in the right tank does
not change. To balance the tank contents, the electric transfer pump moves fuel from the right tank
to the left tank. It is operated through a switch (marked FUEL XFER ³ or FUEL TRANS ³) on the
left of the instrument panel.
The high fuel sensor in the left tank outer top corner automatically switches off the fuel transfer
pump when the fuel level is high in the left tank. The low fuel sensor in the right tank inner bottom
corner automatically switches off the fuel transfer pump when the fuel level is low in the right tank.
C. Emergency Operation
In an emergency (for example, the transfer pump fails) you can set the fuel valve to connect the
right tank transfer line to the fuel supply line. This is the EMERGENCY setting. The engine takes
fuel from the right tank. However, the return fuel still flows through the cooling loop to the left tank.
As fuel is used from the right tank, the level of fuel in the left tank will increase.
Page 6 Doc # 6.02.15
15 Apr 2013 28-00-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
D. Shut-Off Valve Function
During the usual operation, the shut-off function of the fuel valve is used only to isolate the fuel
system when the engine is not operating. In an emergency, the shut-off valve function is used to
stop all fuel flow to the engine.
E. Refueling
Add fuel to the system through the fuel fillers on top of each wing. Fuel flows down the large filler
tube to the related tank. Air in the tank can escape back past the fuel. As the tank becomes full, the
air can also escape through the hoses between the tank and the fuel filler.
F. Fuel Drains
You can use the fuel drain valve in each tank and the drain valve in the gascolator (pull to drain)
to defuel the airplane. Also use it to drain a small quantity of fuel to test for water or other
contamination. Push the bottom part of the valve at the fuel tanks up to release fuel. A spring inside
the valve closes it automatically. The gascolator drain has to be pulled down to release fuel.
Doc # 6.02.15 Page 7
Rev. 2 28-00-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 8 Doc # 6.02.15
15 Apr 2013 28-00-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
Section 28-10
Fuel Storage System
1. General
A. Standard Tank Configuration
This Section describes the following components of the fuel storage system for the DA 40 NG
airplane:
) Fuel tanks.
) Fuel filler assembly.
) Fuel tank vents.
Refer to Section 28-00 for a general description of the fuel system and a schematic of the fuel
system.
B. Long Range Tank Configuration (if OÄM-40-130 installed)
This Section describes the following components of the long range tank fuel storage system for the
DA 40 NG airplane:
) Inboard fuel tank chamber.
) Outboard fuel tank chamber.
) Fuel tank vents.
Refer to Section 28-00 for a general description of the long range tank fuel system and a schematic
of the long range tank fuel system.
Doc # 6.02.15 Page 1
Rev. 2 28-10-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Figure 1: Left Hand Standard Fuel Tank Installation
Page 2 Doc # 6.02.15
15 Apr 2013 28-10-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
Inboard Mounting Rubber (Chafing Protection)
Left Fuel Tank
Outboard Mounting Rubber
Worm-Drive Clamps
Cable Conduit for Flexible Coupling
High Fuel Sensor
Worm-Drive Clamps
Fuel Filler Cap
Adapter for High Fuel Sensor
Mounting Rubber
High Fuel Sensor
Pressure Relief
Vent Hoses
Valve
Bonding Connection
Left Outboard Chamber
Check Valve (Bleed Type)
Bonding Connection
Fuel Quantity Probe
Low Fuel Sensor
Fuel Return Line
Bonding Connection
Finger Filter
Temperature Sensor
Bonding Connection
Drain Valve
Figure 2: Left Hand Long Range Tank Installation (OÄM 40-130 installed)
Doc # 6.02.15 Page 3
Rev. 2 28-10-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
2. Fuel Tank Description
A. Standard Tank Description
The airplane has two fuel tanks. Each tank has a usable capacity of 14 US gal (53 liter). The tanks
are located in the inner part of each wing. Figure 1 shows the left fuel tank assembly. Figure 3
shows the right fuel tank assembly.
Each tank is a welded aluminum structure. Baffles in the tank prevent the fuel from moving quickly
from one end of the tank to the other during flight. The tank has supports welded in the inboard face
for the fuel quantity probe, the low fuel sensor, and the fuel temperature sensor. Other welded
installations provide connection points for hoses.
A finger filter at the tank outlet prevents debris from entering the fuel system. A drain valve is
located in the lower surface of the tank. You can use the drain valve to defuel the fuel tank and for
doing fuel contamination tests.
The outer face of the tank has a large adapter for the fuel filler assembly. A smaller adapter on the
left tank holds a high fuel sensor. There are also two small adapters at the top of the outer face for
vent hoses.
The right tank has two adapters which connect to a pipe loop inside the tank. This is the cooling
loop.
A fuel quantity probe attaches to the inboard end of each fuel tank. Refer to Section 28-40 for more
data on the fuel quantity indication system.
Two ribs hold each fuel tank assembly in position. Padded rubber strips go between the tank and
each rib. The filler cap is attached to the upper skin of the wing with eight screws. It holds the tank
assembly in position in spanwise direction.
Page 4 Doc # 6.02.15
15 Apr 2013 28-10-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
B. Long Range Tank Description (if OÄM-40-130 installed)
The airplane has two long range fuel tanks. Each tank has a usable capacity of 19.5 US gal
(74 liter). Each wing tank consists of two tank chambers. Figure 2 shows the left long range tank
assembly and Figure 4 shows the right long range tank assembly.
Each tank chamber is a welded aluminum structure. Baffles in the chamber prevent the fuel from
moving quickly from one end of the tank to the other during flight. The inboard fuel tank chamber
has supports welded in the inboard face for the fuel quantity probe, the low fuel sensor, and the fuel
temperature sensor. Other welded installations provide connection points for hoses.
A finger filter at the tank outlet prevents debris from entering the fuel system. A drain valve is
located in the lower surface of the tank. You can use the drain valve to defuel the fuel tank and for
doing fuel contamination tests.
The outer face of the inboard fuel tank chamber has a large adapter for the outboard fuel tank
chamber. A smaller adapter on the left tank holds a high fuel sensor. There are also two small
adapters at the top of the outer face for vent hoses.
The right tank has two adapters which connect to a pipe loop inside the tank. This is the cooling
loop.
A fuel quantity probe attaches to the inboard end of each fuel tank. Refer to Section 28-40 for more
data on the fuel quantity indication system.
Two ribs hold each fuel tank chamber in position. Padded rubber strips go between the fuel tank
chamber and each rib. The filler cap is attached to the upper skin of the wing with eight screws. It
holds the tank assembly in position in spanwise direction.
Doc # 6.02.15 Page 5
Rev. 2 28-10-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Vent Hose with Restrictor
Fuel Filler Cap
Vent Hoses
Bonding Connection
Worm-Drive Clamps
Bonding Connection Flexible Coupling
Worm-Drive Clamps
Check Valve
(Bleed Type) Bonding Connection
Outboard Mounting Rubber (Chafing Protection)
Fuel Filler Assembly
Right Fuel Tank
Inboard Mounting
Rubber
Fuel Return Line Adapter
Bonding Connection
Temperature Sensor
Low Fuel Sensor
Cooling Loop
Bonding Connection Finger Filter
Drain Valve
Fuel Return Line Adapter
Fuel Quantity Probe
Figure 3: Right Hand Standard Fuel Tank Installation
Page 6 Doc # 6.02.15
15 Apr 2013 28-10-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
Fuel Filler Cap
Vent Hose
with Restrictor
Mounting Rubber
Check Valve Worm-Drive Clamps
(Bleed Type) Flexible Coupling
Worm-Drive Clamps
Right Outboard
Chamber
Outboard Mounting Rubber (Chafing Protection)
Bonding Connection
Right Fuel Tank
Vent Hoses
Inboard Mounting
Rubber
Fuel Return Line Adapter
Bonding Connection
Temperature Sensor
Low Fuel Sensor
Cooling Loop
Bonding Connection Finger Filter
Drain Valve
Fuel Return Line Adapter
Fuel Quantity Probe
Figure 4: Right Hand Long Range Tank Installation (OÄM 40-130 installed)
Doc # 6.02.15 Page 7
Rev. 2 28-10-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
3. Fuel Filler Assembly
Figures 1 and 3 also show the fuel filler assembly. It is a welded tubular aluminum component,
approximately 75 mm (3 in) in diameter. The outboard end has a flange that attaches to the top skin
of the wing. It also has slots that engage the fuel filler cap.
The filler cap has a locking lever. You pull the locking lever up and turn the filler cap counter-clockwise
to release it. You turn the cap clockwise to install it and push down the locking lever to lock it. The area
just below the flange has four adapters for the vent system hoses.
Note: If the filler cap operates too easily, then fuel can leak out. Leaking fuel can cause
the paint finish to become yellow.
A short flexible coupling attaches the fuel filler assembly to the outer face of the fuel tank. Two worm
drive clamps at each end hold the flexible coupling to the tank and the fuel filler assembly. Two small
diameter flexible hoses connect the vent adapters at the top of the tank to the two inboard adapters
on the fuel filler flange.
A bleed type check valve is screwed into one of the two outer adapters on the filler flange. A short
flexible hose connects the bleed type check valve to an adapter in the outer fuel tank access panel at
the bottom surface of the wing.
A second short flexible hose connects to the other outer adapter on the fuel filler flange. It has a
restrictor (right wing) or relief valve (left wing) in it. It connects to an adapter in the outer fuel tank
access panel at the bottom surface of the wing.
Bonding strips connect the tank to the fuel filler assembly and the airplane bonding system.
For the long range tank installation the fuel filler assembly function is identical to the standard tank.
The two vent lines connect in the long range tank configuration directly to the outer fuel tank chamber
and the filler assembly is integral part of the outer fuel tank chamber. See Figure 2 and Figure 4.
Page 8 Doc # 6.02.15
15 Apr 2013 28-10-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the possible defects of the fuel storage system. When experiencing trouble
detailed in the Trouble column read across to the Possible Cause column, then perform the repair
given in the Repair column.
Trouble Possible Cause Repair
Filler cap leaking. Filler cap gasket damaged. Replace filler cap gasket.
Filler cap does not have a tight Tighten nut on lower side of
fit. cap.
Fuel drain valve leaking. Drain valve damaged. Replace fuel drain valve.
Contamination in drain valve. Open and close drain valve.
Do this until the drain seals. If
the drain does not seal then
replace the drain valve.
Doc # 6.02.15 Page 101
Rev. 2 28-10-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 28-10-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices describe how to remove/install the fuel tanks. Obey the safety
precautions for fuel at all times.
WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE.
WARNING: DO NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN CAUSE
INJURY TO PERSONS AND DAMAGE TO EQUIPMENT.
WARNING: DO NOT BREATH FUEL VAPOR. FUEL VAPOR CAN MAKE YOU ILL.
2. Remove/Disassemble the Fuel Tank Assembly
A. Remove the Fuel Tank Assembly
Detail Steps/Work Items Key Items/References
(1) Make sure that the fuel tank that you will remove Defuel and drain the fuel tank.
is empty.
(2) Remove the wing which has the fuel tank that you Refer to Section 57-10.
will remove and support the wing on trestles.
(3) Remove the access panels from the wing:
S Remove the access panel from the root rib:
S Remove the 11 nuts and washers from the
studs.
S If access panel is made from aluminum
remove bonding cable.
S Pull the access panel from the studs and
clear of the airplane.
S Remove the access panel for the fuel drain Refer to Section 52-40.
valve.
(4) Remove the fuel drain valve: Refer to Figure 3.
S Cut the lock-wire.
S Remove the drain valve from its mounting.
Doc # 6.02.15 Page 201
Rev. 2 28-10-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(5) Disconnect the following electrical connectors: At the inboard end of the tank.
S Fuel quantity probe.
S Low fuel sensor.
S High fuel sensor (left wing only).
S Fuel temperature sensor.
(6) Release the bonding strip from the inboard end of
the tank:
S Remove the nut and washer from the bolt.
S Remove the bonding strip from the bolt and
move it clear of the tank.
S Remove the bolt.
(7) Disconnect the two vent hoses from the adapters Near the outboard end of the filler
on the access panel: assembly.
S Remove the access panel from the outer Refer to Section 52-40.
lower surface of the wing.
S Remove the clamps that hold the vent hoses
to the adapters on the access panel.
S Disconnect the vent hoses from the adapters
on the access panel.
(8) Disconnect the bonding connection at the Through the access panel in the wing
outboard end of the fuel filler assembly. bottom skin.
(9) Release the fuel filler assembly:
S Remove the fuel filler cap and disconnect the
bonding cable.
S Remove the 8 screws which attach the filler
flange.
S Release the filler flange and the O-ring seal. Discard the O-ring seal.
Page 202 Doc # 6.02.15
15 Apr 2013 28-10-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
Detail Steps/Work Items Key Items/References
(10) Gently pull the tank and fuel filler assembly out of Make sure that the tank does not catch
the wing through the wing inboard rib. Move the on the wing ribs. Make sure that you do
assembly clear of the wing and support it on a not damage the tanks.
clean work bench.
B. Disassemble the Fuel Tank Assembly
Detail Steps/Work Items Key Items/References
(1) Remove the fuel tank assembly from the wing. Refer to Paragraph 2.A.
(2) Remove the connecting link that attaches the Refer to Figures 1 and 3.
tank to the fuel filler assembly:
S Remove the 2 nuts and washers from the
bolts.
S Remove the link plate.
S Remove the 2 bolts.
(3) Remove the clips which attach the vent hoses to
the tank.
(4) Remove the worm drive clamps that attach the
flexible coupling to the tank.
(5) Pull the fuel filler assembly away from the tank
until the vent hoses and flexible coupling
disconnect from the tank.
(6) If necessary, remove the clips which attach the
vent hoses to the fuel filler assembly and pull the
hoses from the connectors.
(7) If necessary, remove the worm drive clamp which
attaches the flexible coupling to the fuel filler
assembly and pull the coupling from the fuel filler
assembly connector.
Doc # 6.02.15 Page 203
Rev. 2 28-10-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
3. Assemble/Install the Fuel Tank Assembly
A. Preparation
Detail Steps/Work Items Key Items/References
(1) Examine the fuel tank. Look specially for:
S Damage to the aluminum skins and welded Use a strong light and a magnifying
seams of the tank. glass.
S Corrosion.
S Damage/wear to the rubber mounting bands
at the outside of the tanks.
(2) Examine the vent hoses which connect the tank
and fuel filler assembly. Look specially for:
S Cuts or damage, specially at the ends where
the attaching clips locate.
S Distortion or cracking.
(3) Examine the flexible coupling. Look specially for:
S Cuts or damage, specially at the ends where
the attaching clips are located.
S Distortion or cracking.
(4) Examine the fuel filler flange. Look specially for:
S Corrosion on the mating faces.
S Cracking around the flange. Use a strong light and a magnifying
glass.
(5) Examine the insides of the tank for cleanliness.
Page 204 Doc # 6.02.15
15 Apr 2013 28-10-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
B. Assemble the Tank
Detail Steps/Work Items Key Items/References
(1) Install the flexible coupling: Refer to Figure 3.
S Push the flexible coupling onto the connector Make sure that the coupling is correctly
of the fuel filler assembly. positioned.
S Install the worm drive clamps onto the Torque: 2.5 Nm (1.84 lbf.ft.).
coupling and tighten the clamps.
(2) Install the vent hoses onto the fuel filler
assembly:
S Push the hoses onto the connectors. Make sure that the hose is correctly
positioned.
S Install the attaching clips.
(3) Connect the tank to the fuel filler assembly:
S Move the tank into position by the fuel filler
assembly. Engage the tank vent connectors
and the flexible coupling connector into their
related hoses/couplings on the fuel filler
assembly.
S Push the tank towards the fuel filler assembly The surface of the filler flange must be
until the vent hoses and the flexible coupling parallel with the upper surface of the
are correctly positioned on their related fuel tank.
connectors.
S Install the worm drive clamps that attach the
flexible coupling to the tank connector.
S Tighten the worm drive clamps. Torque: 6 Nm (4.43 lbf.ft.).
S Install the clips which attach the vent
connecting hoses to the inboard tank
connectors.
Doc # 6.02.15 Page 205
Rev. 2 28-10-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(4) Install the connecting link which attaches the tank
to the fuel filler assembly:
S Move the link into position on the connecting
brackets.
S Install the two bolts through the link and the
connecting brackets.
S Install the 2 washers and nuts onto the bolts.
S Tighten the nuts and bolts.
C. Install the Tank Assembly
Detail Steps/Work Items Key Items/References
(1) Move the tank assembly into position in the wing. Make sure that the tank assembly is
correctly located.
(2) Install the fuel filler assembly:
S Install a new O-ring seal on the fuel filler
flange.
S Make sure that the mounting in the fuel filler If necessary, move the tank assembly
assembly is correctly aligned with the hole in to give correct alignment.
the top surface of the wing.
S Install a new O-ring seal in position on the top Make sure that the O-ring is correctly
surface of the wing. positioned.
S Apply a thin layer of sealant to the contact Use DP 300 or equivalent.
area between the fuel filler flange and the ring
for the filler cap.
S Put the ring for the filler cap in position over
the filler flange.
S Install the 8 screws which attach the fuel filler Finger tight only.
and the ring for the filler cap to the wing.
S When all of the screws are installed, then Tighten opposite screws.
tighten the screws.
Page 206 Doc # 6.02.15
15 Apr 2013 28-10-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
Detail Steps/Work Items Key Items/References
(3) Connect two the vent hoses to the adapters on Near the outboard end of the fuel filler
the access panel: assembly.
S Push the vent hoses onto the adapters on the
access panel.
S Install the clamps which hold the vent hoses
to the adapters on the access panel.
(4) Connect the bonding cable to the fuel filler
assembly.
(5) Install the access panel on the bottom surface of Refer to Section 52-40.
the wing.
(6) Attach the bonding strip to the inboard end of the
tank:
S Put the bolt up through the bonding tag on
the inboard tank.
S Move the bonding cable into position on the
bolt.
S Install the washer and nut onto the bolt.
S Tighten the bolt.
(7) Connect the following electrical connectors: At the inboard end of the tank.
S Fuel quantity probe.
S Low fuel sensor.
S High fuel sensor (left wing only).
S Fuel temperature sensor.
Doc # 6.02.15 Page 207
Rev. 2 28-10-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(8) Install the access panel at the wing root rib:
S Put the access panel into position on the
studs.
S If access panel is made from aluminum install Install on 3rd bolt from bottom aft corner.
bonding cable.
S Install the 11 washers and nuts.
S Tighten the nuts.
(9) Install the drain valve:
S Install a new O-ring onto the drain valve
assembly.
% S Install the drain valve assembly into the Torque: 1 - 3 Nm (0.73 - 2.21 lbf.ft.).
mounting at the bottom of the inboard tank.
S Secure the drain valve assembly with lock-
wire.
S Install the access panel. Refer to Section 52-40.
(10) Install the wing onto the airplane. Refer to Section 57-10.
(11) Refuel the airplane. Refer to Section 12-10. Look specially
for fuel leaks from the tanks assembly
which you have installed.
(12) Do an engine ground test. Refer to Section 71-00.
Page 208 Doc # 6.02.15
15 Apr 2013 28-10-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
4. Remove/Disassemble the Long Range Tank Assembly (if OÄM-40-130 installed)
A. Remove the Fuel Tank Assembly
Detail Steps/Work Items Key Items/References
(1) Remove the wing which has the fuel tank that you Refer to Section 57-10.
will remove and support the wing on trestles.
(2) Remove these access panels from the wing: Refer to Section 52-40.
S Remove the access panel from the root rib:
S Remove the 11 nuts and washers from the
studs.
S Pull the access panel from the studs and
clear of the airplane.
S Remove the access panel for the fuel drain
valve.
(3) Remove the fuel drain valve: Refer to Figures 2 and 4.
S Cut the lock-wire.
S Remove the drain valve from its mounting.
(4) Disconnect the following electrical connectors: At the inboard end of the tank.
S Fuel quantity probe.
S Low fuel sensor.
S High fuel sensor (left wing only).
S Fuel temperature sensor.
(5) Release the bonding strip from the inboard end of
the inboard fuel tank chamber:
S Remove the nut and washer from the bolt.
S Remove the bonding strip from the bolt and
move it clear of the tank.
S Remove the bolt.
Doc # 6.02.15 Page 209
Rev. 2 28-10-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(6) Disconnect the two vent hoses from the adapters Near the outboard end of the outboard
on the access panel: fuel tank chamber.
S Remove the access panel from the outer Refer to Section 52-40.
lower surface of the wing.
S Remove the clamps that hold the vent hoses
to the adapters on the access panel.
S Disconnect the vent hoses from the adapters
on the access panel.
(7) Disconnect the bonding connection at the Through the access panel in the wing
outboard end of the outboard fuel tank chamber. bottom skin.
(8) Release the fuel filler flange:
S Remove the fuel filler cap and disconnect the
bonding cable.
S Remove the 8 screws which attach the filler
flange.
S Release the filler flange and the O-ring seal. Discard the O-ring seal.
S Remove the spacer ring.
(9) Gently pull the inboard fuel tank chamber and the Make sure that the tank does not catch
outboard fuel tank chamber out of the wing on the wing ribs. Make sure that you do
through the wing inboard rib. Move the assembly not damage the tanks.
clear of the wing and support it on a clean work
bench.
Page 210 Doc # 6.02.15
15 Apr 2013 28-10-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
B. Disassemble the Fuel Tank Assembly
Detail Steps/Work Items Key Items/References
(1) Remove the fuel tank assembly from the wing. Refer to Paragraph 2A.
(2) Remove the connecting link that attaches the Refer to Figures 2 and 4.
inboard fuel tank chamber to the outboard fuel
tank chamber:
S Remove the 2 nuts and washers from the
bolts.
S Remove the link plate.
S Remove the 2 bolts.
(3) Remove the clips which attach the vent hoses to
the tank.
(4) Remove the worm drive clamps that attach the
flexible coupling to the tank.
(5) Pull the outboard fuel tank chamber away from the
inboard fuel tank chamber until the vent hoses and
flexible coupling disconnect from the tank.
(6) If necessary, remove the clips which attach the
vent hoses to the outboard fuel tank chamber and
pull the hoses from the connectors.
(7) If necessary, remove the worm drive clamp which
attaches the flexible coupling to the outboard fuel
tank chamber and pull the coupling from the fuel
tank chamber connector.
Doc # 6.02.15 Page 211
Rev. 2 28-10-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
5. Assemble/Install the Long Range Tank Assembly (if OÄM 40-130 installed)
A. Preparation
Detail Steps/Work Items Key Items/References
(1) Examine the fuel tank. Look specially for:
S Damage to the skins and welded seams of the Use a strong light and a magnifying
tank. glass.
S Corrosion.
S Damage/wear to the rubber mounting bands at
the outside of the tanks.
(2) Examine the vent hoses which connect the inboard
and the outboard fuel tank chamber. Look
specially for:
S Cuts or damage, specially at the ends where
the attaching clips locate.
S Distortion or cracking.
(3) Examine the flexible coupling. Look specially for:
S Cuts or damage, specially at the ends where
the attaching clips locate.
S Distortion or cracking.
(4) Examine the fuel filler flange. Look specially for:
S Corrosion on the matching faces.
S Cracking around the flange. Use a strong light and a magnifying
glass.
Examine spacer ring. Look specially for:
S Corrosion on the mating faces.
S Cracking around the flange. Use a strong light and a magnifying
glass.
(5) Examine the insides of the fuel tank chambers for
cleanliness.
Page 212 Doc # 6.02.15
15 Apr 2013 28-10-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
B. Assemble the Tank
Detail Steps/Work Items Key Items/References
(1) Install the flexible coupling: Refer to Figures 2 and 4.
S Push the flexible coupling onto the connector Make sure that the coupling is correctly
of the outboard fuel tank chamber. positioned.
S Install the worm drive clamps onto the coupling
and tighten the clamps.
(2) Install the vent hoses onto the outboard fuel tank
chamber:
S Push the hoses onto the connectors. Make sure that the hose is correctly
positioned.
S Install the attaching clips.
(3) Connect the inner to the outboard fuel tank
chamber:
S Move the inboard fuel tank chamber into
position by the outboard fuel tank chamber.
Engage the tank vent connectors and the
flexible coupling connector into their related
hoses/couplings on the outboard fuel tank
chamber.
S Push the inboard fuel tank chamber towards The upper surface of both fuel tank
the outboard fuel tank chamber until the vent chambers must be parallel.
hoses and the flexible coupling are correctly
positioned on their related connectors.
S Install the worm drive clamps that attach the
flexible coupling to the inboard tank chamber
connector.
S Tighten the worm drive clamps.
S Install the clips which attach the vent
connecting hoses to the inboard fuel tank
chamber connectors.
Doc # 6.02.15 Page 213
Rev. 2 28-10-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(4) Install the connecting link which attaches the
inboard fuel tank chamber to the outboard tank
chamber:
S Move the link into position on the connecting
brackets.
S Install the two bolts through the link and the
connecting brackets.
S Install the 2 washers and nuts onto the bolts.
S Tighten the nuts and bolts.
Page 214 Doc # 6.02.15
15 Apr 2013 28-10-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
C. Install the Tank Assembly
Detail Steps/Work Items Key Items/References
(1) Move the tank assembly into position in the wing. Make sure that the tank assembly is
correctly located.
(2) Install the fuel tank:
S Make sure that the fuel filler flange in the If necessary, move the tank assembly
outboard tank chamber is correctly aligned to give correct alignment.
with the hole in the top surface of the wing.
S Apply a thin layer of sealant to the contact area Use DP 300 or equivalent.
between spacer ring and fuel filler flange.
S Install the spacer ring onto the tank filler
flange.
S Install a new O-ring seal in position on the top Make sure that the O-ring is correctly
surface of the wing. positioned.
S Apply a thin layer of sealant to the contact area Use DP 300 or equivalent.
between the spacer ring and the ring for the
filler cap.
S Put the ring for the filler cap in position over the
filler flange.
S Install the 8 screws which attach the fuel filler Finger tight only.
and the ring for the filler cap to the wing.
S When all of the screws are installed, then Tighten opposite screws.
tighten the screws.
(3) Connect two the vent hoses to the adapters on the Near the outboard end of the outboard
access panel: fuel tank chamber.
S Push the vent hoses onto the adapters on the
access panel.
S Install the clamps which hold the vent hoses to
the adapters on the access panel.
(4) Connect the bonding connection at the outboard
end of the outboard fuel tank chamber.
(5) Install the access panel on the bottom surface of Refer to Section 52-40.
the wing.
Doc # 6.02.15 Page 215
Rev. 2 28-10-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(6) Attach the bonding strip to the inboard end of the
inboard fuel tank chamber:
S Put the bolt up through the bonding tag on the
inboard fuel tank chamber.
S Move the bonding cable into position on the
bolt.
S Install the washer and nut onto the bolt.
S Tighten the bolt.
(7) Connect the following electrical connectors: At the inboard end of the tank.
S Fuel quantity probe.
S Low fuel sensor.
S High fuel sensor (left wing only).
S Fuel temperature sensor.
(8) Install the access panel at the wing root rib:
S Put the access panel into position on the studs.
S Install the 11 washers and nuts.
S Tighten the nuts.
(9) Install the drain valve:
S Install a new O-ring onto the drain valve
assembly.
S Install the drain valve assembly into the
mounting at the bottom of the inboard fuel tank
chamber.
S Secure the drain valve assembly with lock-
wire.
S Install the access panel. Refer to Section 52-40.
(10) Install the wing onto the airplane. Refer to Section 57-10.
Page 216 Doc # 6.02.15
15 Apr 2013 28-10-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
Detail Steps/Work Items Key Items/References
(11) Refuel the airplane. Refer to Section 12-10. Look specially
for fuel leaks from the tanks assembly
which you have installed.
(12) Do an engine ground test. Refer to Section 71-00.
Doc # 6.02.15 Page 217
Rev. 2 28-10-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 218 Doc # 6.02.15
15 Apr 2013 28-10-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
Section 28-20
Fuel Distribution System
1. General
This Section describes the fuel distribution system of the DA 40 NG airplane. The fuel distribution
system supplies fuel from the fuel tanks to the engine. The following components are part of the fuel
distribution system:
) Flexible fuel hoses.
) Fuel valve.
) Fuel gascolator with filter.
) Fine fuel filter.
) Electric fuel transfer pump.
) Electrically driven fuel pumps with bypass valve.
) Fuel pressure pulsation damper.
) Fuel cooler and check valve.
Refer to Section 28-00 for a general description of the fuel system and for the schematic diagram of
the fuel system.
Doc # 6.02.15 Page 1
Rev. 2 28-20-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Fuel Return Line
From Aux Tank (RH)
Fuel Return Line
From Engine
Check Valve
Fuel Transfer Line
From Aux Tank (RH)
T-Fitting Fuel Transfer Line
to Transfer Pump and
Fuel Selector then to Main Tank
Gascolator Fuel Return Line
90° Fitting
to Main Tank (LH)
T-Fitting
Fuel Supply Line
Firewall
90° Fitting
Fuel Supply Line
Fuel Return Bypass Valve From Main Tank (LH)
Line
Straight Bypass
Fitting
Fuel Pumps
Figure 1: Fuel System Components in the Fuselage
Page 2 Doc # 6.02.15
15 Apr 2013 28-20-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
2. Description
Figure 1 shows the main components of the fuel distribution system for the DA 40 NG.
A flexible fuel hose connects the left wing fuel tank to the fuel valve. The fuel valve is located in the
center fuselage, below the cockpit floor. The fuel valve connects to the gascolator.
Flexible hoses connect the outlet of the gascolator to the fuel pump assy with the bypass loop. The
outlet of the bypass valve is connected to the bulkhead fitting via a flexible fuel line. A fuel line with fire
sleeve connects the fuel filter to a fuel pressure pulsation damper (if MÄM 40-468 is installed) and then
to the engine driven high pressure fuel pump.
The fuel return line from the engine is routed through the firewall and connects to a check valve in the
fuselage. From there a fuel line connects to the cooling loop inlet of the right wing tank. The cooling
loop outlet from the right tank leads to the fuel cooler and then via the return line to the return inlet of
the left fuel tank.
A flexible hose connects the right wing tank outlet to a T-fitting which is attached to the emergency inlet
of the fuel valve. A flexible hose from the T-fitting connects to a check valve and further to the inlet of
the fuel transfer pump. Another flexible hose leads from the outlet of the fuel transfer pump to a
T-fitting in the fuel return line.
3. Fuel System Components
A. Flexible Hoses
The fuel system uses (synthetic) flexible hoses. The flexible fuel lines firewall forward are equipped
with integral fire-protection sleeves.
Only approved and pressure tested hoses are suitable for the DA 40 NG fuel system.
B. Fuel Valve
The fuel valve is located below the cockpit floor. It is a three-way valve. A shaft connects the valve
to a control lever which is located in the center console of the cockpit, aft of the engine control
assembly.
To move the control lever you must lift a safety lock on top of the lever while you turn the control
lever.
If the control lever is set to NORMAL only the left wing tank will supply fuel. If the control lever is
set to EMERGENCY then only the right wing tank will supply fuel. If the control lever is set to OFF
then fuel will not be supplied from the tanks.
Doc # 6.02.15 Page 3
Rev. 2 28-20-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
C. Fuel Gascolator and Filter
The gascolator connects to the fuel valve and is equipped with a fuel filter and a fuel drain. The filter
can be removed for cleaning/replacement. Use the fuel drain to drain the fuel distribution system
and to drain fuel to test for fuel contamination.
D. Fine Fuel Filter
If MÄM 40-468 is installed, a fine fuel filter is located firewall forward and is installed to the engine
mount via a bracket.
E. Fuel Transfer Pump
The fuel transfer pump is located in the LH wing stub between the wing spars. Electrical power is
supplied from the main electrical bus. The FUEL XFER ³ or FUEL TRANS ³ switch in the lower
left side of the instrument panel controls the fuel transfer pump. A 5 Ampère circuit-breaker protects
the fuel transfer pump electrical system.
The pump is a high-pressure rotary pump.
F. Electrically Driven Fuel Pumps with Bypass Valve
The two electrically driven fuel pumps with bypass valve are located below the cockpit floor. The
bypass valve reduces the fuel pressure during operation of both electrically driven fuel pumps.
G. Fuel Cooler and Check Valves
The fuel cooler is located in the RH wing stub between the wing spars. It is accessible through the
RH main landing gear cover on the bottom side of the RH wing stub.
The fuel return line incorporates a check valve which is located in the RH wing stub upstream of
the auxiliary fuel tank cooling loop.
H. Fuel Pressure Pulsation Damper
If MÄM 40-468 is installed, a fuel pressure pulsation damper is installed in the fuel supply line
firewall forward between the fine fuel filter and the engine driven high pressure fuel pump.
Page 4 Doc # 6.02.15
15 Apr 2013 28-20-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
4. Fuel Transfer System Operation
In the usual operation, fuel flows from the left tank, through the fuel valve to the engine. Return fuel
from the engine passes through the cooling loop in the right tank and then into the left tank.
If the FUEL XFER ³ or FUEL TRANS ³ switch is set to ON, the transfer pump moves fuel from the
right tank to the left tank until either:
) The fuel transfer pump shut-off switch (high fuel sensor) in the left tank senses that the left tank is
full. This shuts the pump OFF.
) The fuel transfer pump shut-off switch (low fuel sensor) in the right tank senses that the fuel tank
is empty. This shuts the pump OFF.
Doc # 6.02.15 Page 5
Rev. 2 28-20-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Pulsation Damper
Element
Damper Housing
Damper Housing
O-Rings
Note: Recess on this side
O-Rings
Pulsating Damper Assy
Fuel Supply Line
Fuel Return Line
Fine Fuel Filter
Figure 2: Fuel System Components Firewall Forward (if MÄM 40-468 is installed)
Page 6 Doc # 6.02.15
15 Apr 2013 28-20-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the possible defects of the fuel distribution system. When experiencing trouble
detailed in the Trouble column read across to the Possible Cause column, then perform the repair
given in the Repair column.
Trouble Possible Cause Repair
Airplane smells of fuel. Hose/Pipe leaking. Examine all hoses and pipes.
Replace defective
components.
Loose connection. Examine all connections.
Tighten loose connections.
Component leaking. Examine all components.
Replace defective
components.
Fuel does not transfer Fuel transfer pump circuit- Set the transfer pump circuit-
correctly. breaker not set. breaker.
Fuel transfer pump defective. Replace the transfer pump.
Low fuel sensor in right tank Replace the sensor.
defective.
High fuel sensor in left tank Replace the sensor.
defective
FUEL XFER ³ or Replace the switch.
FUEL TRANS ³ switch in
instrument panel defective.
Wiring defective. Repair wiring.
Doc # 6.02.15 Page 101
Rev. 2 28-20-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 28-20-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
Maintenance Practices
1. General
This Section describes the Maintenance Practices for the fuel distribution system. The procedures are
limited to the removal/installation of the main components of the system.
Obey the safety precautions for fuel at all times.
WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE.
WARNING: DO NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN CAUSE
INJURY TO PERSONS AND DAMAGE TO EQUIPMENT.
WARNING: DO NOT BREATH FUEL VAPOR. FUEL VAPOR CAN MAKE YOU ILL.
2. Remove/Install the Fuel Valve and the Gascolator
A. Remove the Fuel Valve and the Gascolator
Remove the fuel valve and the gascolator as an assembly.
Obey the safety precautions for fuel at all times.
Detail Steps/Work Items Key Items/References
(1) Defuel the airplane. Refer to Section 12-10.
(2) Remove the access panel from the bottom of the Refer to Section 52-40.
fuselage around the gascolator drain valve.
(3) Drain the fuel from the distribution system. Use a suitable container. Drain the fuel
from the gascolator drain valve.
(4) Disconnect the flexible hose which connects the Put caps on the connections.
left fuel tank to the fuel valve, at the valve.
(5) Disconnect the T-fitting which connects the fuel Put caps on the connections.
transfer line.
(6) Disconnect the fuel line to the fuel pumps. Put caps on the connections.
Doc # 6.02.15 Page 201
Rev. 2 28-20-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(7) Remove the fuel valve and the gascolator:
S Remove the bolt and washer which attach the
gascolator mounting bracket.
S Remove the four bolts and washers which Hold the fuel valve!
attach the fuel valve to the fuselage.
S Lower the fuel valve and the gascolator clear
of the airplane.
Page 202 Doc # 6.02.15
15 Apr 2013 28-20-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
B. Install the Fuel Valve and the Gascolator
Detail Steps/Work Items Key Items/References
(1) Remove the left pilot's seat. Refer to Section 25-10.
(2) Move the fuel valve and the gascolator into Make sure that the gascolator mounting
position in the fuselage. bracket is correctly located.
Slide connecting shaft into the mating
part of the fuel valve.
Make sure that both the control lever in
the cockpit and the fuel valve are at the
same position.
(3) Install the fuel valve and the gascolator:
S Install the 4 washers on the 4 bolts.
S Put the bolts and washers into position
through the fuel valve into the anchor-nuts.
S Install the bolt and washer which attach the
gascolator mounting bracket.
S Tighten the bolts.
(4) Connect the pipe from the gascolator to the
firewall.
(5) Connect the T-fitting to the selector valve.
(6) Connect the flexible hose from the left fuel tank to
the selector valve.
(7) Refuel the airplane. Refer to Section 12-10.
(8) Do a test for fuel leaks from the connections
which you have worked on.
(9) Install the access panel under the fuselage Refer to Section 52-40.
around the gascolator drain valve.
(10) Install the left pilot's seat. Refer to Section 25-10.
(11) Do an engine ground run-up. Make sure that the
fuel system operates correctly.
Doc # 6.02.15 Page 203
Rev. 2 28-20-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
3. Remove/Install the Gascolator Filter
Obey the safety precautions for fuel at all times.
A. Remove the Gascolator Filter
Detail Steps/Work Items Key Items/References
(1) Set the fuel valve to OFF.
(2) Remove the access panel under the fuselage Refer to Section 52-40.
around the gascolator drain valve.
(3) Drain the fuel from the gascolator drain valve. Use a suitable container.
(4) Loosen the retaining ring which holds the Remove the lock-wire from the retaining
gascolator filter bowl to the gascolator. ring and fuel drain.
Hold the filter bowl!
(5) Lower the filter bowl clear of the gascolator and Discard the seal if it is damaged.
remove the filter.
Page 204 Doc # 6.02.15
15 Apr 2013 28-20-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
B. Install the Gascolator Filter
Detail Steps/Work Items Key Items/References
(1) Put the filter into position in the gascolator,
tighten filter hand tight.
(2) Install a new seal in the filter bowl.
(3) Install the filter bowl:
S Move the filter bowl into position onto the Make sure that the seal is correctly
gascolator. positioned.
S Align the arrow marks on the filter bowl with
the marks on the gascolator.
S Tighten the retaining ring which holds the
filter bowl in position.
S Secure retaining ring and fuel drain with
lock-wire.
(4) Do a test for leaks of the gascolator filter bowl:
S Make sure that there is fuel in the left tank.
S Set the fuel valve to NORMAL.
S Examine the gascolator bowl for leaks.
S Set the fuel valve to OFF.
(5) Install the access panel under the fuselage Refer to Section 52-40.
around the gascolator drain valve.
Doc # 6.02.15 Page 205
Rev. 2 28-20-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
4. Remove/Replace/Install the Fuel Pressure Pulsation Damper (if MÄM 40-468 is installed)
Obey the safety precautions for fuel at all times.
A. Remove the Fuel Pressure Pulsation Damper Assy
Detail Steps/Work Items Key Items/References
(1) Set the ENGINE MASTER to OFF.
(2) Remove the upper cowling.
(3) Remove the P-clamp which positions the fuel
pressure pulsation damper installation.
(4) Remove the lock wires at the lines on the fuel
pressure pulsation damper housing.
(5) Disconnect the two fuel lines which are
connected to the fuel pressure pulsation damper
housing.
B. Replace the Fuel Pressure Pulsation Damper
Detail Steps/Work Items Key Items/References
(1) Remove the wire locking of the fuel pressure
pulsation damper housing.
(2) Open the fuel pressure pulsation damper housing
by turning the cover counterclockwise.
(3) Remove and discard the fuel pressure pulsation
damper and the four O-rings.
(4) Clean the inside of the fuel pressure pulsation Flush with fuel approved for the
damper housing. airplane.
No contamination allowed.
(5) Install the four new O-rings.
(6) Apply 09-25300 ‘Fuelube EZTurn 1LB’ to the
outside thread and sealing surface of the fuel
pressure pulsation damper housing.
(7) Install the new fuel pressure pulsation damper in Refer to Figure 2.
the housing. Watch out for the installation
direction of the fuel pressure pulsation damper in
the housing.
Page 206 Doc # 6.02.15
15 Apr 2013 28-20-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
Detail Steps/Work Items Key Items/References
(8) Tighten the fuel pressure pulsation damper Torque 80 ± 4 Nm (59.0 ± 2.9 lbf.ft).
housing.
(9) Secure the fuel pressure pulsation damper
housing with locking wire.
C. Install the Fuel Pressure Pulsation Damper Housing Assy
Detail Steps/Work Items Key Items/References
(1) Flush the fuel pressure pulsation damper assy
with fuel approved for the airplane.
No contamination allowed.
(2) Connect the fuel pressure pulsation damper
housing to the fuel supply lines and secure with
locking wire. Watch out for the flow direction
(arrow).
(3) Install the P-clamp and mount the fuel pressure
pulsation damper assy to the engine.
(4) Install the upper cowling.
(5) Conduct an engine ground run.
(6) Inspect the airplane for fuel leakage.
Doc # 6.02.15 Page 207
Rev. 2 28-20-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
5. Remove/Install the Electrically Driven Fuel Pumps with Bypass Valve
Obey the safety precautions for fuel at all times.
A. Remove the Electrically Driven Fuel Pumps with Bypass Valve
Detail Steps/Work Items Key Items/References
(1) Set the ENGINE MASTER to OFF.
(2) Remove the access panel from the bottom Refer to Section 52-40.
fuselage around the gascolator drain valve.
(3) Disconnect electrical wire from the fuel pumps.
(4) Set the fuel selector to OFF.
(5) Drain the gascolator.
(6) Remove fuel lines to and from the fuel pumps.
(7) Remove the bypass unit:
S Fuel line, bypass valve and T-fitting.
(8) Remove the two nuts which attach the fuel pump
banjo to the support bracket.
(9) Remove the fuel pump assy:
S Loosen the four worm drive clamps.
S Move the worm drive clamps to each other.
S Remove the fuel pump assy.
Page 208 Doc # 6.02.15
15 Apr 2013 28-20-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
B. Install the Electrically Driven Fuel Pumps with Bypass Valve
Detail Steps/Work Items Key Items/References
(1) Install the fuel pump assembly and tighten the
four worm drive clamps.
(2) Install and tighten the two nuts which attach the
fuel pump banjo to the support bracket.
(3) Install the bypass unit:
S Fuel line, bypass valve and T-fitting.
(4) Connect the electrical wires of the fuel pumps to
the airplane electrical system.
(5) Install the access panel under the fuselage Refer to Section 52-40.
around the gascolator drain valve.
(6) Conduct an engine ground run. Refer to Section 71-00.
(7) Inspect the airplane for fuel leakage.
Doc # 6.02.15 Page 209
Rev. 2 28-20-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
6. Remove/Install the Fuel Transfer Pump
Obey the safety precautions for fuel at all times.
A. Remove the Fuel Transfer Pump
Detail Steps/Work Items Key Items/References
(1) Defuel the airplane. Refer to Section 12-10.
(2) Remove the cover plate at the left main landing
gear.
(3) Disconnect the electrical connector from the fuel
transfer pump.
(4) Disconnect both fuel lines from the transfer Mark fuel lines for ease of assembly.
pump.
(5) Remove the P-clamps and the fuel transfer
pump.
(6) Disconnect the ground wire from the fuel transfer Mark position of ground wire.
pump.
(7) Remove the fuel transfer pump.
B. Install the Fuel Transfer Pump
Detail Steps/Work Items Key Items/References
(1) Move the fuel transfer pump into position.
(2) Connect the ground wire to the previous marked As marked in Paragraph 6A, step 6.
position at the fuel transfer pump.
(3) Install and tighten the P-clamps.
(4) Install both fuel lines of the fuel transfer pump.
(5) Connect electrical wire of the fuel transfer pump.
(6) Install the cover plate at the left main landing
gear.
(7) Conduct an engine ground run. Refer to Section 71-00.
(8) Inspect the airplane for fuel leakage.
Page 210 Doc # 6.02.15
15 Apr 2013 28-20-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
7. Disassemble/Assemble the Fuel Transfer Pump Assembly
A. Disassemble the Fuel Transfer Pump Assembly
Detail Steps/Work Items Key Items/References
(1) Loosen jam nuts on 90° fittings and remove Note the installation direction of the
fittings from ”in” and ”out” port of the pump. fittings.
(2) Remove O-rings from the fittings. Discard O-rings.
(3) Remove the drain fitting. Hold the drain fitting.
(4) Remove lock wire from bolt of pump housing
which holds the bonding cable.
(5) Remove bolt and bonding cable. Hold the bonding cable.
(6) Re-install bolt.
(7) Put caps on the open connections.
B. Assemble a New Fuel Transfer Pump Assembly
Detail Steps/Work Items Key Items/References
(1) Cut electrical wires and crimp connectors onto Length: 24 cm (9.4 in).
the ends.
(2) Fix pins in the housing and apply appropriate There is no sensitivity to the polarity.
chafing protection on the wires.
(3) Examine the thread and the conical seats of the
fittings.
(4) Install new O-rings on the fittings.
(5) Remove protective caps from the pump and Observe the installation direction of the
install the fittings to the pump ”in” and ”out” ports. fittings.
(6) Tighten the jam nuts.
(7) Install the enclosed new screw on top of the "Top" means related to the installation
pump housing. in the airplane.
(8) Install the drain fitting on the bottom side of the
pump housing.
Doc # 6.02.15 Page 211
Rev. 2 28-20-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(9) Remove one of the top bolts from the pump Remove the lock wire.
housing.
"Top" means related to the installation
in the airplane.
(10) Grind housing around the hole where the bolt is To get electrical conductivity.
removed.
(11) Install bolt together with the bonding cable and
tighten the bolt.
(12) Install new lock wire on the bolts.
(13) Seal the grinded area around bolt of the pump To prevent corrosion.
housing with paint.
Page 212 Doc # 6.02.15
15 Apr 2013 28-20-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
8. Remove/Install the Fuel Cooler
A. Remove the Fuel Cooler
Detail Steps/Work Items Key Items/References
(1) Defuel the airplane. Refer to Section 12-10.
(2) Remove the RH main landing gear cover. On stub wing bottom side.
(3) Remove the rubber gasket on the air duct.
(4) Remove the air duct.
(5) Dis-connect the fuel lines at the fuel cooler.
(6) Open the mounting bolts (4x). Mark position of ground wire.
(7) Remove the fuel cooler.
B. Install the Fuel Cooler
Detail Steps/Work Items Key Items/References
(1) Put the fuel cooler in place.
(2) Attach the fuel cooler including ground wire with
the four bolts.
(3) Connect the fuel lines to the fuel cooler.
(4) Put the air duct to the fuel cooler.
(5) Install rubber gasket on air duct.
(6) Install RH main landing gear cover.
(7) Conduct an engine ground run. Refer to Section 71-00.
(8) Inspect the airplane for fuel leakage.
Doc # 6.02.15 Page 213
Rev. 2 28-20-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
9. Test the Fuel Valve
CAUTION: YOU MUST REPLACE THE FUEL VALVE IF THE TEST FAILS.
Detail Steps/Work Items Key Items/References
(1) Remove the cowling.
(2) Set the ENGINE MASTER switch to OFF.
(3) Disconnect the fuel return line from the engine Refer to AE Maintenance Manual, latest
driven fuel pump: revision.
S Remove lock-wire.
S Put caps on open fuel lines.
(4) Connect the external fuel line to the engine driven
fuel pump outlet.
(5) Set the fuel valve to NORMAL.
(6) Set the ENGINE MASTER switch to ON. Catch fuel in a suitable container.
Fuel must flow with a rate of about
3 liter/min.
(7) Turn ON the fuel pump. Flow rate must be increased.
(8) Turn OFF the fuel pump.
(9) Set fuel valve to EMERGENCY. Verify that fuel level is reducing in
auxiliary fuel tank (see G1000 MFD).
(10) Set the fuel valve to OFF. Fuel flow must be interrupted.
(11) Set the ENGINE MASTER switch to OFF.
(12) Disconnect the external fuel line from the engine
driven fuel pump outlet.
(13) Install the fuel return line to the engine driven fuel
pump:
S Install lock-wire.
(14) Install the cowling.
Page 214 Doc # 6.02.15
15 Apr 2013 28-20-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
10.Test the Check Valve in the Fuel Return Line
CAUTION: YOU MUST REPLACE THE CHECK VALVE IF THE TEST FAILS.
Detail Steps/Work Items Key Items/References
(1) Make sure that the left fuel tank (main tank) is Refer to Section 12-10.
full.
(2) Remove the cowling.
(3) Set the ENGINE MASTER switch to OFF.
(4) Disconnect the fuel return line at the firewall
forward connection.
(5) Connect an external fuel line with the additional
fuel pump to the firewall forward fuel return fitting.
(6) Turn ON the external fuel pump. Only a small amount of fuel is allowed
to come out of the additional fuel pump.
(7) Turn OFF the external fuel pump.
(8) Disconnect the external fuel line with additional
fuel pump from the firewall forward fuel return
fitting.
(9) Connect the fuel return line from the engine to the
firewall forward fuel return fitting.
Doc # 6.02.15 Page 215
Rev. 2 28-20-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 216 Doc # 6.02.15
15 Apr 2013 28-20-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
Section 28-40
Fuel Quantity Indicating
1. General
This Section describes the fuel quantity indicating system of the DA 40 NG. Refer to Section 28-00 for
the general data on the fuel system. Refer to Section 31-10 for data on replacing the fuel quantity
indicator.
2. Description
A. Standard Tank Configuration
Figure 1 shows the fuel quantity indication system main components. The fuel quantity indication
system is part of the engine indicating system. The fuel tank in each wing has a fuel probe with a
Teflon sleeve on the outboard end. The fuel quantity indicating system cannot be calibrated in
service.
Electric cables connect the fuel probes to the engine indicating system. The system displays the
fuel quantity.
Electric cables also connect the low fuel sensor in the left tank to a low fuel caution light in the
annunciator panel. Refer to Section 31-10 (if G1000 is installed) or 31-51 (if the conventional
cockpit with the White Wire annunciator panel is installed) for more data on the annunciator panel.
B. Long Range Tank Configuration (if OÄM-40-130 installed)
In the DA 40 NG long range tank the fuel quantity indication is the same as in the standard tank.
The fuel probe is installed in the inboard fuel tank chamber. This fuel probe measures a fuel
quantity of maximum 14 US gal (53 liter), which is the maximum quantity of indicated fuel.
Doc # 6.02.15 Page 1
Rev. 2 28-40-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
3. Operation
A. Standard Tank Configuration
As the fuel level in the fuel tanks decreases, the area of the fuel probe which is “wetted” with fuel
will also decrease. The amount of "wetted" area is converted into an electrical signal which sets the
fuel quantity reading at the fuel quantity indicator. The fuel quantity indicator displays the quantity
of fuel in the left fuel tank and the right fuel tank. The fuel quantity indicator is shown on the MFD
of the G1000 or on the SED. The display shows the fuel quantity in US gallons. The maximum
indicated fuel quantity is 14 US gal (53 liter) per tank.
The low fuel sensor in the left tank operates a caution light on the annunciator panel. When the fuel
level in the left tank falls below 3 US gal (+2/-1 US gal) the caution light comes on. Refer to Section
31-10 for more data on the LOW FUEL caution light (if G1000 is installed) or to Section 31-51 for
more data on the FUEL LOW caution light (if the conventional cockpit with the White Wire
annunciator panel is installed).
B. Long Range Tank Configuration (if OÄM-40-130 installed)
The total useable fuel quantity is 19.5 US gal (73.8 liter) per tank. The indicated fuel quantity is
14 US gal (53 liter) per tank. Thus the remaining 5.5 US gal (20.8 liter) per tank are not indicated
on the MFD of the G1000 or on the SED.
Page 2 Doc # 6.02.15
15 Apr 2013 28-40-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
Low Fuel Sensor
Left Fuel Tank
Fuel Temperature Sensor
Fuel Quantity Probe
VIEW ON INBOARD END OF LEFT FUEL TANK
Figure 1: Fuel Quantity Indication Components in the Left Hand Fuel Tank
Doc # 6.02.15 Page 3
Rev. 2 28-40-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Temperature Sensor
Low Fuel Sensor
Right Fuel Tank
VIEW ON INBOARD END OF RIGHT FUEL TANK
Fuel Quantity Probe
Figure 2: Fuel Quantity Indication Components in the Right Hand Fuel Tank
Page 4 Doc # 6.02.15
15 Apr 2013 28-40-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the possible defects of the fuel quantity indicating system. When experiencing
trouble detailed in the Trouble column read across to the Possible Cause column, then perform the
repair given in the Repair column.
Trouble Possible Cause Repair
Fuel quantity indication for one Fuel probe unit in fuel tank Defuel/refuel the related tank to
tank incorrect, or first and last defective/contaminated. flush the fuel probe. If the
LED on fuel quantity indicator indication is still incorrect then
illuminated. Other tank reads replace the fuel probe.
correctly.
Fuel quantity indication system Do a test of the indication
wiring defective. system wiring. Refer to
Chapter 92-00 for the wiring
diagrams.
Fuel quantity indication on both Fuel quantity indicator Replace the fuel quantity
tanks incorrect/blank. defective. indicator.
Fuel quantity indication system Do a test of the indication
wiring defective. system wiring. Refer to
Chapter 92-00 for the wiring
diagrams.
Fuel low level caution shows Fuel low level sensor Replace the fuel low level
on the annunciator panel when defective. sensor.
the left tank has more than
5 US gal (19 liter) of fuel.
Doc # 6.02.15 Page 101
Rev. 2 28-40-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 28-40-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
Maintenance Practices
1. General
The Maintenance Practices in this Section describes how to replace a fuel tank probe and a fuel tank
sensor.
Refer to Section 31-10 for data on removing/installing a fuel quantity indicator.
Obey the safety precautions for fuel at all times.
WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE.
WARNING: DO NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN CAUSE
INJURY TO PERSONS AND DAMAGE TO EQUIPMENT.
WARNING: DO NOT BREATH FUEL VAPOR. FUEL VAPOR CAN MAKE YOU ILL.
2. Remove/Install a Low Fuel Sensor
Each tank has a low fuel sensor.
Obey the safety precautions for fuel at all times.
A. Remove a Low Fuel Sensor
Detail Steps/Work Items Key Items/References
(1) Remove the wing where the low fuel sensor will Refer to Section 57-10.
be removed.
(2) Remove the access panel from the root rib of the
wing:
S Remove the 11 nuts and washers from the
studs.
S Pull the access panel off the studs and clear
of the airplane.
(3) Disconnect the electrical cables of the low fuel At the in-line connector.
sensor.
(4) Remove the low fuel sensor from the tank.
Doc # 6.02.15 Page 201
Rev. 2 28-40-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
B. Install a Low Fuel Sensor
Detail Steps/Work Items Key Items/References
(1) Install the low fuel sensor in the fuel tank:
S Apply sealant to the thread of the low fuel Use Loctite 243 or 'seal-lube' or
sensor. 'fuel-lube'.
S Move the low fuel sensor into position in the
fuel tank mount.
S Screw the low fuel sensor fully home into the
mount.
S Tighten the low fuel sensor. The arrow must point down.
(2) Connect the electrical cables to the low fuel At the in-line connector.
switch.
(3) Install the access panel at the wing root rib:
S Put the access panel into position on the
studs.
S Install the 11 washers and nuts.
S Tighten the nuts.
(4) Install the wing, but do not refuel the airplane. Refer to Section 57-10.
(5) Do a test for the correct operation of the low fuel Right tank: Make sure that it switches
sensor. off the fuel transfer pump when the fuel
level is low.
Left tank: Make sure that it switches on
the LOW FUEL caution light when the
fuel level is at 3 US gal (+2/-1 US gal).
(6) Refuel the airplane. Refer to Section 12-10.
(7) Do a check for leaks.
Page 202 Doc # 6.02.15
15 Apr 2013 28-40-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
3. Remove/Install the High Fuel Sensor
Only the left tank has a high fuel sensor.
Obey the safety precautions for fuel at all times.
A. Remove the High Fuel Sensor
Detail Steps/Work Items Key Items/References
(1) Remove the left wing. Refer to Section 57-10.
(2) Remove the left fuel tank assembly. Refer to Section 28-10.
(3) Disconnect the electrical cables of the high fuel At the in-line connector near the high
sensor. fuel sensor.
(4) Remove the high fuel sensor from the tank.
B. Install the High Fuel Sensor
Detail Steps/Work Items Key Items/References
(1) Install the high fuel sensor in the fuel tank:
S Apply sealant to the thread of the high fuel Use 'seal-lube' or 'fuel-lube'.
sensor.
S Move the high fuel sensor into position in the
fuel tank mount.
S Screw the high fuel sensor fully home into the The arrow must point up.
mount.
S Tighten the high fuel sensor.
(2) Connect the electrical cables to the high fuel At the in-line connector.
sensor.
(3) Install the left fuel tank assembly. Refer to Section 28-10.
(4) Install the left wing, but do not refuel the airplane. Refer to Section 57-10.
(5) Do a test for the correct operation of the high fuel Make sure that the fuel transfer pump
sensor. switches off when the fuel level in the
left tank is high.
(6) Refuel the airplane. Refer to Section 12-10.
(7) Do a check for leaks.
Doc # 6.02.15 Page 203
Rev. 2 28-40-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
4. Remove/Install a Fuel Quantity Probe
Obey the safety precautions for fuel at all times.
A. Remove a Fuel Quantity Probe
Detail Steps/Work Items Key Items/References
(1) Remove the wing where the fuel quantity probe Refer to Section 57-10.
will be removed, and support the wing on trestles.
(2) Remove fuel tank assembly from the wing. Refer to Section 28-10.
(3) Remove the fuel quantity probe from the
threaded mounting.
Page 204 Doc # 6.02.15
15 Apr 2013 28-40-00 Rev. 2
DA 40 NG AMM Fuel System
AIRCRAFT
B. Install a Fuel Quantity Probe
Detail Steps/Work Items Key Items/References
(1) Separate the fuel filler assembly from the fuel Refer to Section 28-10.
tank.
To gain access to the guide at the
outboard end of the fuel tank.
(2) Install the fuel quantity probe into the fuel tank:
S Apply sealant to the thread of the fuel Use 'seal-lube' or 'fuel-lube'.
quantity probe.
S Install a new O-ring seal.
S Install the Teflon sleeve to the fuel probe.
S Carefully move the fuel quantity probe into Make sure that the fuel quantity probe
position in the inboard tank. Engage the goes into the guide at the outboard end
thread. of the fuel tank.
S Turn the probe clockwise, by hand, until the
fuel quantity probe is fully engaged in its
mount.
S Tighten the fuel quantity probe until the
O-ring seals.
(3) Re-connect the fuel filler assembly to the fuel Refer to Section 28-10.
tank.
(4) Install fuel tank assembly into wing. Refer to Section 28-10.
(5) Install the wing to the airplane. Refer to Section 57-10.
(6) Examine the fuel quantity probe installation for
fuel leaks.
(7) Install the access panel for the fuel tank. Refer to Section 52-40.
Doc # 6.02.15 Page 205
Rev. 2 28-40-00 15 Apr 2013
Fuel System DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 206 Doc # 6.02.15
15 Apr 2013 28-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
CHAPTER 31
INDICATING SYSTEMS
Doc # 6.02.15 Page 1
Rev. 2 31-TITLE 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 31-TITLE Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 31
INDICATING SYSTEMS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 31-10
Instrument and Control Panels
with G1000 System Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Instrument Panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Center Console Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Engine Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 31-11
Instrument and Control Panels
with Conventional Cockpit Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Instrument Panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section 31-20
Independent Instruments
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Doc # 6.02.15 Page 1
Rev. 2 31-CONTENTS 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Digital Chronometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 31-40
Central Computers
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a GDU 104X Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3. Remove/Install a GIA 63 Integrated Avionics Unit (IAU) . . . . . . . . . . . . . . . . . . . 207
4. Remove/Install the GTX33 Transponder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
5. Remove/Install the GRS77 Attitude, Heading and Reference Unit (AHRS) . . . 213
6. Remove/Install the GDC 74A Air Data Computer (ADC) . . . . . . . . . . . . . . . . . . 215
7. Remove/Install the GEA 71 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
8. GMU 44 Magnetometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Section 31-51
Central Warning System
with Conventional Cockpit Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation - White Wire Annunciator Panel . . . . . . . . . . . . . . . . . . 1
3. Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Page 2 Doc # 6.02.15
15 Apr 2013 31-CONTENTS Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Annunciator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Test the Annunciator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Doc # 6.02.15 Page 3
Rev. 2 31-CONTENTS 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 31-CONTENTS Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
CHAPTER 31
INDICATING 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 DA 40 NG with G1000 system
installed.
) Section 31-11. The instrument and control panels for the DA 40 NG with conventional
cockpit installed.
) Section 31-20. Independent instruments.
) Section 31-40. The integrated cockpit system.
) Section 31-51. Central warning system with conventional cockpit installed.
The DA 40 NG has these indicating systems:
) An instrument panel. The instrument panel is made in several pieces with a shelf. The shelf
goes between the panel and the firewall.
) A control panel in the center console. This panel has the engine controls, fuel controls, cabin
heat control levers, parking brake and trim. It has a forward part and an aft part.
) Integrated cockpit system (ICS), if the G1000 system is installed. The airplane has an
integrated cockpit system with two displays which give the airplane flight and navigation
displays, engine instrument displays and airplane systems indications. The ICS has “softkeys”
on the display screens for the option of selecting which indications will be displayed on the
screen.
) Main engine display (MED).
) Secondary engine display (SED).
) White wire annunciator panel.
This Section does not tell you about the indicators that belong to systems. See the related system for
data.
Doc # 6.02.15 Page 1
Rev. 2 31-00-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Note: Equipment which is certified for installation in the DA 40 NG is listed in Section 6.5
of the Airplane Flight Manual. Such equipment may be installed in accordance with
the Airplane Maintenance Manual.
Any equipment which is not listed in Section 6.5 of the Airplane Flight Manual is
called "Additional Equipment". The installation of Additional Equipment is a
modification which must be handled in accordance with national regulations or a
Service Bulletin.
Page 2 Doc # 6.02.15
15 Apr 2013 31-00-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Section 31-10
Instrument and Control Panels
with G1000 System Installed
1. General
The DA 40 NG has these instrument and control panels:
) An instrument panel. The instrument panel is made in several pieces with a shelf. The shelf
goes between the panel and the instrument panel frame.
) A control panel in the center console. This panel has a forward cover and an aft cover. The
forward cover has the cabin heat control levers, parking brake lever and rudder trim control. The
aft cover has the engine controls and fuel transfer/shut-off valve.
See the related Chapter or Section for data about the controls. For example, see Section 76-00 for
data on the engine controls.
Doc # 6.02.15 Page 1
Rev. 2 31-10-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
24 10 11 12 17 25 18 19 20 26 21
13
16
9 16
7
8
6 Manouvering speed:
V A=11
1 KIAS (above 1036 up to 1200 kg / above 2284 up to 2646 lb)
V A=94 KIAS (780 to 1036 kg / 1720 to 2284lb)
This airplane may only be oper ated in acco rdance with theAirplane Flight
Manual. It can be operated in the "Normal" and "Utility" ca tegories in
non-icing conditions. Provided that national operational requirements
are me t and the appropr iate equipment is insta led, this airplane is ap-
proved for the following kinds of opera tion: day VFR, night VFRand
Ess Bus
not for
normal
operation
See AFM
L imitatio ns for G FC 700 Au topi lot Sys te m:
Do not use AP fi “Alternate St atic” is open.
Conduct AP an d tr imc heck pr ior to e ach flight (s ee AFM) .
Auto pilot OFF dur ing take -off and la nding.
Maximum speed for au top ilot oper ation is 165 KIAS.
Minimum speed f or aut opilot oper ation is 7 0 KIAS.
Minimum altitude for autopilo t oper ation:
IFR. All aeroba tics ma neuvers including spinning are prohibited. For Cr uise, Climb, Descen t an d Man euv erin g: 8 00 fee t AGL
further operational limitations refer to the Airplane Flight Manual. Approach: 2 00 fee t AGL
No smoking
15 5 4 1 2 3 14 22
Figure 1: Instrument Panel
Major Instruments and Controls
1 ELECTRIC MASTER key switch 14 FLAP SELECTOR switch
2 FUEL TRANSFER switch 15 Alternate static valve
3 PITOT HEAT switch 16 Ventilation nozzles
4 AVIONIC MASTER switch 17 Backup airspeed indicator
5 ESSENTIAL BUS switch 18 Backup artificial horizon
6 FUEL PUMPS switch 19 Backup altimeter
7 ECU Test button 20 Emergency compass
8 ECU VOTER switch 21 ELT control unit
9 ENGINE MASTER switch 22 Accessory power socket
10 Rotary buttons for instrument lighting 24 Primary flight display (PFD)
and flood light
11 Light switches 25 Audio amplifier / Intercom /
Marker beacon receiver
12 EMERGENCY switch 26 Multi function display (MFD)
including autopilot controls (if autopilot
GFC 700 is installed)
13 Circuit breakers
Page 2 Doc # 6.02.15
15 Apr 2013 31-10-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
2. Instrument Panel Description
Several pieces of aluminum alloy make the instrument panel. The panel has a vertical face with
instruments and a horizontal 'shelf' with electrical components. The shelf goes between the firewall
and the vertical face of the panel.
The DA 40 NG has an integrated cockpit system (ICS). The ICS has two large LCD display screens
which are located in the instrument panel. These two display screens can digitally display all of the
flight, navigation and airplane system data. An audio control panel is located between the display
screens. The audio control panel integrates with the ICS and is used to control all of the airplane radio
and navigation audio systems. Refer to Section 31-40 for more data about the ICS.
An airspeed indicator, artificial horizon, altimeter and magnetic compass are located along the top of
the instrument panel. These instrument provide the basic data required to fly the airplane in the event
of a power failure and the loss of the ICS. The artificial horizon is a gyroscopic instrument that can be
powered from an emergency power pack. An emergency switch is located near the artificial horizon
and has a guard installed to prevent accidental selection.
The circuit-breakers for the electrical systems are all located on the right side of the instrument panel.
The electrical system bus-bars are directly connected to the rear of the circuit-breakers.
The shelf part of the instrument panel holds relays, junction blocks, connectors and ground studs.
The instrument panel has a cover attached by screws.
Refer to Chapter 24 for more data about the electrical system and Chapter 34 for more data about the
autopilot system.
Doc # 6.02.15 Page 3
Rev. 2 31-10-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Top Bracket
Front Bracket Center Bracket Rear Bracket
Right Side Plate
Left Side Plate
Figure 2: Engine Control Assembly Structure
Page 4 Doc # 6.02.15
15 Apr 2013 31-10-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
3. Center Console Description
The engine control assembly holds the parking brake and heating controls. It also holds the engine
power lever.
Figure 2 shows the center console structure. Refer to the related Chapters for the data on the controls.
The engine control assembly has two aluminum alloy side plates. Four brackets attach to the side
plates with rivets. The front bracket has holes to anchor the outer sheaths of the brake and heat control
cables. The top bracket has two anchor-nuts. Bolts engage the anchor nuts to attach the engine
control assembly to the top of the floor panel.
The center bracket has two anchor nuts for the control cover plates. The rear bracket attaches to the
elevator trim control assembly.
There are no user-maintainable parts in the engine control assembly structure.
Doc # 6.02.15 Page 5
Rev. 2 31-10-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 6 Doc # 6.02.15
15 Apr 2013 31-10-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the control panel in the center console. If you
have the trouble detailed in the Trouble column read across to the Possible Cause column. Then do
the repair given in the Repair column.
Trouble Possible Cause Repair
Parking brake or cabin heat Friction tension too low. Adjust the friction.
control levers do not stay in the
Too much wear in the friction Replace the friction washers.
set position.
washers.
Doc # 6.02.15 Page 101
Rev. 2 31-10-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 31-10-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove/install the engine control assembly. See the
related Chapter for data about indicators in other systems.
2. Remove/Install the Engine Control Assembly
A. Remove the Engine Control Assembly
Detail Steps/Work Items Key Items/References
(1) Remove the knob from the emergency fuel valve:
S Remove the cross-head screw from the
center of the control-knob and pull the knob
up and off the fuel selector valve.
S Remove the mounting plate.
(2) Remove the engine power control lever Refer to Section 76-00.
assembly.
(3) Remove the bolts that attach the engine control
assembly to the floor panel at the front and at the
rear.
(4) Remove the front cover plate.
(5) Move the engine control assembly to a position
where you can reach the control cables.
(6) Disconnect the following control cables from the
center console:
S Cabin heat control cable. Refer to Section 21-00.
S Cabin heat distribution control cable. Refer to Section 21-00.
S Parking brake control cable. Refer to Section 32-40.
(7) Move the engine control assembly clear of the
airplane.
Doc # 6.02.15 Page 201
Rev. 2 31-10-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
B. Install the Engine Control Assembly
Detail Steps/Work Items Key Items/References
(1) Make sure that there are no loose items,
specially in the center console.
(2) Move the engine control assembly onto the
center console and support it in a position where
you can install the control cables.
(3) Connect these control cables to the engine
control assembly:
S Parking brake control cable. Refer to Section 32-40.
S Cabin heat distribution control cable. Refer to Section 21-00.
S Cabin heat control cable. Refer to Section 21-00.
(4) Move the engine control assembly fully into
position in the floor panel.
(5) Install the engine control assembly front cover
plate:
S Move the cover plate into position on the
engine control assembly.
S Install the 2 hex-headed bolts which attach Do not tighten.
the cover plate and engine control assembly
to the floor panel.
(6) Install the engine power control lever. Refer to Section 76-00.
(7) Tighten the 2 hex-headed bolts in the front cover
plate.
(8) Do a test for correct range, full and free Refer to Section 21-00.
movement of the cabin heat control system.
(9) Do a test for correct range, full and free Refer to Section 21-00.
movement of the cabin heat distribution system.
Page 202 Doc # 6.02.15
15 Apr 2013 31-10-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Detail Steps/Work Items Key Items/References
(10) Install the knob on the emergency fuel valve:
S Install the mounting plate.
S Push the knob onto the fuel valve selector
shaft.
S Install the cross-head screw which attaches
the knob to the shaft.
Doc # 6.02.15 Page 203
Rev. 2 31-10-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 204 Doc # 6.02.15
15 Apr 2013 31-10-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Section 31-11
Instrument and Control Panels
with Conventional Cockpit Installed
1. General
The DA 40 NG with the conventional cockpit installed has these instrument and control panels:
) An instrument panel. The instrument panel is made in one piece with a shelf. The shelf goes
between the panel and the firewall.
) A control panel in the center console. This panel has a forward cover and an aft cover. The forward
cover has the cabin heat control levers and parking brake lever. The aft cover has the engine
control and emergency fuel valve.
See the related Chapter or Section for data about the controls. For example, see Section 76-00 for
data on the engine controls.
The following Figure shows the instrument panel with conventional instrumentation:
Note: The instruments and avionic equipment cannot be installed in any arbitrary
combination. The airplane manufacturer must be contacted before removing or
installing equipment, with the exception of replacing a unit by an identical unit.
Doc # 6.02.15 Page 1
Rev. 2 31-11-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Figure 2: Instrument Panel with Conventional Instrumentation
Page 2 Doc # 6.02.15
15 Apr 2013 31-11-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Major Instruments and Controls
1 ELECTRIC MASTER key switch 21 ELT control unit
2 FUEL TRANSFER switch 22 Accessory power socket
3 PITOT HEAT switch 27 Airspeed Indicator
4 AVIONICS MASTER switch 28 Attitude Gyro (artificial horizon)
5 ESSENTIAL BUS switch 29 Altimeter
6 FUEL PUMPS switch 30 Vertical Speed Indicator (VSI)
7 ECU Test button 31 Directional Gyro
8 ECU VOTER switch 32 Turn & Bank indicator
9 ENGINE MASTER switch 33 Intercom
10 Rotary buttons for instrument 34 Annunciator panel
lighting and flood light
11 Light switches 35 Main Engine Display (MED)
13 Circuit breakers 36 Secondary Engine Display (SED)
14 FLAP SELECTOR switch 37 Chronometer with OAT Indicator
15 Alternate static valve 38 COM/NAV
16 Ventilation nozzles 39 Transponder
Doc # 6.02.15 Page 3
Rev. 2 31-11-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
2. Instrument Panel Description
A single piece of aluminum alloy makes the instrument panel. The panel has a vertical face with
instruments and a horizontal ‘shelf’ with electrical components. The shelf goes between the firewall
and the vertical face of the panel.
The left side of the panel has the usual flight instruments. Refer to Chapter 34 for data on these
instruments.
The right part of the panel has the standard-size avionic equipment. It holds the trays for the
transponder and radio. Refer to Chapters 23 and 34 for data on this equipment.
The right side of the panel also contains the engine instruments. The engine data shows on two digital
instruments. There is also a digital OAT indicator and clock that can also show voltage. Refer to
Chapter 77 for data on these instruments.
The bottom left of the panel has the switch panel. The ELECTRIC MASTER key switch is a master
switch and starter switch (as in motor vehicles). Setting it to the ON position applies power to the bus
system. Refer to Chapter 24-01 for data on the electrical system.
The far left of the panel has the rheostat switches for lighting control.
The bottom part of the panel has the circuit-breakers. The circuit-breakers are grouped in bus order.
Refer to Section 24-61 for more data about the circuit-breakers and bus system.
The shelf part of the instrument panel holds relays, junction blocks, connectors and ground studs.
The instrument panel has a cover attached by screws.
Page 4 Doc # 6.02.15
15 Apr 2013 31-11-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Section 31-20
Independent Instruments
1. General
This Section tells you about the digital chronometer which can be installed in the DA 40 NG. Refer to
the equipment manufacturers' manuals for more data about the equipment.
2. Description
A. Davtron M803 Digital Chronometer
Figure 1 shows the Davtron M803 digital chronometer. It is located in the instrument panel, see
Section 31-10 or 31-11. Refer to Section 34-10 for more information about the OAT indication
functions of the unit.
The front of the Davtron M803 digital chronometer consists of three buttons and an LCD. The
background of the LCD is illuminated.
The chronometer has the following functions:
) Clock function. The time can be displayed in 'Universal Time' format or 'Local Time' format.
) Elapsed Timer Count Up. The unit displays the minutes and seconds during the first hour, then
the hours and minutes until 99 hours and 50 minutes.
) Elapsed Timer Count Down. A count down from any time, a maximum of 59 minutes and
59 seconds can be set.
) Flight Time Alarm. The display will flash when the Flight Time equals the previous set alarm
time.
) OAT/Volts. One button control steps sequentially through E, F, C. (E-Voltage (EMF), F-OAT
Fahrenheit, C-OAT Centigrade).
The chronometer and lighting are supplied with power by the main bus. The chronometer has an
internally back-up 1.5 V AA battery.
Doc # 6.02.15 Page 1
Rev. 2 31-20-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Figure 1: Davtron M803 Digital Chronometer
Page 2 Doc # 6.02.15
15 Apr 2013 31-20-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to replace the digital chronometer. Refer to the equipment manufacturer's
manuals for more data on the digital chronometer.
2. Remove/Install the Digital Chronometer
A. Remove the Digital Chronometer
Detail Steps/Work Items Key Items/References
(1) Open the OAT circuit-breaker.
(2) Remove the instrument panel cover. Refer to Section 25-10.
(3) Disconnect the electrical cable from the
chronometer.
(4) Remove the screws which attach the Hold the chronometer.
chronometer to the instrument panel.
(5) Move the chronometer out of the instrument
panel and lift clear of the airplane.
Doc # 6.02.15 Page 201
Rev. 2 31-20-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
B. Install the Digital Chronometer
Detail Steps/Work Items Key Items/References
(1) Move the chronometer into its position in the
instrument panel.
(2) Install the screws which attach the
chronometer to the instrument panel.
(3) Connect the electrical cable to the rear of the
chronometer.
(4) Do a test for correct OAT indication.
S Close the OAT circuit-breaker.
S Set the ELECTRIC MASTER key switch to
ON.
S Read OAT indication. The OAT indicator must indicate the
ambient temperature ±2°.
S Set the ELECTRIC MASTER key switch to
OFF.
(5) Davtron M803: Refer to equipment manufacturer's
manuals.
S If necessary, set the time.
(6) Install the instrument panel cover. Refer to Section 25-10.
Page 202 Doc # 6.02.15
15 Apr 2013 31-20-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Section 31-40
Central Computers
1. General
The DA 40 NG has a Garmin G1000 Integrated Cockpit System (ICS). The ICS integrates all the usual
flight, avionic and airframe system indications into one system. The system displays the data on two
display screens located in the instrument panel. An audio control panel is located between the two
display screens. The audio control panel integrates and controls the airplane radio, navigation and
intercom systems.
Refer to Section 23-50 for more data about the audio control panel.
Electrical power is supplied to the ICS control and display screens when the ELECTRIC MASTER key
switch is set to ON. Power is supplied to the audio control panel when the AVIONIC MASTER switch
is set to ON.
During normal operation the left display screen is referred to as the primary flight display (PFD) and
the right display screen as the multi function display (MFD). Either display can be used as PFD or
MFD. If one display fails the remaining screen can be switched to the reversionary mode. Reversionary
mode is a mode of operation in which both the PFD and MFD are identically configured to display all
of the important flight parameters in the event of display failure.
For more detailed data about the ICS refer to the G1000 Cockpit Reference Guide for the DA 40 NG
Airplane.
Figure 1 shows the ICS system schematic.
Doc # 6.02.15 Page 1
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Master
Configuration
Module
GMA 1347
Audio Panel
Reversionary Reversionary
No. 1 Switch Switch No. 2
GDU 1040 ARINC 429 GDU 1044
Primary Multi-Function
Flight Display ARINC 429 Display
Ethernet
Ethernet RS-232 Ethernet
Digital COM Digital COM
Audio Audio
No. 1 No. 2
Digital NAV Digital NAV
GIA 63 W GIA 63 W
Audio Audio
Integrated Integrated
Avionics RS-232 GPT 59 OAT Avionics
Unit Probe Unit
RS-232 GDC 74A
Air Data ARINC 429
ARINC 429
Computer
ARINC 429 Configuration
Module
RS-232
GRS 77 RS-232
ARINC 429 AHRS
ARINC 429
RS-485
Configuration
Module GMU 44
Magnetometer
RS-232 GTX 32/33 RS-232
Transponder
RS-485 RS-485
GEA 71
Engine/Airframe
Unit
Engine/Airframe Configuration
Sensors Module
Figure 1: Integrated Cockpit System Schematic Diagram
Page 2 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
2. Description
Figure 1 shows the schematic diagram for the ICS. The ICS has these main components:
A. Primary Flight Display (PFD)
Figure 3 shows the PFD.
The PFD is a 10.4 in liquid crystal display. Bezels on the left and right side of the PFD have the
controls for the ICS. The lower edge of the PFD has 'softkeys'. The function of the softkeys relates
to the on-screen display and the display will show the function of the key.
The PFD shows the basic primary flight display plus a number of additional options that can
selected manually. Some other indications will be generated automatically for example, alert
captions.
The left side bezel has these controls:
) NAV Vol/Sq knob. This controls the NAV audio level. Press the knob to toggle the ident filter
OFF/ON.
) NAV Frequency Transfer key. Press this key to make the standby NAV frequency the active
frequency.
) NAV knob. This control has a large outer knob and a smaller inner knob. Rotate these knobs
to select the NAV frequency. Rotate the large outer knob to select the MHz and the inner knob
to select the KHz. Pressing the smaller inner knob will toggle the tuning cursor between the
NAV1 and NAV2 frequency display.
) HDG knob. You can manually select the heading with this control. Pressing this knob will cause
a heading window to momentarily appear to the left of the heading indicator. This window will
show the airplane heading in a digital display and the heading bug will align with the compass
lubber line.
) ALT SEL knob. Sets the selected altitude in the window over the altimeter tape display. The
large outer knob sets the thousands indication and the inner knob sets the hundreds indication.
The right side bezel has these controls:
) COM VOL/SQ knob. Controls the COM audio level. Press the knob to toggle the COM automatic
squelch ON/OFF.
) COM Frequency Transfer key. Press this key momentarily to make the standby COM frequency
active. Press and hold this key to automatically make the emergency frequency (121.5 MHz)
the standby frequency.
Doc # 6.02.15 Page 3
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
NAV Vol/Sq
Garmin Display Unit
V OL PU SH
NAV Frequency V OL PUIDSH
NAV COM
SQ
Transfer
EMERG
NAV Frequency P USH
1-2
P USH
1-2
HDG CRS BARO
Selector SD Card Slots
Heading Selector P USH
HDG S YNC
P USH
CRS CTR
RANGE
P USH
PAN
D ME NU
FPL PR OC
CLR EN T
ALT DFLT MAP FMS
Altitude Selector
Left Side Bezel Soft Keys Right Side Bezel
Figure 2: Garmin G1000 Display Screens and Audio Integrating Unit
Page 4 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
) COM knob. This control has a large outer knob and a smaller inner knob. Rotate these knobs
to select the COM frequency. Rotate the large outer knob to select the MHz and the inner knob
to select the KHz. Pressing the smaller inner knob will toggle the tuning cursor between the
COM1 and COM2 frequency display.
) CRS/BARO knob. This control has a large outer knob and a small inner knob. The outer knob
sets the barometric pressure. The inner knob sets the airplane course.
) RANGE/PAN JOYSTICK knob. Rotate the knob to increase/decrease the map scale. Use the
knob as a joystick to pan the map display.
) DIRECT TO key. Press this key to activate the direct-to function. This will give the direct course
to a waypoint selected from the active route or to a position indicated by the map cursor.
) MENU key. Press the key to display the menu. The menu displays the options associated with
the currently displayed page.
) FPL key. Press this key to display the active flight plan page. You can create or edit an existing
flight plan using the bezel controls and soft keys when this page is displayed.
) PROC key. Press this key to display the procedures page. If this page is used with a selected
flight plan then the procedures page will display the data associated with the flight plan. If the
page is not used with a flight plan then an airfield and its related procedures can be selected
from a database.
) CLR key. Press this key to cancel an entry or delete information. Press and hold this key to
immediately display the Default Navigation Map Page.
) ENT key. Press to accept a menu selection or data entry. Use this key to approve an operation
or to complete a data entry.
) FMS knobs. Use these concentric knobs select the page to be displayed. The outer large knob
selects a page group and the inner knob selects a specific page from within the selected page
group. Press the inner knob to activates an on-screen cursor. When the cursor is activated the
outer knob can be used to move the cursor on the page and the small inner knob can used to
scroll the cursor through an item or menu selected by the outer knob.
) Secure Digital (SD) Cards. Secure digital cards can be inserted into the slots in the right side
bezel. These cards can contain data such as updated GPS navigation charts or special-to-type
airplane check-lists.
Doc # 6.02.15 Page 5
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Nav Frequency Waypoint Status Marker Beacon
Window Window Annunciation Com Frequency Window
NAV1 117.90 112.20 MPT KTYS DIS 140% DTK 291% TRX 291% 136.975 118.000 VOL PUSH
VOL PUSH
ID
SQ
NAV2 108.00 117.95 136.975 118.000
NAV EMERG
COM
TRAFFIC
0
M
140 2
20 20 6600
PUSH PUSH
1-2 130 1 1-2
10 10 6400
HDG
60
CRS BARO Glideslope
120
63 40
20
100
Indicator
110
6200 1 PUSH
PUSH 10 10 CRS CTR
HDG SYNC
100 DOOR OPEN
ALTERNATOR RANGE
291° 6000 2 PITOT OFF
Warnings &
80 R FUEL LOW
TAS 120% 30 29.68
w 33
L FUEL LOW
Cautions
24
NORTH UP
GPS ENR
ALERTS PUSH
PAN
Annunciation
21
DOOR OPEN - Canopy and/or rear
N
door isn't closed and locked.
KCL ALTERNATOR - Alternator failed
D MENU
S
Battery is only elec source.
6 PITOT OFF - Pitot heat is off. FPL PROC
15 E Turn switch on to avoid icing.
12
CLR ENT
ALT
OAT 08 XPDR 1200 STBY LD 12:03:25
DFLT MAP FMS
System Time
INSET PFD CDI OBS XPDR REFS NRST WARNING
Outside Air Nav Map Transponder Alerts
Temperature Window Window
Window
Figure 3: Primary Flight Display
Page 6 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
The basic flight instruments are:
) Airspeed Indicator (ASI). The airspeed indicator is on the left side of the display and indicates
the airspeed on a rolling number gauge using a moving tape. The airspeed indicator also
displays speed ranges for different airplane configurations, airspeed trends and ‘V’ speeds. If
the airspeed indicator fails the display marks the airspeed display area with a red ‘X’ and yellow
text spelling out ‘AIRSPEED FAIL’.
) TAS. True airspeed is digitally displayed in a small window below the airspeed indicator.
) Attitude Indicator (Artificial Horizon). The attitude indicator is located in the center of the PFD,
at the top. The attitude indicator shows the pitch, roll and yaw situation of the airplane. If the
attitude indicator fails the display marks the pitch attitude display area with a red ‘X’ and yellow
text spelling out ‘ATTITUDE FAIL’.
) Altimeter. The altimeter is located at the top right of the PFD. The altimeter displays the airplane
altitude in feet on a rolling number gauge using a moving tape. The altimeter also shows a
altitude ‘bug’ at the selected altitude or the edge of the tape, whichever is closest to the current
altitude. If the altitude indicator fails the display marks the tape display area with a red ‘X’ and
yellow text spelling out ‘ALTITUDE FAIL’.
) Barometric Pressure Indicator. The barometric pressure indicator is located immediately below
the altitude indicator. The indicator shows the barometric pressure that has been set in either
inches of mercury (Hg) or hectopascal number (hPa)
) Vertical Speed Indicator (VSI). The vertical speed indicator is located to the right of the altitude
indicator. The indicator displays the airplane vertical speed in feet/min. A numeric pointer moves
vertically up/down a fixed tape. The vertical speed indication is also shown digitally on the
pointer. A negative sign is shown on the pointer to indicate negative vertical speeds (airplane
descending). If the VSI fails the display marks the tape display area with a red ‘X’ and yellow
text spelling out ‘VERT SPEED FAIL’.
) Horizontal Situation Indicator (HSI). The HSI s located in the center of the PFD at the bottom.
The HSI displays a rotating circular compass with heading markings. The HSI shows the
following information:
) Heading information. The heading is shown digitally in a window at the top of the rotating
compass.
) Turn Rate Indicator. A turn rate indicator is located between the digital heading window and the
rotating compass.
Doc # 6.02.15 Page 7
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
) Course Deviation Indicator (CDI). The CDI is a line with an arrowhead that points to the airplane
heading on the rotating compass. The line can slide left or right of the center marking to show
the deviation of the actual course being flown to the required course. Course data can be
supplied from the airplane VOR, LOC or GPS system. If the heading data is invalid the digital
heading display window is marked with a red cross and yellow text spelling ‘HDG’.
) Vertical Deviation (Glidescope) Indicator. The glidescope indicator is located to the left of the
vertical speed indicator.
) Alerts Window. The alerts window is located on the lower right side of the PFD. This window
opens when an alert is activated or when the WARNINGS softkey is operated.
) Warnings and Cautions Window. The warnings and cautions window is located above the alerts
window. This window opens when a warning or caution is activated or if the WARNING softkey
is operated.
) NAV MAP. The NAV MAP window is located in the lower left of the PFD. The window is
activated by pressing the INSET softkey and when activated shows a pictorial view of the
airplane on a moving map.
Small windows in the top left corner of the PFD show active and standby NAV frequencies. Small
windows in the top right of the PFD show active and standby COM frequencies. A larger window
in the top of the PFD flight planning data when activated.
A small window in the bottom left of the PFD shows the outside air temperature (OAT). A small
windows on the bottom right of the PFD shows the transponder settings and operational state.
Another small window in the right bottom corner of the PFD shows a digital clock.
A set of labels along the very bottom of the PFD identify the function of the softkeys for the current
page being displayed on the PFD.
The PFD has a self-monitoring system. If the self-monitoring system detects a fault the PDF enters
reversionary mode. In the reversionary mode the PDF is configured to display the flight instrument
symbology and the basic engine parameter monitoring indications. The PFD reversionary mode
can also be entered by pressing the DISPLAY BACKUP selector. The DISPLAY BACKUP selector
is located on the bottom of the audio control panel.
Page 8 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
B. Multi-Function Display (MFD)
The MFD is a 10.4 in liquid crystal display. Bezels on the left and right side of the MFD have the
controls for the ICS. The lower edge of the MFD has ‘softkeys’. The function of the soft keys relates
to the on-screen display and if a key has a function related to the current display the display will
show the function of the key.
The MFD displays engine and airplane pages on the left slide of the screen. The remainder of the
screen is used to display navigational pages. The bezels on the left and right side of the MFD have
the same controls and function as the bezels on the PFD. The left side bezel on the MFD has also
the controls for the autopilot system. Refer to Chapter 22 for more information about the autopilot.
The MFD has these displays:
) Engine Instrumentation System Window (EIS). The engine indication system window is on the
left side of the MFD displays a full-time dedicated display of these engine parameters:
) Engine Load. The engine load indicator is at the top of the EIS window. The engine load is
are displayed as a percentage. An analog pointer moves to show the engine load. If the
system fails the display shows a red cross to the left or right of the load indicator to show
which engine system has failed.
) Engine RPM. The engine RPM indicator is located below the engine load indicator. An
analog pointer moves to show the engine RPM. If the system fails the display shows a red
cross to the left or right of the RPM indicator to show which engine system has failed.
) Volts. The essential bus voltage is displayed below the RPM indicator. A pointer above a
horizontal range bar shows the essential bus voltage. The horizontal range bar is color
coded. The green central section of the bar indicates that the voltage is within limits. The red
section at the left end of the range bar indicates too low a voltage. The red section at the
right end of the range bar indicates too high a voltage. Above the range bar is a window
displaying the essential bus voltage digitally.
) Amps. The generator load is shown by an indicator located below the Volts indicator. A
pointer above a horizontal range bar shows the generator load. The range bar is color
coded, green in the normal load range and then red at the high end of the range. The range
bar is also marked numerically at the 0 and 80 Amp indications. The pointer moves from left
to right to show the load on the generator. A small window above the range bar shows the
generator load digitally.
Doc # 6.02.15 Page 9
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
) Engine Gearbox Temperature. Below the Amps indication is the engine gearbox temperature
indication. A pointer above a horizontal range bar shows the gearbox temperature. The
range bar is color coded, green in the normal temperature range, yellow in the caution range
and then red at the high end of the range. The pointer moves from left to right to show the
temperature of the gearbox. A small window above the range bar shows the gearbox
temperature digitally. If the system fails the display shows red crosses in place of the
indications for the failed system(s).
) Coolant Temperature. Below the engine gearbox temperature indication is the engine
coolant temperature indication. A small window shows the engine coolant temperature
digitally. If the system fails a red cross is displayed in place of the digital indication for the
failed system(s).
) Oil Temperature. Below the engine coolant temperature indication is the engine oil
temperature indication. A small window shows the engine oil temperature digitally. If the
system fails a red cross is displayed in place of the digital indication for the failed system(s).
) Oil Pressure. Below the engine oil temperature indication is the engine oil pressure
indication. A small window shows the engine oil pressure digitally. If the system fails a red
cross is displayed in place of the digital indication for the failed system(s).
Pressing the FUEL softkey at the bottom of the MFD will change the display to the FUEL page in
the EIS panel. The display will now give the following indications:
) Engine Load and RPM. These indications are in the same location and format as in the
SYSTEM page.
) Fuel Flow. Below the engine load and RPM indications is the fuel flow indication. A small
window shows the engine fuel flow digitally. If the system fails a red cross is displayed in place
of the digital indication for the failed system(s).
) Oil Temperature. The engine oil temperature is shown below the fuel flow indication. A pointer
above a horizontal range bar shows the engine oil temperature. The range bar is color coded
yellow at the cool end of the range bar, then green to show the normal operating range and
yellow in the high range. The pointer moves from left to right to indicate the temperature of the
engine oil.
Page 10 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
) Oil Pressure. The engine oil pressure indication is shown below the engine oil temperature
indication. A pointer above a range bar indicates the oil pressure. The range bar is color coded
yellow at the low pressure (left) end of the range bar, green to show the normal operating range,
yellow in the cautionary range and red in the high range. The pointer moves from left to right
to indicate the oil pressure.
) Coolant Temperature. The coolant temperature indication is shown below the engine oil
pressure indication. A pointer above a range bar indicates the coolant temperature. The range
bar is color coded yellow at the low temperature (left) end of the range bar, green to show the
normal operating range, yellow in the cautionary range and red in the high range. The pointer
moves from left to right to indicate the coolant temperature.
) Fuel Temperature. The fuel temperature indication is located below the coolant temperature
indication. Pointers above and below a range bar indicate the fuel temperature. The range bar
is color coded yellow at the low temperature (left) end of the range bar, green to show the
normal operating range, yellow in the cautionary range and red in the high range. The pointers
move from left to right to indicate the fuel temperature. The pointer above the range bar
indicates the temperature of the fuel in the left fuel tank and the pointer below the range bar
indicates the temperature of the fuel in the right fuel tank.
) Fuel Quantity. The fuel quantity indication is located at the bottom of the EIS. Pointers above
and below a range bar indicate the fuel quantities. The pointers move from left (low) to right
(full) to indicate the fuel quantity. The pointer above the range bar indicates the quantity of fuel
in the left fuel tank and the pointer below the range bar indicates the quantity of fuel in the right
fuel tank.
From this page you can use softkeys to enter data for the fuel system. Refer to the Garmin G1000
Cockpit Reference Guide for more data about entering data into the ICS.
C. GMA 1347 Audio Control Panel
The GMA 1347 audio control panel is located in the airplane instrument panel between the
two display screens. The audio control panel integrates the NAV/COM digital audio, intercom
system and marker beacon controls. Manual display reversion is also controlled from the
GMA 1347. The GMA 1347 communicates with both IAUs using RS-232 digital interface. For more
data about the audio control panel refer to Section 23-50.
Doc # 6.02.15 Page 11
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
D. GIA 63 Integrated Avionics Unit (IAU)
The ICS has two GIA 63 IAUs. The two IAUs are identical and independent. They are both installed
in the avionics rack in the rear fuselage, just aft of the rear baggage frame. The IAU processes all
the data that is displayed on the cockpit display. Either IAU can supply data to either cockpit
display. You cannot service the IAU.
E. GTX 33 Transponder
The GTX 33 transponder is a solid state Mode-S transponder. The transponder provides modes
A, C and S functions. The unit is operated directly through the PFD in the cockpit. The transponder
is linked to both IAUs via RS-232 digital interface. The transponder is installed in the in the avionics
rack in the rear fuselage, just aft of the rear baggage frame.
F. GRS 77 Attitude, Heading and Reference Unit (AHRS)
The GRS 77 provides airplane attitude and related flight data to the cockpit displays. The GRS 77
receives data from the air data computer, the GMU 44 magnetometer and GPS signals from the
GIA 63. The GRS communicates with both the GIA 63s and the cockpit displays via ARINC 429
digital interface. The GRS 77 is located next to the avionics rack in the rear fuselage, just aft of the
rear baggage frame.
G. GDC 74A Air Data Computer (ADC)
The ADC receives data from the Pitot/static system and an OAT sensor. The ADC uses this data
to provide pressure altitude, airspeed, vertical speed and outside air temperature data to the G1000
system. The ADC communicates with the GIA 63s, GDU 1040 display screens and the GRS 77
using ARINC 429 digital interface. Software and configuration data is received through RS-232
digital interface with the GIA 63s. The ADC is located on the instrument panel shelf.
H. GEA 71
The GEA 71 is a microprocessor based unit that receives and processes signals from airframe and
engine sensors. The GEA 71 communicates directly with both IAUs using RS 485 digital interface.
The GEA 71 is located on the instrument panel shelf.
I. GMU 44 Magnetometer
The magnetometer senses magnetic field information. Data is sent to the GRS 77 ARHS for
processing. The magnetometer receives power form the GRS 77 and communicates with the
GRS 77 using RS-485 digital interface. The magnetometer is located in the right outer wing and
can accessed through a panel in the lower surface of the wing.
Page 12 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Trouble-Shooting
1. General
The Garmin ICS has a built-in test and trouble-shooting facility. For more data about troubleshooting
the ICS refer to the G1000 System Maintenance Manual.
Doc # 6.02.15 Page 101
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Procedures tell you how to replace the main components of the ICS. They do not
tell you how to maintain the components. For data about removing/installing the GMA 1347 audio
control unit refer to Section 23-50. For more data about maintaining the equipment refer to the G1000
Line Maintenance Manual. The G1000 Line Maintenance Manual gives you particular information on:
) Unit related alerts and problems.
) Equipment removal and installation.
) Uploading software, configuring and testing.
) Final system checkout.
) Periodic maintenance.
) G1000 system software and configuration.
) GDU lighting setup.
Refer to the DAI service documentation for data about the approved software configurations (available
for download at www.diamond-air.at).
Doc # 6.02.15 Page 201
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
The specific DA 40 NG values as to the equipment basic setting are given in the table below:
Item Basic Setting
Main Lighting - Display. Source . . . . . . . . . . . . . . . . . . . . . . . . . 28 VDC
Response Time . . . . . . . . . . . . . . . . . . . . . . . 3
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
Edit Curve Vertex . . . . . . . . . . . . . . . . . . . none
Photo Transition . . . . . . . . . . . . . . . . . . . . 20 %
Edit Photo Vertex . . . . . . . . . . . . . . . . . . . none
GMA Annunciator Gain . . . . . . . . . . . . . . . 1.00
GMA Annunciator Offset . . . . . . . . . . . . . . . . 0
Main Lighting - Key. Source . . . . . . . . . . . . . . . . . . . . . . . . . 28 VDC
Response Time . . . . . . . . . . . . . . . . . . . . . . . 1
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.75
GMA Key Gain . . . . . . . . . . . . . . . . . . . . . . 2.00
GMA Key Offset . . . . . . . . . . . . . . . . . . . . . . . 2
Audio Alert Configuration. Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Voice . . . . . . . . . . . . . . . . . . . . . . . . . . . . male
Transponder Configuration. VFR Code . . . . . . . . . . . . . . . . . . . Europe: 7000
USA: 1200
Aircraft Weight . . . . . . . . . . . . . . . < 15,500 lbs
Max Airspeed . . . . . . . . . . . . . . . . . . <= 150 kts
Address Type . . . . . . . . . . . . . . . Europe: hex id
USA: us tail
Flight ID Type . . . . . . . . . . . Europe: PFD entry
USA: same as tail
GMA Configuration S Headset Volume. Music #1: . . . . . . . . . . . . . . . . . . . . . . . . . . . -20
Music #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . -20
Unswitched in #1 . . . . . . . . . . . . . . . . . . . . . -20
Unswitched in #2 . . . . . . . . . . . . . . . . . . . . . -20
Unswitched in #3 . . . . . . . . . . . . . . . . . . . . . -20
Altitude Warning . . . . . . . . . . . . . . . . . . . . . . -20
GMA Configuration S Speaker Volume. Crew Audio . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GMA Configuration S Master Squelch. Threshold Value . . . . . . . . . . . . . . . . . . . . . . -16
GMA Configuration S Marker Beacon HI SENSE THRESHOLD: specific to airplane
LO SENSE THRESHOLD: specific to airplane
Page 202 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Item Basic Setting
GMA Configuration S KEYPAD Annunciators Disable COM3: set
Disable TEL: set
Disable DME: specific to airplane
Disable ADF: specific to airplane
Disable AUX: set
Disable SPEAKER: blank
Disable PA: set
Disable PLAY: blank
Disable MUSIC: set
Disable REC: set
Disable CABIN: set
Note: Unlisted items are preset. You must not change their values.
Note: Some items are specific to the airplane. Note down the settings prior to performing
a software upload.
Doc # 6.02.15 Page 203
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
2. Remove/Install a GDU 104X Display
A. Remove a GDU 104X Display
Detail Steps/Work Items Key Items/References
(1) Make sure that the ELECTRIC MASTER key
switch is set to OFF.
(2) Set the PFD and MFD circuit-breakers open. Right side of instrument panel.
(3) Remove the display unit: Refer to Figure 4.
S Rotate the 4 locking studs that attach the
display to the instrument panel 90°
counterclockwise.
S Move the instrument panel aft and disconnect At the in-line connector.
the electrical cables.
S Move the display unit clear of the instrument
panel.
Page 204 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Locking Socket
In-Line Connector Rivet
GDU 1040 Display Unit
Locking Studs
Figure 4: GDU 104X Display Unit Installation
Doc # 6.02.15 Page 205
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
B. Install a GDU 104X Display
Detail Steps/Work Items Key Items/References
(1) If necessary, set the PFD and MFD Right side of instrument panel.
circuit-breakers open.
(2) Install the display unit:
S Move the display unit into position at the
instrument panel.
S Connect the electrical cables to the display At the in-line connector.
unit
S Move the display unit fully forward into Make sure that you do not trap the
position n the instrument panel. electrical cables.
S Rotate the 4 locking studs that attach the The locking studs should be oriented
display unit to the instrument panel 90° with the alignment marks in the vertical
clockwise. position for installation. When locked,
the alignment marks are in the
horizontal position.
(3) Reset the PFD and MFD circuit-breakers. Right side of instrument panel.
(4) Do a test for the correct operation of the
integrated cockpit system (ICS):
S Set the ELECTRIC MASTER key switch to The ICS must power-up and
ON. successfully complete its self-test
procedure.
S Set the ELECTRIC MASTER key switch to
OFF.
Page 206 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
3. Remove/Install a GIA 63 Integrated Avionics Unit (IAU)
A. Remove a GIA 63 Integrated Avionics Unit (IAU)
Detail Steps/Work Items Key Items/References
(1) Make sure that the ELECTRIC MASTER key
switch is set to OFF.
(2) Remove the lower access panel from the rear Refer to Section 25-50.
baggage compartment.
(3) Remove the GIA IAU: Refer to Figure 5.
S Identify the unit that you will remove.
S Release the locking screw from the retainer.
S Lift the retainer clear of the unit.
S Lift the IAU clear of the mounting rack and
the airplane.
Doc # 6.02.15 Page 207
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
B. Install a GIA 63 Integrated Avionics Unit (IAU)
Detail Steps/Work Items Key Items/References
(1) Install the IAU:
S Move the GIA IAU into position at the Make sure that the unit is seated
mounting and lower the unit into position in correctly. Do not force the unit into
the rack. position!
S Move the retainer into position and secure
with the locking screw.
(2) Install the lower access panel in the rear Refer to Section 25-50.
baggage compartment.
(3) Do a test for the correct operation of the
integrated cockpit system (ICS):
S Set the ELECTRIC MASTER key switch to The ICS must power-up and
ON. successfully complete its self-test
procedure.
S Set the ELECTRIC MASTER key switch to
OFF.
Page 208 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Figure 5: GIA 63 Integrated Avionics Unit (IAU) Installation
Doc # 6.02.15 Page 209
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
4. Remove/Install the GTX33 Transponder
A. Remove the GTX33 Transponder
Detail Steps/Work Items Key Items/References
(1) Make sure that the ELECTRIC MASTER key
switch is set to OFF.
(2) Remove the lower access panel from the rear Refer to Section 25-50.
baggage compartment.
(3) Remove the GTX33: Refer to Figure 6.
S Identify the unit that you will remove.
S Release the locking screw from the retainer.
S Lift the retainer clear of the unit.
S Lift the GTX33 clear of the mounting rack
and the airplane.
Page 210 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
B. Install the GTX33 Transponder
Detail Steps/Work Items Key Items/References
(1) Install the GTX33:
S Move the GTX33 into position at the Make sure that the unit is seated
mounting and lower the unit into position in correctly. Do not force the unit into
the rack. position!
S Move the retainer into position and secure
with the locking screw.
(2) Install the lower access panel in the rear Refer to Section 25-50.
baggage compartment.
(3) Do a test for the correct operation of the
integrated cockpit system (ICS):
S Set the ELECTRIC MASTER key switch to The ICS must power-up and
ON. successfully complete its self-test
procedure.
S Set the ELECTRIC MASTER key switch to
OFF.
Doc # 6.02.15 Page 211
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Figure 6: GTX33 Transponder Installation
Page 212 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
5. Remove/Install the GRS77 Attitude, Heading and Reference Unit (AHRS)
A. Remove the GRS77 Attitude, Heading and Reference Unit (AHRS)
Detail Steps/Work Items Key Items/References
(1) Make sure that the ELECTRIC MASTER key
switch is set to OFF.
(2) Remove the lower access panel from the rear Refer to Section 25-50.
baggage compartment.
(3) Remove the GRS77: Refer to Figure 7.
S Disconnect the electrical cables.
S Remove the 4 screws that attach the GRS77
to the mounting.
S Move the GRS77 clear of the airplane.
B. Install the GRS77 Attitude, Heading and Reference Unit (AHRS)
Detail Steps/Work Items Key Items/References
(1) Install the GRS77 unit:
S Move the unit into position next to the
avionics rack.
S Install the 4 screws that attach the unit to the
mount.
S Connect the electrical cables. At the in-line connector.
(2) Install the lower access panel in the rear Refer to Section 25-50.
baggage compartment.
(3) Do a test for the correct operation of the
integrated cockpit system (ICS):
S Set the ELECTRIC MASTER key switch to The ICS must power-up and success-
ON. fully complete its self-test procedure.
S Set the ELECTRIC MASTER key switch to
OFF.
Doc # 6.02.15 Page 213
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
GRS77 AHRS Unit
Connector
Figure 7: GRS77 Attitude, Heading and Reference Unit (AHRS) Installation
Page 214 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
6. Remove/Install the GDC 74A Air Data Computer (ADC)
A. Remove the GDC 74A Air Data Computer (ADC)
Detail Steps/Work Items Key Items/References
(1) Disconnect the airplane main battery. Refer to Section 24-31.
(2) Remove the instrument panel cover. Refer to Section 25-10.
(3) Remove the GDC 74A:
S Locate the GDC 74A on the instrument panel
shelf.
S Disconnect the electrical cables.
S Disconnect the Pitot/static tubes from the Note the connections!
unit.
S Remove the 2 screws that attach the
GDC 74A to its mounting rack.
S Move the GDC 74A clear of the airplane.
Doc # 6.02.15 Page 215
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
B. Install the GDC 74A Air Data Computer (ADC)
Detail Steps/Work Items Key Items/References
(1) Install the GDC 74A:
S Move the GDC 74A into position on the
mounting rack.
S Install the 2 screws that attach the GDC 74A
to the mounting rack.
S Install the Pitot/static tubes to the unit. As noted in 6A.
S Connect the electrical cables At the in-line connector.
(2) Install the instrument panel cover. Refer to Section 25-10.
(3) Connect the airplane main battery. Refer to Section 24-31.
(4) Do a test for the correct operation of the
integrated cockpit system (ICS):
S Set the ELECTRIC MASTER key switch to The ICS must power-up and
ON. successfully complete its self-test
procedure.
S Set the ELECTRIC MASTER key switch to
OFF.
(5) Do a Pitot/static leak test. Refer to Section 34-10.
Page 216 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
7. Remove/Install the GEA 71 Processor
A. Remove the GEA 71 Processor
Detail Steps/Work Items Key Items/References
(1) Disconnect the airplane main battery. Refer to Section 24-31.
(2) Remove the instrument panel cover. Refer to Section 25-10.
(3) Remove the GEA 71: Refer to Figure 8.
S Locate the GEA 71 on the instrument panel
shelf.
S Release the screw that secures the retainer.
S Move the retainer clear and lift the GEA 71 If necessary, remove the standby
clear of the mounting. altimeter. Refer to Section 34-10.
B. Install the GEA 71 Processor
Detail Steps/Work Items Key Items/References
(1) Install the GEA 71:
S Move the GEA 71 into position at its
mounting.
S Lower the GEA 71 into its mounting.
S Install the retainer and secure the retainer If removed, install the standby altimeter.
with the retaining screw. Refer to Section 34-10.
(2) Install the instrument panel cover. Refer to Section 25-50.
(3) Connect the airplane main battery. Refer to Section 24-31.
(4) Do a test for the correct operation of the
integrated cockpit system (ICS):
S Set the ELECTRIC MASTER key switch to The ICS must power-up and success-
ON. fully complete its self-test procedure.
S Set the ELECTRIC MASTER key switch to
OFF.
Doc # 6.02.15 Page 217
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Garmin GEA 71 Unit
Retainer
Screw
Retainer
Mounting Rack
Figure 8: GEA 71 Processor Installation
Page 218 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
8. GMU 44 Magnetometer
A. Remove the GMU 44 Magnetometer
Detail Steps/Work Items Key Items/References
(1) Make sure that the ELECTRIC MASTER key
switch is set to OFF.
(2) Remove the magnetometer assembly: Refer to Figure 9.
S Remove the 3 screws that attach the Support the assembly.
magnetometer assembly to the lower surface
of the right wing.
S Lower the magnetometer assembly clear of
the structure and disconnect the electrical
cables.
S Move the magnetometer assembly clear of
the airplane.
(3) If necessary, remove the magnetometer from the
panel.
Doc # 6.02.15 Page 219
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
B. Install the GMU 44 Magnetometer
Detail Steps/Work Items Key Items/References
(1) Install the magnetometer assembly:
S Move the magnetometer assembly into Pay attention on the dedicated mounting
position at the right wing. direction marked by an arrow!
S Connect the electrical cables to the At the in-line connector.
magnetometer assembly.
S Move the magnetometer assembly fully into
position in the lower surface of the right
wing.
S Install the 3 screws that attach the
magnetometer assembly to the wing.
(2) Do a test for the correct operation of the
integrated cockpit system (ICS):
S Set the ELECTRIC MASTER key switch to The ICS must power-up and
ON. successfully complete its self-test
procedure.
(3) Do a magnetometer calibration. Refer to the G1000 System
Maintenance Manual.
Page 220 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Figure 9: Magnetometer Assembly Installation
Doc # 6.02.15 Page 221
Rev. 2 31-40-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 222 Doc # 6.02.15
15 Apr 2013 31-40-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Section 31-51
Central Warning System
with Conventional Cockpit Installed
1. General
The DA 40 NG with the conventional cockpit has warning, caution and status lights combined in one
'White Wire' annunciator panel. Figure 1 shows the annunciator panel.
2. Description and Operation - White Wire Annunciator Panel
A. Warning Messages
A warning gives these indications:
) A continuous aural alert sounded in the airplane's intercom system.
) The red master WARNING light flashes.
) The red warning light for the related system flashes.
) The green acknowledge button lights.
Push the 'acknowledge' button to cancel the aural alert. The red master WARNING light will go off.
The red warning light for the related system will change from flashing to a continuous light.
B. Caution Messages
A caution gives these indications:
) A short aural alert sounded in the airplane's intercom system.
) The amber master CAUTION light flashes.
) The amber caution light for the related system flashes.
) The green acknowledge button lights.
Push the 'acknowledge' button, to cancel the aural alert. The amber master CAUTION light will go
off. The amber caution light for the related system will change from flashing to a continuous light.
Doc # 6.02.15 Page 1
Rev. 2 31-51-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Figure 1: Central Warning System: White Wire Annunciator Panel
C. Warning, Caution and Status Lights
) START. A red warning light shows that the starter solenoid is energized. The warning light
receives an electrical current from the starter side of the starter solenoid. The
starter warning message shows when the connection between the starter motor
and the engine has not been broken. This occurs when the pinion of the starter
motor remains engaged with the engine flywheel.
When the starter is operated, the starter warning light is ON continuously. In this
case the master WARNING light and the aural alert do not operate.
) DOORS. A red warning light shows that the canopy or door is unlocked. Micro-switches
connected parallel operate the doors warning message when either the door or
canopy is unlocked.
) LOW VOLTS.
An amber caution light shows low voltage. The low voltage caution message
shows when the voltage falls below 25.0 Volts.
) ENGINE. An amber caution light shows when any indication on an engine instrument (MED
or SED) changes from the green to the yellow range.
Page 2 Doc # 6.02.15
15 Apr 2013 31-51-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
) ALTERNATOR.
A red warning light shows alternator failure. The regulator of the alternator
operates the ALTERNATOR warning message.
) ECU A. An amber caution light shows when the ECU A fails.
) ECU B. An amber caution light shows when the ECU B fails.
) FUEL TRANS.
A white status light shows when the fuel transfer pump is ON.
) PITOT. An amber caution light shows that the Pitot heating system is OFF. The caution
light receives an electrical current from the heater side of the Pitot heat relay. The
Pitot heating caution message shows when the Pitot heating is not switched ON,
or when there is a failure of the Pitot heating system.
) LOW FUEL. An amber caution light shows low fuel level is less than 3 US gal (+2/-1 US gal)
in the left fuel tank. The fuel level switch in the left fuel tank operates the low fuel
caution message.
) TRIM FAIL. Not used.
) GLOW. A status message shows when the glow relay is energized. This is usually only
before or during start.
3. Functional Check
The functional check is automatically started after switching the ELECTRIC MASTER key switch ON.
All lights are flashed, and the aural alert is muted. By pressing the 'acknowledge' button, the lights are
extinguished, and a short aural alert is sounded. This test verifies functionality of the microprocessor,
the lights, and the aural signal.
You may do additional system tests by holding the 'acknowledge' button for 2 seconds. All lights will
begin flashing, and the aural alert will sound continuously.
4. Wiring Diagrams
Refer to Chapter 92 for the wiring diagram for the central warning system.
Doc # 6.02.15 Page 3
Rev. 2 31-51-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 31-51-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the central warning system. If you have the
trouble detailed in the Trouble column read across to the Possible Cause column. Then do the repair
given in the Repair column.
Trouble Possible Cause Repair
Warning/Caution/Status Sensor defective. Replace the sensor.
indication incorrect.
Annunciator panel defective. Replace the annunciator panel.
High resistance or open Do resistance and continuity
connection in the electrical tests between the indicator and
wiring from the sensor. the sensor. Repair the
defective connection or wire.
Doc # 6.02.15 Page 101
Rev. 2 31-51-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 31-51-00 Rev. 2
DA 40 NG AMM Indicating Systems
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to replace the main components of the central warning system. Refer to the
equipment manufacturer's manuals for more data on the annunciator panel. Refer to the related
Chapter for data on the warning sensors.
Refer to Chapter 92 for the Wiring Diagrams.
2. Remove/Install the Annunciator Panel
A. Remove the Annunciator Panel
Detail Steps/Work Items Key Items/References
(1) Remove the instrument panel cover. Refer to Section 25-10.
(2) Disconnect the electrical connector from the
annunciator panel.
(3) Remove the 4 cross-head screws which attach Hold the annunciator panel.
the annunciator panel to the instrument panel.
(4) Move the annunciator panel out of the instrument
panel and lift it clear of the airplane.
B. Install the Annunciator Panel
Detail Steps/Work Items Key Items/References
(1) Move the annunciator panel into its position in the
instrument panel.
(2) Install the 4 cross-head screws which attach the
annunciator panel to the instrument panel.
(3) Connect the electrical connector to the rear of the
annunciator panel.
(4) Install the instrument panel cover. Refer to Section 25-10.
(5) Do a test of the annunciator panel. Refer to Paragraph 3.
Doc # 6.02.15 Page 201
Rev. 2 31-51-00 15 Apr 2013
Indicating Systems DA 40 NG AMM
AIRCRAFT
3. Test the Annunciator Panel
Detail Steps/Work Items Key Items/References
(1) Close front canopy and rear door.
(2) Put on a head-set. To hear the aural alert.
(3) Set the ELECTRIC MASTER key switch to ON. All lights on the annunciator panel must
be flashed. The aural alert must be
muted.
(4) Set the AVIONIC MASTER switch to ON.
(5) Switch the intercom ON. To hear the aural alert.
(6) Press the 'acknowledge' button. The PITOT, ECU A and ECU B caution
lights must be on.
The ALTERNATOR WARNING light
must be on if the engine is not running.
The LOW VOLTS caution light can be
on or off.
All other lights on the annunciator panel
must be extinguished, and a short aural
alert must be sounded.
(7) Set the AVIONIC MASTER switch to OFF.
(8) Set the ELECTRIC MASTER key switch to OFF.
Page 202 Doc # 6.02.15
15 Apr 2013 31-51-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
CHAPTER 32
LANDING GEAR
Doc # 6.02.15 Page 1
Rev. 2 32-TITLE 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 32-TITLE Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 32
LANDING GEAR
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 32-10
Main Landing Gear
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Main Landing Gear Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Test/Adjust the Main Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Section 32-20
Nose Landing Gear
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Doc # 6.02.15 Page 1
Rev. 2 32-CONTENTS 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Nose Landing Gear Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Elastomer Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4. Replace the Elastomer Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5. Adjust the Nose Wheel Steering Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
6. Nose Wheel Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Section 32-40
Wheels and Brakes
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Main Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Nose Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Remove/Install a Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
5. Remove/Install a Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
6. Remove/Install the Parking Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
7. Bleed the Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
8. Condition the Brake Linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Page 2 Doc # 6.02.15
15 Apr 2013 32-CONTENTS Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
CHAPTER 32
LANDING GEAR
1. General
The DA 40 NG has a fixed tricycle landing gear and a castor nose wheel. This Section gives you the
general description and operation of the landing gear. See Section 32-10 for Trouble-Shooting and
Maintenance Practices for the main gear. See Section 32-20 for Trouble-Shooting and Maintenance
Practices for the nose gear. See Section 32-40 for Trouble-Shooting and Maintenance Practices for
the for the wheels and brakes.
Note: Equipment which is certified for installation in the DA 40 NG is listed in Section 6.5
of the Airplane Flight Manual. Such equipment may be installed in accordance with
the Airplane Maintenance Manual.
Any equipment which is not listed in Section 6.5 of the Airplane Flight Manual is
called "Additional Equipment". The installation of Additional Equipment is a
modification which must be handled in accordance with national regulations or a
Service Bulletin.
2. Description and Operation
Flat section steel leaf-springs make the main gear struts. Two mountings attach each main gear strut
to the center section of the fuselage. The bottom of each strut has an axle, a brake torque plate and
a mounting plate for the GFRP wheel fairing.
The nose gear is a tubular strut. A strong pivot attaches it to the forward fuselage. An elastomer spring
pack (elastomer pack) attaches the strut to the engine mount. A pivot at the bottom of the strut has a
% trailing fork for the wheel. It also holds the GFRP wheel fairing (if standard landing gear is installed).
Both nose and main gear have single wheels with low pressure tires. Each main gear strut has a disk
brake. Toe-brake pedals on the rudder pedals operate the disk brakes. A parking brake valve allows
the brakes to be set ON for parking.
The landing gear absorbs vertical loads (for example, landing loads). Each main gear strut is a
leaf-spring which deflects upwards as the load increases. The elastomer pack in the nose gear
compresses as the load increases. In each case, the spring returns to the original position when the
load is removed.
Push on both toe-brake pedals at the same time to apply both disk brakes. The airplane will stop in
a straight line. Push on one toe-brake pedal to apply the disk brake on that side only. The airplane will
steer to that side. Move the parking brake lever fully up. Then push on both toe-brake pedals a few
times to apply the parking brake. Move the parking brake lever fully down to release the parking brake.
Doc # 6.02.15 Page 1
Rev. 2 32-00-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 32-00-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
Section 32-10
Main Landing Gear
1. General
This Section gives you the data for the main landing gear. It gives you the Trouble-Shooting and
Maintenance Practices. Refer to Section 32-40 for data for the main wheels and the brakes.
2. Description and Operation
% Figures 1 and 2 show the main gear strut mounting. Each main gear strut is a steel alloy leaf spring.
Two strong mounts attach each spring to the center section of the fuselage. Small panels with flexible
centers seal the gaps where each strut goes through the fuselage shell.
The inner mount is a large vertical bolt. The bolt goes through a metal block which attaches to the
center closing rib of the fuselage center section. Spring washers separate the top face of the spring
from the block. A convex and a concave washer separate the bottom face of the spring from a castle
nut. The castle-nut pre-loads the spring washers.
The outer mount has two parts. The upper part locates on top of the main strut and the lower retaining
% bar locates below the main strut. Two bolts attach the assembly to the main landing gear ribs. The
% main landing gear ribs are bonded into the fuselage center section. Reinforced synthetic rubber inserts
go between the leaf spring and the retaining bar to prevent chafing damage and allow angular
movement of the leaf spring in the mount.
% Figures 3, 4 and 5 show the main landing gear axle installation. Six bolts at the outer end of each strut
attach these components:
) An axle, made from aluminum.
) A brake torque-plate.
% ) A shim (if MÄM 40-574 is installed).
) A mounting plate for the GFRP wheel fairing.
When the airplane is on the ground, the inner end of the leaf spring pulls down on the inner mounting.
The outer end pushes up against the outer mounting. When the airplane is flying, the inner end of the
leaf spring pushes up on the inner mounting. And the outer end pulls down against the retaining bar
of the outer mounting.
Doc # 6.02.15 Page 1
Rev. 2 32-10-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
Inner Bolt
Washer
Washer
Nut
Retaining Bolt
Bolt
Mounting
Block
Washer
Spring Washers
Polyamide Insert
Convex Washer
Concave Washer
Castle Nut
Cotter Pin
Flexible Insert
Retaining Bar
Washer
Nut
Figure 1: Main Landing Gear Strut Mounting
Page 2 Doc # 6.02.15
15 Apr 2013 32-10-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
%
%
%
%
%
%
%
%
% Inner Bolt
% Main Landing Gear Ribs
% Washer
Washer
Nut
% Retaining Bolt
%
% Nut
%
Mounting
%
Block
%
% Washer
Spring Washers
%
Polyamide Insert
% Convex Washer
%
Concave Washer
%
% Washer
%
% Castle Nut
% Cotter Pin
%
Flexible Insert
%
%
% Retaining Bar
%
Washer
%
%
% Bolt
%
%
%
% Figure 2: Main Landing Gear Strut Mounting (if MÄM 40-574 or OÄM 40-334 is installed)
Doc # 6.02.15 Page 3
Rev. 2 32-10-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 32-10-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
Trouble-Shooting
1. General
Use the data below to trouble-shoot the main landing gear.
WARNING: YOU MUST DO A HARD LANDING CHECK AFTER A HARD LANDING.
HARD LANDING CAN CAUSE DAMAGE TO THE STRUCTURE AS
WELL AS THE LANDING GEAR.
Trouble Possible Cause Repair
Strut bent. Hard landing. Do a hard landing check. Refer
to Section 05-50.
Replace the strut.
Negative camber. Strut bent, hard landing. Do a hard landing check. Refer
to Section 05-50.
Replace the strut.
Too much tire wear. Incorrect toe-in. Adjust the toe-in. Refer to
'Test/Adjust the Main Landing
Gear' procedure described
later in this Section.
Doc # 6.02.15 Page 101
Rev. 2 32-10-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 32-10-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove, install and adjust the main landing gear. Refer
to the manufacturer for further data.
2. Remove/Install a Main Landing Gear Strut
A. Equipment
Item Quantity Part Number
Airplane jacks. 3 Commercial.
Nose trestle. 1 Commercial.
Wing trestles. 2 Commercial.
B. Remove a Main Landing Gear Strut
Detail Steps/Work Items Key Items/References
(1) Lift the airplane on jacks. Refer to Section 07-10.
% (2) Remove the wheel fairing (if installed):
S Remove the outer bolt.
S Remove 4 screws from the inner side.
(3) Remove the back-plate from the brake caliper. Refer to Section 32-40.
(4) Remove the wheel. Refer to Section 32-40.
(5) Release the brake caliper.
% (6) Remove the 6 bolts which attach the axle. Refer to Figure 3.
% Refer to Figure 4 (if OÄM 40-334 is
% installed).
% Refer to Figure 5 (if MÄM 40-574 is
% installed).
% Remove the axle, torque-plate, shim (if Only if you will install a different strut.
% MÄM 40-574 is installed) and mounting plate for
the wheel fairing.
(7) Disconnect the bonding cable from the strut.
Doc # 6.02.15 Page 201
Rev. 2 32-10-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
% (8) Remove the 6 bolts, washers and nuts which Refer to Figures 1 and 2.
hold the mounting block to the web.
(9) Remove the nuts which hold the retaining bar to Hold the strut!
the outer mounting bracket.
(10) Remove the strut. Move the strut outboard.
% (11) If necessary remove the nut and bolt at the inner Refer to Figures 1 and 2.
attachment mount.
Page 202 Doc # 6.02.15
15 Apr 2013 32-10-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
Main Gear Leg
Mounting Plate for Fairing
Brake Torque Plate
Brake Unit
Nut
Washer
Washer
Axle
Bolt
Axle Nut
Figure 3: Main Landing Gear Axle Installation
Doc # 6.02.15 Page 203
Rev. 2 32-10-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
%
%
%
%
%
%
%
%
Main Gear Leg
%
%
%
%
%
% Brake Torque Plate
%
%
Nut
%
Washer
%
Brake Unit
%
%
%
%
Split Pin
%
%
%
% Axle
Bolt
%
%
Axle Nut
%
%
%
%
%
%
%
%
% Figure 4: Main Landing Gear Axle Installation (if OÄM 40-334 is installed)
Page 204 Doc # 6.02.15
15 Apr 2013 32-10-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
%
%
%
%
%
%
%
%
%
% Main Gear Leg
%
%
%
% Mounting Plate for Fairing
%
%
% Brake Torque Plate
%
%
Shim
% Brake Unit
% Nut
% Washer
%
%
%
%
%
% Bolt Axle
%
% Axle Nut
%
%
%
%
%
%
% Figure 5: Main Landing Gear Axle Installation (if MÄM 40-574 is installed)
Doc # 6.02.15 Page 205
Rev. 2 32-10-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
C. Install a Main Landing Gear Strut
Detail Steps/Work Items Key Items/References
(1) Examine the center section in the area of the Refer to Section 51-10 for GFRP
main landing gear mountings. Look specially for inspection procedures.
damage to the GFRP structure.
% (2) If necessary install the nut and the bolt at the Refer to Figures 1 and 2.
inner attachment mount.
(3) Put the strut in position. Move it inboard through the center
section access panel.
(4) Put the inserts in position above and below the Hold the strut!
strut at the outer mounting.
(5) Install the retaining bar. Torque: 25 Nm (18.4 lbf.ft.).
% If MÄM 40-574 or OÄM 40-334 is
% installed: Torque: 30 Nm (22.1 lbf.ft.).
Make sure that the flexible insert is
glued in position. Use Loctite
Superglue.
% (6) If necessary install the mounting block to the web Refer to Figures 1 and 2. Torque the six
by use of the 6 bolts, washers and nuts. bolts with 15 Nm (11.1 lbf.ft.). Make
sure that the spring washers are
between the top of the strut and the
mounting block (concave sides facing).
Make sure that the convex and concave
washers are between the nut and the
strut.
(7) Tighten the nut on the inner bolt and install a To give a height of the spring washers of
cotter pin. 4 mm (+0.5 mm / -0 mm) or
0.16 in. (+0.02 in / -0 in).
(8) Connect the bonding cable to the strut. Install the nut and bolt near the inner
mounting block.
% (9) Install the axle, brake torque-plate, shim Refer to Figures 3, 4 and 5.
% (if MÄM 40-574 is installed) and the mounting Torque: 6.5 Nm (4.8 lbf.ft.).
plate for the wheel fairing. Install the 6 bolts
% If OÄM 40-334 is installed:
which attach the axle.
% Torque: 12 Nm (8.9 lbf.ft.).
Page 206 Doc # 6.02.15
15 Apr 2013 32-10-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
Detail Steps/Work Items Key Items/References
(10) Install the brake caliper. Refer to Section 32-40.
(11) Install the wheel. Refer to Section 32-40.
(12) Install the back-plate to the brake caliper. Refer to Section 32-40.
(13) Lower the airplane with jacks. Refer to Section 07-10.
(14) Do a test for correct adjustment of the landing See Paragraph 3.
gear.
(15) Do a function test of the wheel brake system.
% (16) Install the wheel fairing (if wheel fairing was
% installed):
S Install the outer bolt.
S Install 4 screws on the inner side.
3. Test/Adjust the Main Landing Gear
Do this work at the following times:
) When required by the maintenance checklist (Chapter 05).
) After a hard landing.
) After any reinstallation or repair to the main landing gear strut.
A. Equipment
Item Quantity Part Number
Slide sheets - 2 per side. 4 Commercial.
Doc # 6.02.15 Page 207
Rev. 2 32-10-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
Figure 6: Measure Toe-In and Camber
Page 208 Doc # 6.02.15
15 Apr 2013 32-10-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
B. Procedure
Detail Steps/Work Items Key Items/References
(1) Make sure that the airplane is at the empty See the Adjustment Report for the
weight. airplane.
% (2) Remove the wheel fairings (if installed): For each wheel.
S Remove the outer bolt.
S Remove 4 screws from the inner side.
(3) Move the airplane to put the main wheels on the
slide sheets.
% (4) Measure the toe-in. Refer to Figure 6.
% (5) Measure the camber. Refer to Figure 6.
WARNING: USE ONLY THE SHIMS LISTED FOR THE PURPOSE IN THE
ILLUSTRATED PARTS CATALOGUE. OTHER SHIMS COULD CAUSE
LANDING GEAR FAILURE.
(6) If necessary, adjust the toe-in and/or camber. Refer to Chapter 06-00 for limits.
Maximum 2° shim per side (camber and
toe). See the Illustrated Parts
Catalogue for the correct shims.
% If MÄM 40-574 or OÄM 40-334 is
% installed: Maximum 1° shim per side
% (camber and toe).
Put shims between the strut and the
axle.
This changes the angle between the
axle and the airplane longitudinal or
vertical axis.
(7) Measure the wheel track. Across the airplane from the outermost
point on one axle to the outermost point
on the other axle.
(8) Move the airplane off the slide sheets.
Doc # 6.02.15 Page 209
Rev. 2 32-10-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
% (9) Install the wheel fairings (if the wheel fairings
% were installed):
S Install the outer bolt.
S Install 4 screws on the inner side.
Page 210 Doc # 6.02.15
15 Apr 2013 32-10-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
Section 32-20
Nose Landing Gear
1. General
This Section gives you the data for the nose landing gear. It gives you the Trouble-Shooting and
Maintenance Practices. Refer to Section 32-40 for the data for the nose wheel.
2. Description and Operation
% Figures 1 and 2 show the nose landing gear installation. The DA 40 NG has a fixed nose landing gear
with a castor wheel. The nose landing gear strut is a welded tubular-steel component. The aft upper
end has a transverse tube which holds the main attachment journal bearings. These journal bearings
allow the strut to move only up and down.
Forward and below the attachment bearing is a welded bracket which holds the bottom of an
elastomeric spring pack (elastomer pack). The upper end of the elastomer pack attaches to the engine
mount.
The forward bottom end of the nose landing gear strut has a near vertical pivot for the nose-wheel fork.
This lets the nose wheel castor. Stops limit the castor movement to ± 30°.
When the airplane is on the ground, the elastomer pack pushes up against the engine mount. The
journal bearings pull down against the front fuselage. When the airplane is flying, the elastomer pack
pulls down against the engine mount. And the journal bearing pushes up against the front fuselage.
The journal bearings in the fuselage keep the nose landing gear strut aligned fore and aft. A side load
on the nose wheel causes it to castor. The stiffness (steering friction) of the nose-wheel fork pivot can
be adjusted with the nose wheel fork mounting screw. This prevents nose wheel shimmy.
Doc # 6.02.15 Page 1
Rev. 2 32-20-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
Lock Bolt
Journal Bearings
Elastomer Pack
Nose Gear Leg
Tubular Strut
Nose Wheel Axle
Castor Stop
Nose Wheel Fork
Figure 1: Nose Landing Gear
Page 2 Doc # 6.02.15
15 Apr 2013 32-20-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
%
%
%
%
%
%
%
%
%
%
% Lock Bolt
%
% Elastomer Pack
%
Journal Bearings
%
%
%
%
%
%
%
% Nose Gear Leg
% Tubular Strut
%
%
%
%
%
%
%
Nose Wheel Axle
%
%
%
%
% Castor Stop
%
Nose Wheel Fork
%
%
% Figure 2: Nose Landing Gear (if MÄM 40-574 or OÄM 40-334 is installed)
Doc # 6.02.15 Page 3
Rev. 2 32-20-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 32-20-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
Trouble-Shooting
1. General
Use the data below to trouble-shoot the nose landing gear.
WARNING: YOU MUST DO A HARD LANDING CHECK AFTER A HARD LANDING.
HARD LANDINGS CAN CAUSE DAMAGE TO THE STRUCTURE AS
WELL AS THE LANDING GEAR.
Trouble Possible Cause Repair
Strut bent. Hard landing. Do a hard landing check. Refer
to Section 05-50.
Replace the strut.
Nose wheel shimmy. Steering friction too low. Adjust the nose wheel steering
friction.
Doc # 6.02.15 Page 101
Rev. 2 32-20-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 32-20-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove, install and adjust the nose landing gear. Refer
to the manufacturer for further data.
2. Remove/Install the Nose Landing Gear Strut
A. Equipment
Item Quantity Part Number
Padded trestles. 1 Commercial.
Weight and strap. 1 Commercial.
B. Remove the Nose Landing Gear Strut
Detail Steps/Work Items Key Items
(1) Use weights to hold the rear fuselage down with Use a strap around the fuselage.
the nose wheel clear of the ground.
(2) Put a padded trestle under the front fuselage just
aft of the nose gear mounting.
(3) Remove the engine cowling. Refer to Section 71-10.
% (4) Disconnect the elastomer pack from the engine Refer to Figures 1 and 2.
mount.
% (5) Remove the lock bolt from the journal bearing. Refer to Figures 1 and 2 and
Section 71-20, Figure 1.
(6) Compress the journal bearing unit inwards.
(7) Release the journal bearing unit from the fuselage
bearings.
(8) Remove the nose gear strut from the airplane in a
downward direction.
Doc # 6.02.15 Page 201
Rev. 2 32-20-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
%
%
%
%
%
%
% Eye End
%
% Elastomer Element
Washer
%
Spacer Plate
% Top End Cap
%
% Threaded Pin
%
% Standard: 5
% MÄM 40-574
or OÄM 40-334: 6
%
% MÄM 40-574
Center Tube and MÄM 40-631
% (OÄM 40-334
% not installed): 5
%
%
%
% Elastomer
Pack
%
Threaded Pin
%
%
Bearing
%
%
Bottom End Cap
%
% Trunnion
% Large Washer Washer
% with Flange
Bolt
% Small Elastomer Element
%
Large Washer
%
Adjusting Nut
% Bearing Plate
%
Figure 3: Elastomer Pack and Journal Assembly
Page 202 Doc # 6.02.15
15 Apr 2013 32-20-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
C. Install the Nose Landing Gear Strut
Detail Steps/Work Items Key Items/References
% (1) Preparation: Refer to Figures 1 and 2.
S Liberally apply corrosion protection to these Use LPS.
items:
S The inside of the journal assembly.
S The shank of the lock bolt.
S The shank of the bolt which attaches the
elastomer pack to the engine mount.
(2) Put the nose gear strut in position in the airplane
from below.
% (3) Expand the journals of the unit to engage the Refers to Figures 1 and 2.
bearings in the fuselage.
(4) Install the lock bolt in the journal bearing unit.
(5) Connect the elastomer pack to the engine mount. Refer to Section 71-20.
(6) Adjust the nose wheel steering friction. Refer to Paragraph 5.
(7) Remove the trestle from the front fuselage.
(8) Lower the nose wheel to the floor. Remove the weights from the rear
fuselage.
(9) Install the engine cowling. Refer to Section 71-10.
Doc # 6.02.15 Page 203
Rev. 2 32-20-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
3. Remove/Install the Elastomer Pack
A. Equipment
Item Quantity Part Number
Padded trestles. 1 Commercial.
Weight and strap. 1 Commercial.
B. Remove the Elastomer Pack
Detail Steps/Work Items Key Items/References
(1) Use weights to hold the rear fuselage down with Use a strap around the fuselage.
the nose wheel clear of the ground.
(2) Put a padded trestle under the front fuselage just
aft of the nose mounting.
(3) Remove the engine cowling. Refer to Section 71-10.
(4) Disconnect the elastomer pack from the engine Hold the nose-gear strut. Refer to
mount. Figure 3.
(5) Remove the 4 bolts on each side attaching the left
hand and right hand bearing plates.
(6) Remove the assembly from the airplane.
Page 204 Doc # 6.02.15
15 Apr 2013 32-20-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
C. Install the Elastomer Pack
Detail Steps/Work Items Key Items/References
(1) Install the bearing plates on the lower bearing. Refer to Figure 3. Bearing plates must
be installed on journals of trunnion.
(2) Install the 4 washers and bolts for the left hand Put LPS 3 on the shanks of the bolts.
and 4 washers and bolts for the right hand nut Clean corrosion inhibitor from the
plates. threads.
(3) Connect the elastomer pack to the engine mount. Put LPS 3 on the shank of the bolt.
Clean corrosion inhibitor from the
threads.
(4) Remove the trestle from the front fuselage.
(5) Lower the nose wheel to the floor. Remove the weights from the rear
fuselage.
(6) Install the engine cowling. Refer to Section 71-10.
Doc # 6.02.15 Page 205
Rev. 2 32-20-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
4. Replace the Elastomer Elements
CAUTION: YOU MUST ALWAYS REPLACE CRACKED OR WORN ELASTOMER
ELEMENTS. IF YOU DO NOT REPLACE CRACKED OR WORN
ELASTOMER ELEMENTS, THE PROPELLER CAN HIT AN OBJECT.
Detail Steps/Work Items Key Items/References
(1) Remove the elastomer pack from the airplane. Refer to Paragraph 3.
WARNING: DO NOT STAND IN THE LINE OF THE ELASTOMER PACK WHEN
YOU REMOVE THE NUT. THE ASSEMBLY CAN EXPAND WITH A
LOT OF FORCE.
(2) Remove the adjusting nut from the elastomer
pack.
(3) Check center tube. If the center tube shows signs
of wear or deformation replace the center tube
assembly. No asymmetric wear allowed.
(4) Replace the defective elements.
% (5) Install the adjusting nut. Refer to Figure 3.
The distance between the center of the
eye-end bearing and the center of the
lower journal bearing must be
329 ± 1 mm (12.95 ± 0.04 in.)
% if 5 elastomer elements are installed.
% The distance between the center of the
% eye-end bearing and the center of the
% lower journal bearing must be
% 349 ± 1 mm (13.74 ± 0.04 in.)
% if 6 elastomer elements are installed.
(6) Install the elastomer pack in the airplane. Refer to Paragraph 3.
Page 206 Doc # 6.02.15
15 Apr 2013 32-20-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
5. Adjust the Nose Wheel Steering Friction
Steering friction prevents nose wheel shimmy.
A. Equipment
Item Quantity Reference
Padded trestle. 1 Commercial.
Weight and strap. 1 Commercial.
Spring balance. 1 Commercial.
B. Procedure
Detail Steps/Work Items Key Items/References
(1) Use weights to hold the rear fuselage down with Use a strap around the fuselage.
the nose wheel clear of the ground.
(2) Put a padded trestle under the front fuselage just
aft of the nose wheel mounting.
% (3) Remove the nose wheel fairing (if installed).
(4) Adjust the nose wheel fork pivot nut. The nose-wheel must just castor when
you apply a force of 30-50 N (6.75 -
11.25 lb) acting in the direction of the
nose wheel axle. If the cotter pin hole
does not align, tighten the nut to the
next slot.
Refer to Figure 4.
(5) Apply corrosion protection to the nut, stud and Use CRC corrosion shell.
washers only.
Do not get CRC corrosion shell on the
tire or the fiberglass.
% (6) Install the nose-wheel fairing (if the nose wheel
% fairing was installed).
(7) Remove the trestle from the front fuselage.
(8) Lower the nose-wheel to the floor. Remove the weights from the rear
fuselage.
Doc # 6.02.15 Page 207
Rev. 2 32-20-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
6. Nose Wheel Balancing
Always have the nose-wheel balanced before installation.
Apply a force of
30 - 50 N (6.75 - 11.25 lb.)
in both directions along
Pivot Nut the line of the Axle
Figure 4: Adjust the Nose Wheel Steering Friction
Page 208 Doc # 6.02.15
15 Apr 2013 32-20-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
Section 32-40
Wheels and Brakes
1. General
This Section gives you the data for the main and nose wheels. It also gives you the data for the brake
system. And it gives you the Trouble-Shooting and Maintenance Practices.
2. Description and Operation
A. Main Wheel
% Figures 1 shows the wheels. The main wheel hub has two magnesium (aluminium, if OÄM 40-334
% is installed) halves. Three bolts (six bolts, if OÄM 40-334 is installed) hold the two halves together.
% The bolts also hold a brake disk to the inner half of the hub. A distance washer is installed between
% brake disc and inner half of the hub, if OÄM 40-334 is installed.
The wheel has a tire with an inner tube. Snap rings hold tapered roller bearings and grease seals
in each half of the hub. You can remove the bearings for maintenance. The outer half of the hub
has a hole for the valve stem.
B. Nose Wheel
The nose wheel has a similar construction to the main wheel with tapered bearings.
% The nose wheel hub consists of two magnesium halves. Three bolts hold the two halves together.
Doc # 6.02.15 Page 1
Rev. 2 32-40-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
%
%
%
%
%
%
Bolt
%
%
%
%
% Hub Half
Brake Disk
%
Hub Half
%
% Distance Washer
% if OÄM 40-334
is installed
% Bolt
%
Hub Half
%
Hub Half Bearing
%
Seals
%
Snap Ring
%
%
Inner Tube
%
%
% Tapered Bearing Tire
% MAIN WHEEL
%
% Inner Tube
%
%
Tire
%
% NOSE WHEEL
%
%
%
%
%
Figure 1: Main and Nose Wheels
Page 2 Doc # 6.02.15
15 Apr 2013 32-40-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
%
Max Level 12 mm (0.5 in.)
%
Min Level 25 mm (1 in.)
%
% Vented Plug
%
%
Master Master Fluid Level
Cylinders Cylinders
%
%
%
%
% Brake Fluid
% Reservoir
Pilot's Pedals Co-Pilot's Pedals
%
%
% LOCK
% PARKING BRAKE
% Flexible Hose
RELEASE
%
%
%
% Parking Brake Valve
%
%
%
%
%
%
%
Brake Disk Brake Disk
% Pressure
% Plate
% Flexible Hose Flexible Hose
%
%
%
%
%
% Back Plate
Brake Caliper
%
%
Figure 2: Brake System Schematic
Doc # 6.02.15 Page 3
Rev. 2 32-40-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
C. Brake System
Figure 2 shows the brake system schematic diagram. The DA 40 NG has two separate brake
systems. The pilot’s and co-pilot’s left toe brake pedals operate the left system. They supply
pressure to the left brake caliper. The right toe brake pedals operate the right brake system and
supply pressure to the right caliper.
Figure 3 shows the brake master cylinder and reservoir installation. Each system has a brake fluid
reservoir. The reservoir attaches to the master cylinder on the co-pilot’s rudder pedal. The outlet
from the master cylinder on the co-pilot’s rudder pedal connects to the inlet of the master cylinder
on the pilot’s pedals. The outlet from the master cylinder on the pilot’s rudder pedal connects to the
parking brake valve. The parking brake valve connects to the brake caliper.
% Figures 4 and 5 show the wheel brake assembly.
% Figure 8 shows the parking brake valve installation. The parking brake valve is located on the
bottom flange of the control bulkhead. It contains two valves which can seal the brake pressure into
the calipers. This keeps the brakes ON. The pressure will reduce in time and the brakes will slowly
release. A serviceable parking-brake valve will keep the brakes on for more than 1 day.
(1) Co-Pilot’s Brake Operation
When you press on the co-pilot’s right brake pedal these things happen:
) The connection to the reservoir is cut off by the initial movement.
) Further movement pushes fluid past the piston on the pilot’s master cylinder.
) The fluid flows through the parking-brake valve to the right brake caliper.
) The fluid pushes the piston and the pressure plate against the brake disk.
) The reaction force on the caliper pulls the back-plate against the brake disk.
) The right brake is applied.
In the same way, when you press on the co-pilot’s left brake pedal, the left brake is applied.
Page 4 Doc # 6.02.15
15 Apr 2013 32-40-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
Figure 3: Brake Master Cylinder and Reservoir Installation
Doc # 6.02.15 Page 5
Rev. 2 32-40-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
(2) Pilot’s Brake Operation
When you press on the pilot’s right brake pedal, these things happen:
) The connection from the co-pilot’s master cylinder is cut off by the initial movement. (Note:
Any hydraulic pressure from the co-pilot’s master cylinder pushes on the back of the piston
in the pilot’s master cylinder. This increases the brake pressure).
) The fluid flows through the parking brake valve to the right brake caliper.
) The fluid pushes the piston and the pressure plate against the brake disk.
) The reaction force on the caliper pulls the back plate against the brake disk.
) The right brake is applied.
In the same way, when you press on the pilot’s left brake pedal, the left brake is applied.
Note: If one side of the system fails, one or both pilots can loose braking on that side. For
example, a leak in the pipe between the co-pilot’s and the pilot’s right master
cylinder will cause a right brake failure for the co-pilot. The pilot’s right brake will
operate correctly. If the leak is between the pilot’s right master cylinder and the right
brake caliper, both pilots will have right brake failure.
(3) Parking Brake Operation
To apply the parking brake:
) Press on both pedals.
) Move the parking brake lever to LOCK (fully up).
) Release your foot pressure on the pedals.
) If necessary, pump the brake pedals.
To release the parking brake, move the lever to RELEASE (fully up).
Page 6 Doc # 6.02.15
15 Apr 2013 32-40-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
Figure 4: Wheel Brake Assembly
Doc # 6.02.15 Page 7
Rev. 2 32-40-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
%
%
%
%
%
% Back Plate
% Attaching Bolt
%
% Washer
% Caliper
%
%
%
%
%
Pressure Plate
%
%
%
Back Plates
%
%
%
%
%
%
%
%
%
%
Brake Torque Plate
%
%
%
%
%
%
%
%
%
%
% Figure 5: Wheel Brake Assembly (if OÄM 40-334 is installed)
Page 8 Doc # 6.02.15
15 Apr 2013 32-40-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
Trouble-Shooting
1. General
Use the data below to trouble-shoot the wheel and brake system.
Complaint Possible Cause Remedy
Too much tire wear. Incorrect toe-in. Adjust the toe-in. Refer to
Section 32-10.
Incorrect inflation pressure. Correct inflation pressure.
Too much axial play in a wheel. Main wheel incorrectly Adjust the main wheel.
adjusted.
Defective wheel bearing. Replace the wheel bearing.
Brake disk distorted. Brakes applied too hard. Replace the brake disk.
Hard landing.
Brakes do not hold static Brake fluid level low. Fill the system with brake fluid.
engine run-up with the usual
Air in the brake system. Bleed the brake system.
pedal force.
Defective master cylinder. Replace the master cylinder
and then bleed the brake
system.
Defective caliper. Replace the caliper and then
bleed the brake system.
Worn brake linings. Replace the brake linings and
then bleed the brake system.
Leaking connector. Tighten (or replace) the
connector and then bleed the
brake system.
Doc # 6.02.15 Page 101
Rev. 2 32-40-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 32-40-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove/install components. They also give the
conditioning procedure for the brake linings. Refer to the manufacturer's data (Cleveland/Parker
Hannifin Corporation) for other shop work.
2. Remove/Install a Main Wheel
A. Equipment
Item Quantity Reference
Airplane jacks. 3 Commercial.
B. Remove a Main Wheel
Detail Steps/Work Items Key Items/References
(1) Lift the airplane on jacks. Refer to Section 07-10.
% (2) Remove the wheel fairing (if installed):
S Remove the outboard bolt.
S Remove 4 screws from the inner side.
(3) Remove the back-plate from the brake caliper. Cut the locking wire.
(4) Remove the lock-bolt from the axle nut
% (if lock-bolt is installed).
% (5) If OÄM 40-334 is installed:
% S Remove the dust cap from the wheel.
% S Remove the split pin.
%
(6) Remove the axle nut.
(7) Pull the wheel from the axle.
Doc # 6.02.15 Page 201
Rev. 2 32-40-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
C. Install a Main Wheel
Detail Steps/Work Items Key Items/References
(1) Apply a light coating of grease to the axle where Use grease MIL-G-3545.
the wheel bearings go.
(2) Put the wheel in position on the axle. Make sure that the brake caliper is
correctly engaged on the torque plate.
Note: Turn the wheel by hand while you tighten the axle nut. This will remove grease
(which can separate the bearings) or burrs. Both can cause too much wheel
bearing play later.
(3) Install the axle-nut. Hand tight.
(4) Loosen the axle nut until it is just loose.
(5) Tighten the axle nut. Hand tight.
% (6) Loosen the axle nut until one of the 2 holes (if
% OÄM 40-334 is installed: 4 holes) in the axle
aligns with the nut.
(7) Install the lock-bolt, washer and self-locking nut Do not loosen the nut more than 30°
% (castle nut, if OÄM 40-334 is installed). (half of a flat).
% (8) If OÄM 40-334 is installed: Do not loosen the nut more than 30°
% (half of a flat).
% Install the split pin.
(9) Measure the end play in the hub assembly. There should be 0.025 to 0.125 mm
(0.001 to 0.005 in) of end play when
correctly adjusted.
(10) Lower the airplane with the jacks. Refer to Section 07-10.
Page 202 Doc # 6.02.15
15 Apr 2013 32-40-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
3. Remove/Install the Nose Wheel
A. Equipment
Item Quantity Reference
Padded trestle. 1 Commercial.
Weight and strap. 1 Commercial.
B. Remove the Nose Wheel
Detail Steps/Work Items Key Items/References
% (1) Remove the wheel fairing (if installed):
S Remove 6 screws attaching the left half of the
fairing to the right half.
S Remove the 2 left and 2 right attaching
screws.
S Remove the fairing.
(2) Use weights to hold the rear fuselage down with Use a strap around the rear fuselage.
the nose wheel clear of the ground.
(3) Put a padded trestle under the fuselage just aft of
the nose gear mounting.
(4) Remove the axle bolt:
S Remove the cotter pin from the axle nut.
S Remove the axle nut and washer.
S Remove the axle bolt and washer.
% If OÄM 40-334 is installed:
% S Remove the axle nut. Refer to Figure 5.
% S Remove the axle bolt, washer and flanged Support the nose wheel.
% bushes.
(5) Remove the wheel from the fork.
% (6) Remove the spacers from the axle. Refer to Figures 5 and 7.
% (7) Remove the tubular axle from the wheel. Refer to Figures 5 and 7.
Doc # 6.02.15 Page 203
Rev. 2 32-40-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
C. Install the Nose Wheel
Detail Steps/Work Items Key Items/References
% (1) Install the axle bolt (if OÄM 40-334 is installed): Refer to Figures 5 and 7.
% S Make sure the tubular axle is clean and install
% the axle into the wheel.
%
% S Install the spacers on the axle.
%
% S Move the wheel into position in the fork .
%
% S Install the flanges bushes and make sure they
%
% are installed correctly.
%
% S Install the washer onto the axle bolt (if Put Mastinox 6856K corrosion inhibitor
% OÄM 40-334 is NOT installed). or LPS-3 on the shank of the bolt. Clean
% corrosion inhibitor from the threads.
%
% S Push the axle bolt into position through the
% axle.
%
% S Install a washer onto the axle bolt.
%
% S Install the axle nut hand tight only!
% S Slowly rotate the wheel while tightening the To settle the tapered wheel bearing.
% axle nut, hand tight only! Check installation for smooth rotation
% without any axial free play.
%
% S Turn the axle counter-clock-wise until the next
% cotter pin hole aligns with the axle nut and
% install the cotter pin (if OÄM 40-334 is NOT
% installed).
%
(2) Turn the nose wheel. Make sure that the valve Clearance 2 mm (0.08 in) minimum.
cap does not touch the fork.
(3) Remove the trestle from the front fuselage.
(4) Lower the nose wheel to the ground. Remove the weights from the rear
fuselage.
Page 204 Doc # 6.02.15
15 Apr 2013 32-40-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
Detail Steps/Work Items Key Items/References
% (5) Install the wheel fairing (if the wheel fairing was
% installed):
S Put the 2 halves in position.
S Install the 2 LH and 2 RH mounting screws.
S Install the 6 screws which hold the fairing
halves together.
Doc # 6.02.15 Page 205
Rev. 2 32-40-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
Fork Wheel Assembly
%
Washer
%
Spacer
%
% Bolt
%
%
%
Axle
%
Spacer
%
% Washer
%
Nut
%
%
%
%
%
% Fork
% Figure 6: Nose Wheel Assembly (if OÄM 40-334 is NOT installed)
Page 206 Doc # 6.02.15
15 Apr 2013 32-40-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
Wheel Assembly
% Flanged Bush
% Bolt Spacer
% Washer
%
%
%
% Axle
%
Spacer
%
Flanged Bush
%
%
Washer
%
%
Nut
%
%
%
% Fork
%
% Figure 7: Nose Wheel Assembly (if OÄM 40-334 is installed)
Doc # 6.02.15 Page 207
Rev. 2 32-40-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
4. Remove/Install a Brake Master Cylinder
A. Remove a Brake Master Cylinder
Detail Steps/Work Items Key Items/References
WARNING: DO NOT GET BRAKE FLUID ON YOU. BRAKE FLUID CAN CAUSE
DISEASE.
CAUTION: CLEAN UP SPILT BRAKE FLUID IMMEDIATELY. BRAKE FLUID CAN
DAMAGE PAINT AND OTHER MATERIAL.
(1) Disconnect the brake pipe(s) from the brake Catch the brake fluid. Put caps on all
master cylinder. connections.
% Refer to Figure 3.
(2) Remove the top pivot pin.
S Remove the cotter pin.
S Remove the washer.
S Remove the pivot pin.
(3) Release the bottom pivot pin.
S Remove the cotter pin.
S Remove the washer.
S Move the master cylinder sideways off the
pivot pin.
(4) Lift the master cylinder from the rudder pedal
assembly.
Page 208 Doc # 6.02.15
15 Apr 2013 32-40-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
B. Install a Brake Master Cylinder
Detail Steps/Work Items Key Items/References
WARNING: DO NOT GET BRAKE FLUID ON YOU. BRAKE FLUID CAN CAUSE
DISEASE.
CAUTION: CLEAN UP SPILT BRAKE FLUID IMMEDIATELY. BRAKE FLUID CAN
DAMAGE PAINT AND OTHER MATERIAL.
% (1) Put the master cylinder in position on the bottom Refer to Figure 3.
pivot pin.
(2) Attach the master cylinder to the bottom pivot pin:
S Install the washer.
S Install the cotter pin. Use a new cotter pin.
(3) Install the top pivot pin:
S Install the pivot pin.
S Install the washer.
S Install the cotter pin. Use a new cotter pin.
(4) Connect the brake pipe(s) to the master cylinder.
(5) Bleed the brake system. Refer to Paragraph 7.
(6) Do a function test of the brake system.
Doc # 6.02.15 Page 209
Rev. 2 32-40-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
5. Remove/Install a Brake Cylinder
A. Remove a Brake Cylinder
Detail Steps/Work Items Key Items/References
% (1) Remove the bolts which hold the back-plate. Refer to Figures 4 and 5.
% Remove the back-plate. 4 bolts (if OÄM 40-334 is installed) or
% 2 bolts (otherwise).
WARNING: DO NOT GET BRAKE FLUID ON YOU. BRAKE FLUID CAN CAUSE
DISEASE.
CAUTION: CLEAN UP SPILT BRAKE FLUID IMMEDIATELY. BRAKE FLUID CAN
DAMAGE PAINT AND OTHER MATERIAL.
(2) Disconnect the brake pipe from the brake Catch the brake fluid!
cylinder.
Put caps on all connections.
(3) Remove the pressure plate and the brake cylinder
from the torque plate.
Page 210 Doc # 6.02.15
15 Apr 2013 32-40-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
B. Install a Brake Cylinder
Detail Steps/Work Items Key Items/References
(1) Put the brake cylinder and pressure plate in Use Loctite anti-seize compound 767,
position on the torque plate. Loctite 8009 or equivalent on the
locating pins.
(2) Connect the brake pipe to the brake cylinder.
(3) Put the back-plate in position on the brake
cylinder.
% (4) Install the 2 bolts which attach the back-plate. Torque: according to Cleveland/Parker
% Maintenance Manual, latest revision or
% placard on brake cylinder.
% 4 bolts (if OÄM 40-334 is installed) or
% 2 bolts (otherwise).
% (5) Lock the bolts with wire. If bolts with drilled heads are used.
(6) Bleed the brake system. Refer to Paragraph 7.
(7) Do a function test of the brake system.
Doc # 6.02.15 Page 211
Rev. 2 32-40-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
Control Bulkhead
Attaching Bolt
Swivel Fitting To Right Brake
Parking Brake
Caliper
Lever
Inlet for Right
Brake System
To Left Brake
Caliper
Parking Brake
Valve
Cable Adjuster
Inlet for Left
Brake System
Control Bulkhead
Large Washer
Nut
Bowden Cable from
Parking Brake Control
Lever
Figure 8: Parking Brake Valve Installation
Page 212 Doc # 6.02.15
15 Apr 2013 32-40-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
6. Remove/Install the Parking Brake Valve
A. Remove the Parking Brake Valve
Detail Steps/Work Items Key Items/References
(1) Remove the pilots' seats. Refer to Section 25-10.
WARNING: DO NOT GET BRAKE FLUID ON YOU. BRAKE FLUID CAN CAUSE
DISEASE.
CAUTION: CLEAN UP SPILT BRAKE FLUID IMMEDIATELY. BRAKE FLUID CAN
DAMAGE PAINT AND OTHER MATERIAL.
% (2) Disconnect the Bowden cable: Refer to Figure 8.
S Loosen the screw in the swivel fitting. At the bottom of the control bulkhead.
S Pull the center wire from the swivel fitting.
(3) Disconnect the 4 brake pipes from the parking Catch the brake fluid!
brake valve.
Put caps on all connections.
(4) Remove the 2 nuts, bolts and washers which
attach the valve and bracket.
(5) Move the Bowden cable and bracket clear of the
valve.
(6) Remove the valve from the airplane.
Doc # 6.02.15 Page 213
Rev. 2 32-40-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
B. Install the Parking Brake Valve
Detail Steps/Work Items Key Items/References
(1) Put the parking brake valve in position. At the bottom of the control bulkhead.
% Refer to Figure 8.
(2) Install the 2 nuts, bolts and washers which attach Make sure that the bracket for the
the valve. Bowden cable is in position.
(3) Connect the 4 brake pipes to the parking brake
valve.
(4) Put the center wire of the Bowden cable through
the swivel fitting on the brake valve lever. Tighten
the screw.
(5) Bleed the brake system. Refer to Paragraph 7.
(6) Do a function test of the parking brake system:
S Set the parking brake to LOCK.
S Pump the foot brake pedals.
S The brakes must stay on.
S Set the parking brake to RELEASE.
S The brakes must release.
(7) Install the pilots' seats. Refer to Section 25-10.
Page 214 Doc # 6.02.15
15 Apr 2013 32-40-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
7. Bleed the Brake System
A. Equipment
Item Quantity Reference
Pressure bleed equipment with MIL-H-5606A brake fluid. 1 Commercial.
Transparent overflow pipe and container. 1 Commercial.
B. Bleeding Procedure
This procedure bleeds the air from the braking system on one side of the airplane (left or right). If
necessary, perform this procedure on both braking systems (left and right).
Detail Steps/Work Items Key Items/References
(1) Clean the area of the brake fluid reservoir cap. On the co-pilot’s rudder pedal
% assembly. Refer to Figure 3.
(2) Remove the cap.
WARNING: DO NOT GET BRAKE FLUID ON YOU. BRAKE FLUID CAN CAUSE
DISEASE.
CAUTION: CLEAN UP SPILT BRAKE FLUID IMMEDIATELY. BRAKE FLUID CAN
DAMAGE PAINT AND OTHER MATERIAL.
(3) Connect the transparent overflow pipe to the Put the free end of the pipe in a
reservoir. container.
% (4) Clean the area around the bleed nipple below the Refer to Figure 4.
brake cylinder.
(5) Connect the pressure bleed equipment to the Use only MIL-H-5606A brake fluid.
bleed nipple below the brake cylinder.
(6) Open the bleed nipple about 1/2 to 1 turn.
(7) Use the pressure bleed equipment to fill the brake Monitor the fluid coming from the
system. reservoir for air bubbles.
(8) Operate the parking brake ON and OFF 10 to Continue bleeding the system until the
20 times to remove air from the system. fluid has no bubbles.
Doc # 6.02.15 Page 215
Rev. 2 32-40-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(9) Operate the pilot’s brake pedals many times to Continue bleeding the system until the
remove air from the system. fluid has no bubbles.
(10) Operate the co-pilot’s brake pedals many times to Continue bleeding the system until the
remove air from the system. fluid has no bubbles.
(11) Remove the pressure bleed equipment. Close the
bleed nipple and install the protective cap.
(12) Remove the overflow pipe and container.
(13) Measure the fluid level in the reservoir. If The correct level is 12 mm (0.5 in.)
necessary, add or remove fluid. below the top of the filler hole. When the
level is 25 mm (1 in.) below the top of
the filler hole you must add fluid to the
correct level.
% Refer to Figure 2.
(14) Install the reservoir cap.
(15) Do a function test of the brake system.
Page 216 Doc # 6.02.15
15 Apr 2013 32-40-00 Rev. 2
DA 40 NG AMM Landing Gear
AIRCRAFT
8. Condition the Brake Linings
The brake linings are a non-asbestos organic material. You must condition new brake linings.
Conditioning gives a thin layer of glaze at the friction surface. Usual brake usage keeps the layer of
glaze for the life of the brake lining.
Light brake use can wear off the glaze. This reduces brake performance. If the glaze wears off, do the
conditioning procedure.
Detail Steps/Work Items Key Items/References
WARNING: DO NOT TAXI THE AIRPLANE UNLESS YOU HAVE BEEN TRAINED
TO TAXI AND YOU ARE AUTHORIZED BY YOUR AIRWORTHINESS
AUTHORITY.
CAUTION: MAKE SURE THAT THE BRAKES OPERATE CORRECTLY WHILE
YOU TAXI THE AIRPLANE, IF THE BRAKES FAIL, YOU MUST BE
ABLE TO STOP THE AIRPLANE WITHOUT HITTING ANY PERSONS,
EQUIPMENT OR OTHER OBSTACLES.
(1) Taxi the airplane for 1500 ft with 1700 RPM. Use the brakes to keep the speed at
5 to 10 mph (8 to 16 km/h).
(2) Let the brakes cool for 10 to 15 minutes.
(3) Apply the brakes. Do a high throttle run-up. The brakes must hold with the usual
pedal force.
(4) If the brakes do not hold the static run-up, do
steps 1 to 3 again as necessary.
Doc # 6.02.15 Page 217
Rev. 2 32-40-00 15 Apr 2013
Landing Gear DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 218 Doc # 6.02.15
15 Apr 2013 32-40-00 Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
CHAPTER 33
LIGHTS
Doc # 6.02.15 Page 1
Rev. 2 33-TITLE 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 33-TITLE Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 33
LIGHTS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 33-10
Lights - Flight Compartment
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Cabin Light Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Replace a Filament in a Reading Light Assembly . . . . . . . . . . . . . . . . . . . . . . . 202
4. Remove/Install a Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Section 33-40
Exterior Lights
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Doc # 6.02.15 Page 1
Rev. 2 33-CONTENTS 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Taxi Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Landing Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
% 4. Replace a Filament in the Wing-Tip Light Unit (if OÄM 40-341 is NOT installed)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5. Remove/Install the Light Unit in the Wing-Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6. Remove/Install a Strobe Power Unit in the Wing-Tip . . . . . . . . . . . . . . . . . . . . . 210
Page 2 Doc # 6.02.15
15 Apr 2013 33-CONTENTS Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
CHAPTER 33
LIGHTS
1. General
This Chapter tells you about the cockpit and the exterior lighting of the DA 40 NG. Section 33-10 tells
you about the flight compartment lighting and Section 33-40 tells you about the exterior lighting.
Note: Equipment which is certified for installation in the DA 40 NG is listed in Section 6.5
of the Airplane Flight Manual. Such equipment may be installed in accordance with
the Airplane Maintenance Manual.
Any equipment which is not listed in Section 6.5 of the Airplane Flight Manual is
called "Additional Equipment". The installation of Additional Equipment is a
modification which must be handled in accordance with national regulations or a
Service Bulletin.
2. Description
Figure 1 shows you the location of the lights. The DA 40 NG has these flight compartment lights:
) Reading lights.
) Instrument lights.
) Instrument panel flood light.
Some avionics equipment has internal lighting. Refer to the related Section and the equipment
manufacturers handbooks for the equipment in your airplane. Combined ON/OFF and dimmer
switches for the instrument panel flood lights and the internal instrument lights are located in the
instrument panel, top left.
The DA 40 NG has these exterior lights in one light unit at each wing-tip:
) Left and right position lights. The front part of the light unit has a red (left) or green (right) lens.
% The light can be seen from the front and the side. If OÄM 40-341 is installed, the lenses are
% clear and the LEDs provide the coloration.
) Rear position lights. The aft part of each wing-tip light unit has a clear lens. The lights can be
seen from the rear only.
) Strobe light. The middle part of each wing-tip light unit has a clear lens. The filament gives a
high-intensity flash. The strobe light can be seen from all directions. A separate power unit for
each strobe light is mounted in the wing-tip.
Doc # 6.02.15 Page 1
Rev. 2 33-00-00 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
Right Wing Tip
Light Assy
Reading Lights (3 off)
Left Wing Tip
Light Assy
Instrument Panel
Flood Light Strip
Landing/Taxi Light Assy
Figure 1: Flight Compartment and Exterior Lights
Page 2 Doc # 6.02.15
15 Apr 2013 33-00-00 Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
The DA 40 NG has these exterior lights in one housing in the outer leading edge of the left wing:
) Landing light. It is located inboard in the housing. The landing light has a clear lens and a 35 Watt
filament.
) Taxi light. It is located outboard in the housing. The taxi light has an optic lens and a 35 Watt
filament.
The switches for all the exterior lights are located in the instrument panel, lower left.
Doc # 6.02.15 Page 3
Rev. 2 33-00-00 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 33-00-00 Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
Section 33-10
Lights - Flight Compartment
1. General
This Section tells you about the flight compartment lighting on the DA 40 NG. Refer to Chapter 92 for
the wiring diagrams.
2. Description
The DA 40 NG has these flight compartment lighting systems:
) Reading lights.
) Instrument panel flood lighting.
) Instrument lights.
Some avionics equipment has internal lighting. Refer to the related section and the equipment
manufacturers handbooks for the equipment in your airplane. Combined ON/OFF and dimmer
switches for the instrument panel flood lights and the internal instrument lights are located in the
instrument panel, top left.
A. Reading Lights
Reading lights are located in the roof of the cockpit. The two lights at the front are directed towards
the pilots' seats and the light at the rear is directed towards the passenger seat. Each reading light
assembly has an integral switch and a directional beam. The system is protected by a
circuit-breaker located on the right side of the instrument panel.
B. Instrument Panel Flood Lighting
A 115 V AC foil type light strip makes the instrument flood light. The intensity of the light is
controlled by a dimmer switch located on the left side of the instrument panel. Turn the dimmer
switch fully counter-clockwise to turn the flood light off. Turn the dimmer switch clockwise to turn
the flood light on and to set the level of lighting that you require. The light strip is held in place under
the anti-glare panel with double sided tape. A solid state inverter supplies the 115 V AC current.
The system is protected by a circuit-breaker located on the right side of the instrument panel.
Doc # 6.02.15 Page 1
Rev. 2 33-10-00 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
A A
C
B
Reading Light
(Passengers)
Map/Reading Light
(Co-Pilot)
Map/Reading Light
(Pilot)
Dimmer Switch
Instrument Lights
(placard lights)
Dimmer Switch
Flood Lights
H
O OF F
R
I
Z
O
N ON
G P S N O T A P P R OV E D
F O R W A A S O P E R A T I O NS
EM E RG EN C Y
OE-XX X
Flood Light (Foil Strip)
Ma no u veri n g sp ee d : Limitations for GFC 700 Autopilot System:
V
A =1 11 K I A S (a b ove 10 36 up to 12 00 kg / a bo ve 2 28 4 u p t o 2 64 6 l b )
Do n o t u s e A P if “A l t e rn at e S t a t ic ” i s o p e n.
VA = 94 KI A S (78 0 t o 1 03 6 kg / 1 72 0 t o 2 2 84 lb ) Ess Bu s Co n d u ct A P a n d t ri m c h e ck p rio r t o e ac h f li g h t ( se e A F M) .
T hi s a ri p al ne ma y on l y be op era te d i n a cc ord an ce wit h t h e A ir p la ne Fl i gh t no t fo r max. u sable fuel: 2 x 19.5 US gal
Ma nu a .l I t ca n b e o pe rat ed ni th e "No rma "l a nd "Uti l ti y" c at eg o ri e s in A u t o pi l o t O F F d ur ni g t ak e -o f f a n d la n d in g .
no rmal * Max indicated fuel quant tiy: 2 x 14 US gal
n on -ic ni g c on di t oi ns . P rov di ed t ha t n at i on al op era t io na l re qu i reme nt s M ax i m um s pe e d f or a u t o pi l o t o p e r a t oi n si 1 6 5 K I A S .
a er me t a nd th e a pp rop ri at e e qu i pme nt i s ni st a l e d, th i s ai r pl a ne i s a p- oper atio n * Re fer to AFM t o use entir e tank capa city M ni i m um s pe e d f or a u t o pi l o t op e ra t oi n i s 7 0 K I A S .
p or ve d f o r t h e f ol l owi ng ki nd s of o pe r at i on : d ay VF R, ni gh t V F R an d See AFM * Max differ ence LH/RH tank: 9 US gal M in i m um a l it t u d e f o r a u to p i l ot o p e rat i o n :
I FR. A l ae rob at i cs m an eu ve rs in cl ud i ng spi n ni ng are p ro hi bi t ed . F o r
Cru i s e, Cl i m b, D es c en t a n d M a n eu v e r ni g : 8 00 f e e t A G L
f urt h er op e ra t io na l l i mi ta t io ns ref er t o t h e A ir p la ne Fl i gh t M an ua l .
A p p ro ac h : 20 0 f e et A G L
N o s mo ki ng
Figure 1: Flight Compartment Lights if the G1000 System Is Installed
Page 2 Doc # 6.02.15
15 Apr 2013 33-10-00 Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
A A
C B
Reading Light
(Passengers)
Map/Reading Light
(Co-Pilot)
Map/Reading Light
(Pilot) C
Dimmer Switch
Instrument Lights
Dimmer Switch
Flood Lights
0
P I LO T
OF F
V O L UME
PW R /X M T
S Q UE L C H
ISO
AL L
V OL U ME
PM100 0II
C O-P I L OT
S QUE L CH
Instrument Panel
INSTRUMENT
ON
140
120
160
AIRSPEED 40
KNOTS 60
10
20
20
10 20
10
10
20
8 ALT
7
9
CA LI B R AT E D
TO
2 0, 00 0 F E ET
1
2
3
Flood Light (Foil Strip)
100
OFF 80 6 4 OP
FLOOD 5 LH RH
OT 0 ,9 bar 6 ,5 CT 14
F UE L PRE SS
FLOW- GAL/ hr
14 0
ON 9 1 O.A.T. VOLTS
FT FT
FUEL -3 0 °C 1 40 GT -3 0 °C 10 5
PUMPS 2 3 00
l / m ni %
1 00
10
60 60
10
8 ALT 2
DC VOLTAGE/V CA LI B RAT E D
ON OFF EL EC R PM -3 0 °C 12 0 L R UT LT
24 10
TO
2 0, 00 0 F E ET
21 27 2 4 ,1 32
FT ET
OFF 5 15 -2 5 CURRENT/A -2 5
7 3
UP °C °C
18
VOTER ECU 5 5
30
V E R T I CA L S P E E D SELECT CONTROL
ECU TEST 1 0 0 F E E T P E R M I NU T E
20
LO A D
W AT ER L EV
70
6 4
% 5
15
0 0
33 0
AUTO GAL
T UR N CO OR DI NA T O R 20
12
ECUB L R DOWN
9 3 5 15
2 MI N
NO P I T CH
6 10
I N F O RM A T I ON
PU LL SQ U ELC H
TX
V OL
OF F
ELECTRIC ESS. AVIONIC FUEL TRANS
PITOT LAND ING TAXI POSITIO N STROBE MASTER BUS MASTER
ENGINE ON
G T X 32 8
MA X
ON ST MASTER I DE NT F UN C CR S R 110 KI AS
ON
7000 FL IG HT TIME
AR
F
OF
ALT
ALT
T
ST
01:23:20 MI N
F
S TA R T
VFR
OF
CL R
BY
ST OP 98 KI AS
OFF
0 1 2 3 4 5 6 7 8 9
AR T EX
ELT
E M E R GE N C Y U S E O N L Y
O N
AR M
FUEL FUEL MAIN XFER
MIC EECU A EECU B PWR FAN/ OAT T&B DG INST. LT TAXI/ MAP POSITIO N STROBE START TE ST/ R ESE T AUDIO CO M1 NAV1 XPDR AV. BU S FLAPS HO RIZON ANNUN INST. 1 PITOT LAND ING FLOOD ESS MASTER
PUMP A PUMP B TIE PUMP PR ES S O N
TIE CONTR OL
WAI T 1 SE CO ND
2 8 VDC ACCE SSORY PW R.
ECU BUS MAIN BUS PR ES S AR M
GROUN D O PS. ON LY 2A MAX AVIONIC BUS ESSENTI AL BUS
Figure 2: Flight Compartment Lights if Conventional Cockpit (OÄM 40-321) Is Installed
Doc # 6.02.15 Page 3
Rev. 2 33-10-00 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
C. Instrument Lighting
The instrument lighting is controlled by a dimmer switch mounted on the left side of the instrument
panel. Turn the dimmer switch fully counter-clockwise to turn the instrument lights off. Turn the
dimmer switch clockwise to turn the instrument lights on and to set the level of lighting that you
require. The system is protected by a circuit-breaker located on the right side of the instrument
panel.
Page 4 Doc # 6.02.15
15 Apr 2013 33-10-00 Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the flight compartment lighting system. If you
have the trouble detailed in the Trouble column read across to the Possible Cause column. Then do
the repair given in the Repair column.
Trouble Possible Cause Repair
One of the reading lights does Defective filament. Replace the filament.
not operate.
Defective light unit. Replace the light unit.
The instrument panel flood Circuit-breaker not set. Set the circuit-breaker.
light does not operate
Dimmer switch defective. Replace the dimmer switch.
correctly.
Solid state inverter defective. Replace the solid state
inverter.
Light strip defective. Replace the light strip.
Defective wiring. Do a continuity check of the
wiring. Repair/replace
defective wiring. Refer to
Chapter 92 for the wiring
diagrams.
The instrument lights do not Filament(s) defective. Replace the filament(s).
operate correctly.
Circuit-breaker not set. Set the circuit-breaker.
Dimmer switch defective. Replace the dimmer switch.
Defective wiring. Do a continuity check of the
wiring. Repair/replace
defective wiring. Refer to
Chapter 92 for the wiring
diagrams.
Doc # 6.02.15 Page 101
Rev. 2 33-10-00 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 33-10-00 Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove/install the main components of the flight
compartment lighting systems. Refer to the Chapter 92 for the wiring diagrams.
2. Remove/Install a Cabin Light Assembly
A. Remove a Reading Light Assembly
Detail Steps/Work Items Key Items/References
(1) Pull the circuit-breaker for the reading light. Instrument panel, right side.
(2) Remove the reading light assembly: Hold the reading light assembly.
S Release the spring clip which holds the light At the switch end of the assembly.
assembly in position.
S Lower the light assembly from cockpit roof At the in-line connector.
and disconnect the electrical cable.
S Move the light assembly clear of the airplane.
B. Install a Reading Light Assembly
Detail Steps/Work Items Key Items/References
(1) Move the reading light assembly into position in Hold the reading light assembly.
the cockpit.
(2) Connect the electrical cable to the light assembly. At the in-line connector.
(3) Move the light assembly into position, lamp end Make sure that the light assembly is
first, then push the switch end up into position correctly installed and that the spring
until the spring clip engages. clip is fully engaged.
Doc # 6.02.15 Page 201
Rev. 2 33-10-00 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
3. Replace a Filament in a Reading Light Assembly
Detail Steps/Work Items Key Items/References
(1) Remove the reading light assembly. Refer to Paragraph 2A.
(2) Remove the filament holder from the rear of the
light assembly.
(3) Replace the filament.
(4) Install the filament holder at the rear of the light
assembly.
(5) Install the reading light assembly. Refer to Paragraph 2B.
4. Remove/Install a Dimmer Switch
A. Remove a Dimmer Switch
Detail Steps/Work Items Key Items/References
(1) Disconnect the battery. Refer to Section 24-31.
(2) Remove the instrument panel cover. Refer to Section 25-10.
(3) Remove the knob from the dimmer switch that
you will remove.
(4) Disconnect the electrical wiring from the rear of
the dimmer switch.
(5) Remove the nut and washer from the front of the
dimmer switch.
(6) Move the dimmer switch forward and move it
clear of the instrument panel.
Page 202 Doc # 6.02.15
15 Apr 2013 33-10-00 Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
B. Install a Dimmer Switch
Detail Steps/Work Items Key Items/References
(1) Put the dimmer switch into position in the
instrument panel.
(2) Install the washer and nut which attaches the Make sure that the dimmer switch is
dimmer switch to the instrument panel. orientated correctly.
(3) Connect the electrical wiring to the rear of the Refer to Chapter 92 for the wiring
dimmer switch. diagrams.
(4) Install the knob to the front of the dimmer switch.
(5) Install the instrument panel cover. Refer to Section 25-10.
(6) Connect the airplane battery. Refer to Section 24-31.
(7) Do an operational test of the dimmer switch:
S Set the ELECTRIC MASTER key switch to
ON.
The system light(s) must come on.
S Rotate the dimmer switch clockwise.
The intensity of the light(s) must
S Rotate the dimmer switch fully clockwise.
increase.
The light(s) must go off.
S Rotate the dimmer switch fully counter-
clockwise to the OFF position.
S Set the ELECTRIC MASTER key switch to
OFF.
Doc # 6.02.15 Page 203
Rev. 2 33-10-00 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 204 Doc # 6.02.15
15 Apr 2013 33-10-00 Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
Section 33-40
Exterior Lights
1. General
This Section tells you about the exterior lights on the DA 40 NG.
2. Description
The DA 40 NG has three exterior lights in one light unit at each wing-tip. It also has landing and taxi
% lights in a housing in the leading edge of the left wing. Figures 1 and 2 show a wing-tip light unit.
Doc # 6.02.15 Page 1
Rev. 2 33-40-00 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
Strobe Light Power Unit
In-Line Connector
Rear Position Light
Clear Glass
Strobe Light Filament
Strobe Light Cover
Front Position Light
0-Ring Seal
Screws
Colored Glass
Retaining Cover LH SHOWN
Figure 1: Wing-Tip Light Unit and Strobe Power Unit
Page 2 Doc # 6.02.15
15 Apr 2013 33-40-00 Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
%
%
%
%
%
%
% Strobe Light Power Unit
%
%
%
%
%
% In-Line Connector
% Rear Position Light
%
% Clear Lens
%
%
%
Strobe Light Filament
%
%
%
Strobe Light Cover
Front Position
% Light
%
%
0-Ring Seal
%
% Clear Lens
% Retaining Cover
% Screws
LH SHOWN
%
%
%
%
%
% Figure 2: Wing Tip- Light Unit and Strobe Power Unit (if OÄM 40-341 is installed)
Doc # 6.02.15 Page 3
Rev. 2 33-40-00 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
A. Position Lights
The DA 40 NG has left and right position lights. The front part of the light unit has a red (left) lens
or green (right) lens. The light can be seen from the front or the side of the airplane.
% The light unit also has rear position lights. The aft part of each light unit has a clear lens. If
% OÄM 40-341 is installed, the lenses are clear and the LEDs provide the coloration The light can be
seen from the rear of the airplane only.
A switch on the left instrument panel controls the position lights and the system is protected by a
circuit-breaker.
B. Strobe Light (Anti Collision Light - ACL)
The middle part of each light unit has a clear lens for a strobe light. The filament gives a high
intensity flash. This is followed immediately by a less-bright flash. The double flashes occur about
50 times per minute. The strobe lights can be seen from all round the airplane.
A separate power unit for each strobe light is mounted in the wing tip. A switch on the left
instrument panel controls both the strobe lights and the system is protected by a circuit-breaker.
The power unit generates an electrical impulse of about 600 volts. The pulse ionizes the gas in the
strobe light filament which causes a bright flash. A second less powerful flash occurs immediately
after the main pulse.
C. Landing Light
The landing light is located in a housing in the leading edge of the left wing. The landing light has
a clear lens and a 35 Watt filament. It is located inboard in the housing. A switch on the left
instrument panel controls the light and a circuit-breaker protects the system.
D. Taxi Light
The taxi light is located in a housing in the leading edge of the left wing. The landing light has an
optic lens and a 35 Watt filament. It is located outboard in the housing. A switch in the left
instrument panel controls the light and a circuit-breaker protects the system.
Page 4 Doc # 6.02.15
15 Apr 2013 33-40-00 Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
Mounting Bracket
Landing Light
Retaining
Screw
Screw
Washer
Taxi Light
Landing/Taxi Light Assembly Cover
Figure 3: Landing and Taxi Light Installation
Doc # 6.02.15 Page 5
Rev. 2 33-40-00 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 6 Doc # 6.02.15
15 Apr 2013 33-40-00 Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the exterior light system. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair given
in the Repair column.
WARNING: DO NOT OPERATE THE LANDING/TAXI LIGHTS WHEN PERSONS ARE
CLOSE TO THE AIRPLANE AND DO NOT LOOK AT THE LIGHT WHEN
IT OPERATES. STROBE, TAXI AND LANDING LIGHTS CAN CAUSE
EYE DAMAGE.
WARNING: AFTER YOU SET THE POWER TO OFF, MAKE SURE THAT YOU WAIT
A MINIMUM OF FIVE MINUTES BEFORE YOU REMOVE THE
LANDING/TAXI LIGHT COVER OR ATTEMPT TO WORK ON ANY PART
OF THE LIGHTING SYSTEM. THE POWER SUPPLIES TO THESE
COMPONENTS GENERATE HIGH VOLTAGE. HIGH VOLTAGE CAN
CAUSE DEATH OR INJURY TO PERSONS.
Trouble Possible Cause Repair
Both position lights do not Circuit breaker not set or Set/replace the circuit-breaker.
operate. defective.
Defective position light switch. Replace the switch.
Defective wiring. Repair/replace the wiring.
Refer to Chapter 92 for the
wiring diagrams.
% One position light does not Defective filament or LED. Replace the filament or light
% operate. assembly.
Defective wiring. Repair/replace the wiring.
Refer to Chapter 92 for the
wiring diagrams.
Both strobe lights do not Circuit-breaker not set or Set/replace the circuit-breaker.
operate. defective.
Defective switch. Replace the switch.
Defective wiring. Repair/replace the wiring.
Refer to Chapter 92 for the
wiring diagrams.
Doc # 6.02.15 Page 101
Rev. 2 33-40-00 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
Trouble Possible Cause Repair
One strobe light does not Defective power supply unit. Replace the power supply unit.
operate.
Defective strobe unit. Replace the strobe unit.
Defective wiring. Repair/replace the wiring.
Refer to Chapter 92 for the
wiring diagrams.
Strobe and position light does Connector at wing root Connect the connector.
not operate on one side. disconnected.
Landing light or taxi light does Defective light unit. Replace the light unit.
not operate.
Circuit-breaker not set or Set/replace the circuit-breaker.
defective.
Defective landing light or taxi Replace the related switch.
light switch.
Loose connector at the light Connect the connector
unit. correctly.
Defective wiring. Repair/replace the wiring.
Refer to Chapter 92 for the
wiring diagrams.
Loose connector at the light Connect the connector
unit. correctly.
Page 102 Doc # 6.02.15
15 Apr 2013 33-40-00 Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove/install defective filaments and light units. They
tell you how to adjust the landing light and the taxi light. They also tell you how to remove/install
components in the system. Refer to Chapter 92 for the wiring diagrams.
WARNING: DO NOT OPERATE THE STROBE/LANDING/TAXI LIGHTS WHEN
PERSONS ARE CLOSE TO THE AIRPLANE AND DO NOT LOOK AT
THE LIGHT WHEN IT OPERATES. STROBE, TAXI AND LANDING
LIGHTS CAN CAUSE EYE DAMAGE.
WARNING: AFTER YOU SET THE POWER TO OFF, MAKE SURE THAT YOU WAIT
A MINIMUM OF FIVE MINUTES BEFORE YOU REMOVE THE
STROBE/LANDING/TAXI LIGHT COVER OR ATTEMPT TO WORK ON
ANY PART OF THE LIGHTING SYSTEM. THE POWER SUPPLIES TO
THESE COMPONENTS GENERATE HIGH VOLTAGE. HIGH VOLTAGE
CAN CAUSE DEATH OR INJURY TO PERSONS.
2. Remove/Install the Taxi Light
A. Remove the Taxi Light
Detail Steps/Work Items Key Items/References
(1) Set the ELECTRIC MASTER key switch to OFF.
(2) Set the TAXI light switch to OFF.
(3) Set the TAXI/MAP circuit-breaker open.
(4) Remove the taxi/landing light cover from the wing:
S Remove the 12 screws which attach the light cover
to the wing.
S Pull the light cover clear of the wing.
(5) Remove the screws which attach the taxi light to the The taxi light is the outboard
% wing. assembly. Refer to Figure 3.
Doc # 6.02.15 Page 201
Rev. 2 33-40-00 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(6) Hold the taxi light and carefully move it out from the
wing:
S Disconnect the electrical connector from the rear of
the taxi light.
S Remove the taxi light.
B. Install the Taxi Light
Detail Steps/Work Items Key Items/References
(1) Hold the taxi light in position in the leading edge of the
left wing.
Connect the electrical connector to the rear of the taxi
light.
(2) Install the screws which attach the taxi light assembly to
the wing.
(3) Set the ELECTRIC MASTER key switch to ON.
(4) Set the TAXI/MAP circuit-breaker closed
(5) Set the TAXI light switch to ON.
(6) Set the TAXI light switch to OFF.
(7) Set the ELECTRIC MASTER key switch to OFF.
(8) Install the taxi/landing light cover to the wing:
S Put the light cover in position on the wing.
S Install the 12 screws which attach the light cover to
the wing.
Page 202 Doc # 6.02.15
15 Apr 2013 33-40-00 Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
3. Remove/Install the Landing Light
A. Remove the Landing Light
Detail Steps/Work Items Key Items/References
(1) Set the ELECTRIC MASTER key switch to OFF.
(2) Set the LANDING light switch to OFF.
(3) Set the LANDING circuit breaker open.
(4) Remove the taxi/landing light cover from the wing:
S Remove the 12 screws which attach the light cover
to the wing.
S Pull the light cover clear of the wing.
(5) Remove the screws which attach the landing light to the The landing light is the inboard
% wing. assembly. Refer Figure 3.
(6) Hold the landing light and carefully move the light out
from the wing:
S Disconnect the electrical connector from the rear of
the landing light.
S Remove the landing light.
Doc # 6.02.15 Page 203
Rev. 2 33-40-00 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
B. Install the Landing Light
Detail Steps/Work Items Key Items/References
(1) Hold the taxi light in position in the leading edge of the
left wing.
S Connect the electrical connector to the rear of the
taxi light.
(2) Install the screws which attach the taxi light assembly to
the wing.
(3) Set the ELECTRIC MASTER key switch to ON.
(4) Set the LANDING circuit-breaker closed
(5) Set the LANDING switch to ON.
(6) Set the LANDING light switch to OFF.
(7) Set the ELECTRIC MASTER key switch to OFF.
(8) Install the taxi/landing light cover to the wing:
S Put the light cover in position on the wing.
S Install the 12 screws which attach the light cover to
the wing.
Page 204 Doc # 6.02.15
15 Apr 2013 33-40-00 Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
% 4. Replace a Filament in the Wing-Tip Light Unit (if OÄM 40-341 is NOT installed)
A. Replace a Position Light Filament in the Wing-Tip
Detail Steps/Work Items Key Items/References
(1) Set the ELECTRIC MASTER key switch to OFF.
WARNING: AFTER YOU SET THE POWER TO OFF, MAKE SURE THAT YOU
WAIT A MINIMUM OF FIVE MINUTES BEFORE YOU DO WORK ON
THE STROBE LIGHTS. THE POWER SUPPLIES TO THE STROBE
LIGHTS GENERATE HIGH VOLTAGE. HIGH VOLTAGE CAN CAUSE
DEATH OR INJURY TO PERSONS.
(2) Remove the light unit cover from the wing-tip and the Refer to Figures 1.
lamp glasses.
(3) Replace the filament.
(4) Install the lamp glass and the light unit cover.
(5) Do an operational test of the position light.
Doc # 6.02.15 Page 205
Rev. 2 33-40-00 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
B. Replace a Strobe Light Filament in the Wing-Tip
Detail Steps/Work Items Key Items/References
(1) Set the ELECTRIC MASTER key switch to OFF.
WARNING: AFTER YOU SET THE POWER TO OFF, MAKE SURE THAT YOU
WAIT A MINIMUM OF FIVE MINUTES BEFORE YOU DO WORK ON
THE STROBE LIGHTS. THE POWER SUPPLIES TO THE STROBE
LIGHTS GENERATE HIGH VOLTAGE. HIGH VOLTAGE CAN CAUSE
DEATH OR INJURY TO PERSONS.
(2) Remove the light unit cover from the wing-tip and the Refer to Figures 1.
lamp glasses.
(3) Replace the strobe light filament.
(4) Install the lamp glasses and the light unit cover.
WARNING: DO NOT OPERATE THE STROBE LIGHTS WHEN PERSONS ARE
CLOSE TO THE AIRPLANE AND DO NOT LOOK AT THE LIGHT
WHEN IT OPERATES. STROBE LIGHTS CAN CAUSE EYE DAMAGE.
(5) Do an operational test of the strobe light.
Page 206 Doc # 6.02.15
15 Apr 2013 33-40-00 Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
5. Remove/Install the Light Unit in the Wing-Tip
A. Remove the Light Unit in the Wing-Tip
Detail Steps/Work Items Key Items/References
(1) Set the ELECTRIC MASTER key switch to OFF
and set the LANDING/TAXI/MAP circuit-breakers
open.
WARNING: AFTER YOU SET THE POWER TO OFF, MAKE SURE THAT YOU
WAIT A MINIMUM OF FIVE MINUTES BEFORE YOU DO WORK ON
THE STROBE LIGHTS. THE POWER SUPPLIES TO THE STROBE
LIGHTS GENERATE HIGH VOLTAGE. HIGH VOLTAGE CAN CAUSE
DEATH OR INJURY TO PERSONS.
% (2) Remove the light unit cover from the wing-tip and Refer to Figures 1 and 2.
the lamp glasses.
% (3) Remove the 2 light filaments (if OÄM 40-341 is
% NOT installed).
(4) Remove the light unit from the wing-tip:
S Remove the screws which attach the light unit
to the wing-tip.
S Carefully move the light unit out from the
wing-tip.
S Disconnect the 2 connectors from the rear of
the light unit.
S Move the light unit clear from the airplane.
Doc # 6.02.15 Page 207
Rev. 2 33-40-00 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
B. Install the Light unit in the Wing-Tip
Detail Steps/Work Items Key Items/References
(1) Put the light unit in position in the wing-tip and
connect the 2 electrical connectors to the rear of
the light unit.
(2) Install the screws that attach the light unit to the
wing-tip.
(3) Install the filaments to the light unit
% (if OÄM 40-341 is NOT installed).
WARNING: DO NOT OPERATE THE STROBE LIGHTS WHEN PERSONS ARE
CLOSE TO THE AIRPLANE AND DO NOT LOOK AT THE LIGHT
WHEN IT OPERATES. STROBE LIGHTS CAN CAUSE EYE DAMAGE.
(4) Do an operational test of the position and strobe
lights:
S Set the ELECTRIC MASTER key switch to
ON.
S Set the LANDING, TAXI/MAP and STROBE
circuit-breakers closed.
S Set the POSITION and STROBE switches to
ON.
(5) Set the POSITION and STROBE switches to
OFF.
(6) Set the ELECTRIC MASTER key switch to OFF.
WARNING: AFTER YOU SET THE POWER TO OFF, MAKE SURE THAT YOU
WAIT A MINIMUM OF FIVE MINUTES BEFORE YOU DO WORK ON
THE STROBE LIGHTS. THE POWER SUPPLIES TO THE STROBE
LIGHTS GENERATE HIGH VOLTAGE. HIGH VOLTAGE CAN CAUSE
DEATH OR INJURY TO PERSONS.
(7) Wait for a minimum of 3 minutes and install the
lamp glasses and the light unit cover.
Page 208 Doc # 6.02.15
15 Apr 2013 33-40-00 Rev. 2
DA 40 NG AMM Lights
AIRCRAFT
6. Remove/Install a Strobe Power Unit in the Wing-Tip
A. Remove a Strobe Power Unit in the Wing-Tip
Detail Steps/Work Items Key Items/References
(1) Set the ELECTRIC MASTER key switch to OFF.
(2) Set the STROBE switch to OFF and set the
STROBE circuit-breaker open.
WARNING: AFTER YOU SET THE POWER TO OFF, MAKE SURE THAT YOU
WAIT A MINIMUM OF FIVE MINUTES BEFORE YOU DO WORK ON
THE STROBE LIGHTS. THE POWER SUPPLIES TO THE STROBE
LIGHTS GENERATE HIGH VOLTAGE. HIGH VOLTAGE CAN CAUSE
DEATH OR INJURY TO PERSONS.
(3) Remove the wing-tip from the wing:
S Remove the screws which attach the wing tip
to the wing.
S Move the wing-tip just clear of the wing and
disconnect the electrical connectors.
S Move the wing-tip clear of the airplane
(4) Remove the power unit from the inside of the
wing tip assembly.
Doc # 6.02.15 Page 209
Rev. 2 33-40-00 15 Apr 2013
Lights DA 40 NG AMM
AIRCRAFT
B. Install a Strobe Power Unit in the Wing-Tip
Detail Steps/Work Items Key Items/References
(1) Install the power unit in the wing-tip.
(2) Move the wing-tip close to the wing and connect
the electrical connectors.
(3) Install the wing tip onto the wing:
S Put the wing-tip into position on the wing.
S Install the screws which attach the wing-tip to
the wing.
WARNING: DO NOT OPERATE THE STROBE LIGHTS WHEN PERSONS ARE
CLOSE TO THE AIRPLANE AND DO NOT LOOK AT THE LIGHT
WHEN IT OPERATES. STROBE LIGHTS CAN CAUSE EYE DAMAGE.
(4) Do an operational test of the position and strobe
lights:
S Set the ELECTRIC MASTER key switch to
ON.
S Set the LANDING, TAXI/MAP and STROBE
circuit-breakers closed.
S Set the POSITION and STROBE switches to
ON.
(5) Set the POSITION and STROBE switches to
OFF.
(6) Set the ELECTRIC MASTER key switch to OFF.
Page 210 Doc # 6.02.15
15 Apr 2013 33-40-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
CHAPTER 34
NAVIGATION
Doc # 6.02.15 Page 1
Rev. 2 34-TITLE 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 34-TITLE Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 34
NAVIGATION
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Section 34-10
Flight Environment Data
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Pitot-Static Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Pitot-Static Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Pitot and Static System Leak Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5. Clean the Pitot System and the Static System . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Section 34-20
Attitude and Direction
with G1000 System Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Doc # 6.02.15 Page 1
Rev. 2 34-CONTENTS 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Magnetic Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Test/Adjust the Magnetic Compass (Compass Swing) . . . . . . . . . . . . . . . . . . . . 202
4. Remove/Install the Attitude Gyro (Artificial Horizon) . . . . . . . . . . . . . . . . . . . . . . 204
Section 34-21
Attitude and Direction
with Conventional Cockpit Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 34-22
Magnetic Compass
with Conventional Cockpit Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Magnetic Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Test/Adjust the Magnetic Compass (Compass Swing) . . . . . . . . . . . . . . . . . . . . 202
Section 34-25
Gyro Instruments
with Conventional Cockpit Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Page 2 Doc # 6.02.15
15 Apr 2013 34-CONTENTS Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Gyro Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 34-30
Landing and Taxiing Aids
with G1000 System Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 34-31
Landing and Taxiing Aids
with Conventional Cockpit Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 34-40
Independent Position Determining
with G1000 System Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 34-41
Stormscope System
with G1000 System Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Doc # 6.02.15 Page 3
Rev. 2 34-CONTENTS 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Remove/Install the Stormscope Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Stormscope Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Test of the Stormscope System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
% Section 34-42
% Traffic Advisory System (TAS)
% 1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
% 2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
% Trouble-Shooting
% 1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
% Maintenance Practices
% 1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
% 2. Remove/Install TAS Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
% 3. Remove/Install Transponder Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
% 4. Remove/Install a TAS Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Section 34-50
Dependent Position Determining
with G1000 System Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Replace a Dependent Position Determining System Antenna . . . . . . . . . . . . . . 201
3. Used Types of Flexible Co-Axial Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4. Sealant Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5. Post-Installation Check of the ADF System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Page 4 Doc # 6.02.15
15 Apr 2013 34-CONTENTS Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Section 34-51
Dependent Position Determining
with Conventional Cockpit Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 34-52
VOR/Localizer/Glideslope (VOR/LOC/GS)
with Conventional Cockpit Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 34-56
Transponder (XPDR)
with Conventional Cockpit Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Transponder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Blind Altitude Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Test the Transponder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5. Adjust/Test the Blind Altitude Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Doc # 6.02.15 Page 5
Rev. 2 34-CONTENTS 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 6 Doc # 6.02.15
15 Apr 2013 34-CONTENTS Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
CHAPTER 34
NAVIGATION
1. General
This Chapter tells you about the navigation systems in the airplane. It only tells you about the
installation in the airplane. Refer to the equipment manufacturers' manuals for more data about the
equipment and refer to the Wiring Diagrams in Chapter 92 for more data about the electrical wiring for
the navigation system.
Refer to Section 23-10 and 23-11 for more data about the NAV system which is part of the speech
communication system.
The DA 40 NG can have these navigation systems. Refer to these Sections for data about the
systems:
Section 34-10. Flight environment data (Pitot-static, OAT, flight instruments).
Section 34-20. Attitude and direction with the G1000 system installed (magnetic compass, artificial
horizon).
Section 34-21. Attitude and direction with the conventional cockpit installed (magnetic compass,
turn&bank indicator, attitude gyro, directional gyro).
Section 34-22. Magnetic compass with the conventional cockpit installed.
Section 34-25. Gyro instruments with the conventional cockpit installed.
Section 34-30. Landing and taxiing aids with the G1000 system installed (localizer, glideslope, marker
beacon receiver).
Section 34-31. Landing and taxiing aids with the conventional cockpit installed (localizer, glideslope).
Section 34-40. Independent position determining with the G1000 system installed.
Section 34-41. Stormscope system with the G1000 system installed.
Section 34-50. Dependent positioning determining with the G1000 system installed (VOR/LOC/GS,
ADF, DME, transponder, GPS).
Section 34-51. Dependent positioning determining with the conventional cockpit installed
(VOR/LOC/GS, transponder).
Section 34-52. VOR/Localizer/Glideslope (VOR/LOC/GS) with the conventional cockpit installed.
Section 34-56. Transponder (XPDR) with the conventional cockpit installed.
Doc # 6.02.15 Page 1
Rev. 2 34-00-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Note: Equipment which is certified for installation in the DA 40 NG is listed in Section 6.5
of the Airplane Flight Manual. Such equipment may be installed in accordance with
the Airplane Maintenance Manual.
Any equipment which is not listed in Section 6.5 of the Airplane Flight Manual is
called "Additional Equipment". The installation of Additional Equipment is a
modification which must be handled in accordance with national regulations or a
Service Bulletin.
2. Description
A. Flight Environment Data
The DA 40 NG has the usual flight environment data systems. It has a Pitot system. The Pitot
system has a Pitot probe located under the left wing. The Pitot probe has an electric heater. The
heater is controlled by a switch on the left side of the instrument panel, at the bottom. Flexible
plastic hoses connect the Pitot probe to the airplane instruments. The static probe of the Pitot
system is not used in this installation.
The airplane has a static system. The normal static vents are located on the rear fuselage. An
alternate static vent is located in the cockpit, under the instrument panel, on the left side. The pilot
opens the alternate static vent by turning a valve on the vent.
The Pitot system and the static system connect to these flight instruments and systems:
) Altimeter.
) Airspeed indicator.
If G1000 is installed:
) Integrated cockpit system (ICS).
If conventional cockpit is installed:
) Vertical speed indicator.
) Blind altitude encoder.
The DA 40 NG also has an electronic outside air temperature (OAT) indicator. The indicator is
integral with the ICS if G1000 is installed. Refer to Section 31-40 for more data about the ICS. The
probe for the OAT is located on the right side of the fuselage aft at the co-pilot's step.
Page 2 Doc # 6.02.15
15 Apr 2013 34-00-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
B. Attitude and Direction
If G1000 is installed:
The DA 40 NG has a magnetic compass mounted in the instrument panel, on the right side, at
the top. The airplane is also equipped with an attitude gyro (artificial horizon) mounted at the top
of the instrument panel, centrally arranged.
If conventional cockpit is installed:
The DA 40 NG can have the following systems:
) Magnetic compass.
) Turn & bank indicator.
) Attitude gyro (horizon).
) Directional gyro.
C. Landing and Taxiing Aids
If G1000 is installed:
The DA 40 NG has a localizer system which is part of the ICS. Refer to Section 31-40 for more
data about the landing and taxiing aids which are part of the ICS.
If conventional cockpit is installed:
The DA 40 NG can have the following systems:
) A localizer system which is part of the VOR/LOC/GS system. Refer to Section 34-51 for
more data about the VOR/LOC/GS system.
D. Independent Positioning Determining
If G1000 is installed:
The DA 40 NG can have the following system:
) Stormscope system, consisting of stormscope processor and stormscope antenna.
Doc # 6.02.15 Page 3
Rev. 2 34-00-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
E. Dependent Positioning Determining
If G1000 is installed:
The DA 40 NG has these dependent position determining systems that are integral with the ICS:
) VOR/LOC.
) Global positioning system (GPS).
) Transponder.
) DME.
) ADF.
) Marker beacon receiver.
% ) Traffic advisory system, consisting of a processor, two antennas and a transponder
% coupler.
Refer to Section 31-40 for more data about the integrated cockpit system.
If conventional cockpit is installed:
The DA 40 NG c an have the following systems:
) VOR/LOC.
) Transponder.
Page 4 Doc # 6.02.15
15 Apr 2013 34-00-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Section 34-10
Flight Environment Data
1. General
This Section tells you about the Pitot-static system and the OAT sensor.
It also tells you about the OAT indicating system if the conventional cockpit is installed. Refer to the
manufacturer’s manuals for more data about the equipment.
It does not tell you about the OAT indication which is integral with the ICS, if the G1000 system is
installed. Refer to Section 31-40 for more data about the ICS.
Refer to Section 22-10 for information on the static pressure supplied to the autopilot system (if
installed).
2. Description
Figure 1 shows the Pitot-static system schematic diagram.
Figure 2 shows the OAT indicator, if the conventional cockpit is installed.
Figure 3 shows the equipment locations in the airplane.
A. Pitot-Static System
The Pitot-static system supplies Pitot pressure and static pressure to the air data instruments.
A Pitot probe mounted below the left wing senses Pitot pressure. The static ports on the rear
fuselage sense the static pressure. The probe has a heater element to prevent icing. A switch on
the instrument panel controls the Pitot heat. A circuit-breaker protects the system.
Flexible hoses connect the Pitot-static probe to the air data instruments. Pitot hoses are green and
static hoses are red. Push-fit plastic connectors make the connections in the flexible hoses.
T-pieces make junctions in the hoses.
Both Pitot and static hoses have a water trap at the lowest part of the hose-run. T-pieces divide the
hose into two-runs. The top run goes directly to the instruments. The bottom run forms a sump
before re-joining the top-run at a tee-piece.
Doc # 6.02.15 Page 1
Rev. 2 34-10-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
%
%
%
%
Water Trap
%
%
%
%
Static Port
%
%
%
%
%
%
% Static Port
%
%
%
%
Water Traps
%
%
%
%
Not In Use
%
% To Air Data Instruments & ICS
%
%
%
%
Static Hose (Blue)
%
% Relay
%
% Pitot Hose (Green)
%
%
Pitot Probe
%
%
%
Figure 1: Pitot-Static System
Page 2 Doc # 6.02.15
15 Apr 2013 34-10-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
B. Davtron M803 Digital Chronometer with OAT Indication
Figure 2 shows the Davtron M803 digital chronometer with OAT indication. It is located in the
instrument panel, see Chapter 31. Refer to Section 31-20 for the chronometer functions of the unit.
The OAT indicator is a digital instrument, and is included in the Davtron M803 digital chronometer.
The indicator operates when the ELECTRIC MASTER key switch is set to ON. The probe for the
OAT indicator is located on the right side of the fuselage aft of the co-pilot's step.
Figure 2: Davtron M803 Digital Chronometer with OAT Indication
Doc # 6.02.15 Page 3
Rev. 2 34-10-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Static Ports
OAT Probe
Pitot/Static Tube
Pitot / Static Water Traps
Instruments
Pitot Probe
Figure 3: Component Locations
Page 4 Doc # 6.02.15
15 Apr 2013 34-10-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the flight environment data system. If you have
the trouble detailed in the Trouble column read across to the Possible Cause column. Then do the
repair given in the Repair column.
Trouble Possible Cause Repair
Altimeter lags or reads Faulty indicator. Replace the indicator.
incorrectly. VSI reads
Blocked or kinked static hose. Clear the hose.
incorrectly.
Water in the system. Drain the water.
Airspeed indicator reads low. Faulty indicator. Replace the indicator.
Blocked or kinked Pitot hose. Clear the hose.
Water in the system. Drain the water.
Pitot heat does not operate. Pitot heat circuit-breaker open. Set the circuit-breaker. If the
circuit-breaker opens again, do
a test for a short-circuit in the
Pitot heat wiring.
Pitot heat circuit-breaker Replace the circuit-breaker.
defective.
Pitot heat wiring open-circuit. Do a continuity test of the
wiring. Repair or replace
defective wiring.
Pitot probe defective. Replace the Pitot probe.
OAT indication (on ICS, if OAT probe defective. Replace the OAT probe.
G1000 is installed) incorrect.
OAT circuit-breaker open or Set or replace the
defective (if installed). circuit-breaker (if installed).
Doc # 6.02.15 Page 101
Rev. 2 34-10-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 34-10-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to replace components of the environmental data system.
It also tells you how to test the Pitot-static system. Refer to the equipment manufacturers' manuals for
more data about the equipment.
2. Remove/Install a Pitot-Static Instrument
A. Remove a Pitot-Static Instrument
Detail Steps/Work Items Key Items/References
(1) Remove the instrument panel cover. Refer to Section 25-10.
(2) Disconnect the Pitot-static hose(s) from the rear
of the instrument.
(3) Remove the screws which attach the instrument Hold the instrument!
to the panel.
(4) Remove the instrument from the panel.
B. Install a Pitot-Static Instrument
Detail Steps/Work Items Key Items/References
(1) Remove the port cover(s) from the new
instrument and fit to the removed instrument.
(2) If necessary, transfer the Pitot-static fittings to the
new instrument.
(3) Put the instrument in position in the panel.
(4) Install the screws which attach the instrument to
the panel.
(5) Connect the Pitot-static hoses to the rear of the
instrument.
(6) Do a low-range static leak check. Refer to Paragraph 4C.
(7) For the ASI only:
S Do a Pitot-static leak check. Refer to Paragraph 4.
(8) Install the instrument panel cover. Refer to Section 25-10.
Doc # 6.02.15 Page 201
Rev. 2 34-10-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
C. Remove/Install the Davtron M803 Digital Chronometer with OAT Indication
Refer to Section 31-20.
3. Remove/Install the Pitot-Static Probe
A. Remove the Pitot-Static Probe
Detail Steps/Work Items Key Items/References
(1) Open the PITOT circuit-breaker. Lower left instrument panel.
(2) Remove the Pitot access panel from the lower Refer to Section 52-40.
surface of the wing.
(3) Move the probe down to give access to the
connections.
(4) Disconnect the electrical connector.
(5) Disconnect the Pitot and static hose connections. Identify the connections and put caps
on the hoses.
(6) Disconnect the bonding cable.
(7) Move the Pitot-static probe clear of the airplane.
B. Install the Pitot-Static Probe
Detail Steps/Work Items Key Items/References
(1) Put the Pitot probe in position on the wing.
(2) Install the attaching screws and connect the
bonding cable.
(3) Connect the Pitot and static hoses. Remove the caps from the hoses. Make
sure that you connect the hoses to the
correct locations.
(4) Connect the electrical connector.
(5) Install the Pitot access panel to the lower surface
of the wing.
(6) Do a test of the Pitot heat system.
(7) Do a low-range static leak test. Refer to Paragraph 4C.
(8) Do a Pitot-static leak test. Refer to Paragraph 4.
Page 202 Doc # 6.02.15
15 Apr 2013 34-10-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Detail Steps/Work Items Key Items/References
(9) Install a cap with a red pennant on the Pitot-static
probe.
4. Pitot and Static System Leak Tests
Always do a Pitot leak-test after you do maintenance on the Pitot system. And always do a low-range
static leak-test after you do maintenance on the static system.
CAUTION: OBEY THE FOLLOWING PRECAUTIONS WHEN YOU DO A PITOT OR
STATIC LEAK-TEST. IF YOU DO NOT OBEY THE PRECAUTIONS YOU
DAMAGE THE AIR DATA INSTRUMENTS.
A. Test Precautions
) The pressure in the Pitot system must always be equal to (or greater than) the pressure in the
static system.
) Reversal of the Pitot and static pipes can cause damage to the air data instruments.
) The applied pressure (and rate of change of pressure) must not be greater than the design limits
of the equipment which you will test.
) After doing the test, you must always return the system to its usual operating conditions.
B. Equipment
Item Quantity Part Number
Pitot-static probe adaptor. 1 PS 49742M-3-4.
Pitot-static leak tester. 1 Commercial.
Static port adaptor. 2 SKA 100-4.
Doc # 6.02.15 Page 203
Rev. 2 34-10-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
C. Low Range Static Leak Test
Follow the test equipment manufacturer's instructions for the use of the test-set. Obey the safety
precautions for Pitot-static leak-testing at all times!
Detail Steps/Work Items Key Items/References
CAUTION: IF INSTALLED, THE G1000 CONFIGURATION MODE CONTAINS
CERTAIN PAGES AND SETTINGS THAT ARE CRITICAL TO
AIRPLANE OPERATION AND SAFETY. THESE PAGES ARE
PROTECTED AND CANNOT BE MODIFIED, UNLESS THE
TECHNICIAN IS PROPERLY AUTHORIZED AND EQUIPPED.
HOWEVER, MOST PROTECTED PAGES ARE VIEWABLE TO ALLOW
SYSTEM AWARENESS FOR TROUBLE-SHOOTING.
(1) Remove the blanking cap from the Pitot static Use the test set adaptor.
probe and connect the Pitot-static leak tester to
the probe.
(2) Make sure that the alternate static port is fully Under the instrument panel, left side.
closed.
(3) Remove the aft baggage compartment. Refer to Section 25-10.
(4) Block the static line. At the water trap on top of the fuselage.
Page 204 Doc # 6.02.15
15 Apr 2013 34-10-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Detail Steps/Work Items Key Items/References
(5) If installed, prepare the G1000 system for the Only required for airplanes for which
test: 14 CFR §91.411 and 14 CFR §91.411
part 43 Appendix E is applicable.
S Allow the unit to warm up for 15 minutes
before performing the following tests.
S Start the G1000 system in Normal Mode.
S Remove power to the PFD.
S Turn the PFD on in Configuration Mode by
pressing and holding the ENT key on the
PFD while applying power.
S Release the ENT key after INITIALIZING
SYSTEM appears on the upper left corner of
the PFD.
S Using the outer FMS knob on the PFD turn to
the GRS page group, use the B ALT field for
all CFR Part 43 Appendix E tests for G1000
altitude.
S Place the MFD in Reversionary Mode by
pressing the red DISPLAY BACKUP button
on the GMA 1347 Audio Panel. Baro settings
can then be read from the MFD for the CFR
Part 43 Appendix E tests.
(6) Apply a partial vacuum to the static port until you Note the altitude.
get a pressure altitude of 1000 ft above the
ambient pressure altitude.
(7) Let the pressure stabilize.
(8) Stop the Pitot-static leak-tester.
(9) Monitor the system pressure. The system pressure loss must not be
more than 100 ft/min.
(10) Compare the test equipment altimeter and the The indication error must be less than
airplane altimeter. shown in Table 1 below.
(11) If installed, return both the MFD and PFD to Only required for airplanes for which
Normal Mode. 14 CFR §91.411 and 14 CFR §91.411
part 43 Appendix E is applicable.
Doc # 6.02.15 Page 205
Rev. 2 34-10-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(12) Disconnect the Pitot-static probe adaptor and
install a blanking cap, with pennant, onto the
airplane Pitot static probe.
(13) Remove the blockage of the static line. At the water trap on top of the fuselage.
(14) Install the aft baggage compartment. Refer to Section 25-10.
Table 1: Altimeter Indication Error
Altitude Allowable Error
-1,000 ft* ±20 ft*
Sea Level ±20 ft
4,000 ft ±35 ft
8,000 ft ±60 ft
12,000 ft ±90 ft
16,000 ft ±110 ft
20,000 ft ±130 ft
*Only required for airplanes for which 14 CFR §91.411 and 14 CFR §91.411 part 43 Appendix E is
applicable.
Page 206 Doc # 6.02.15
15 Apr 2013 34-10-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
D. Pitot Test
Follow the test equipment manufacturers' instructions for the use of the test-set. Obey the safety
precautions for Pitot-static leak-testing at all times!
Detail Steps/Work Items Key Items/References
(1) Connect the Pitot-static leak-tester to the Pitot
probe.
(2) Apply a pressure to the Pitot port equal to
150 kts.
(3) Let the pressure stabilize.
(4) Stop the Pitot-static leak-tester.
(5) Monitor the system pressure. The leak rate must not be more than
10 kts/min.
(6) Compare the test-equipment ASI and the The indication error must be less than
airplane ASI. shown in Table 2 below.
Table 2: ASI Indication Error
Airspeed Allowable Error
160 kts ±4 kts
100 kts ±4 kts
40 kts ±1.7 kts
Doc # 6.02.15 Page 207
Rev. 2 34-10-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
5. Clean the Pitot System and the Static System
CAUTION: OBEY THE FOLLOWING PRECAUTIONS WHEN YOU CLEAN THE
PITOT STATIC SYSTEM. IF YOU DO NOT OBEY THE PRECAUTIONS
YOU CAN DAMAGE THE AIR DATA INSTRUMENTS.
A. Precautions
) Never apply pressurized air to the air data instruments. Always apply compressed air to the
hoses from the inboard end to the outboard end.
) Do not apply excessive pressure (above 1 bar/14.5 PSI) to the Pitot and static hoses.
) Do not use compressed air without oil separator.
) Reversal of the Pitot and static hoses can cause damage to the air data instruments.
) After cleaning the system, you must always return the system to usual operating conditions.
B. Equipment
Item Quantity Part Number
Compressed air equipment with oil separator and 1 Commercial.
pressure regulator.
C. Cleaning Procedure
Detail Steps/Work Items Key Items/References
(1) Make sure that the ELECTRIC MASTER key
switch is set to OFF.
(2) Remove the instrument panel cover. Refer to Section 25-10.
(3) Remove the pilot's seat. Refer to Section 25-10.
(4) Remove the aft baggage compartment.
(5) Disconnect the Pitot static hoses from the rear
of the backup instruments.
(6) Disconnect the Pitot static hoses from the air
data computer (ADC), if G1000 is installed or
from all pneumatic instruments, if the
conventional cockpit is installed.
Page 208 Doc # 6.02.15
15 Apr 2013 34-10-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Detail Steps/Work Items Key Items/References
(7) Disconnect the Pitot static hoses from the water Two under the pilot’s seat.
traps.
(8) Blow compressed air through each of the Pitot Maximum pressure: 1 bar (14.5 PSI).
static hoses from the inboard end to the
outboard end.
(9) Check the water traps for dirt. Replace if
necessary.
(10) Reconnect the Pitot static hoses to the water Two under the pilot’s seat.
traps.
(11) Reconnect the Pitot static hoses to the Pitot
probe.
(12) Reconnect the Pitot static hoses to the air data
computer (ADC), if G1000 is installed or to the
pneumatic instruments, if the conventional
cockpit is installed.
(13) Reconnect the Pitot static hoses to the rear of
the backup instruments.
(14) Do a low-range static leak test. Refer to Paragraph 4C.
(15) Do a Pitot static leak test. Refer to Paragraph 4.
(16) Install the pilot's seat. Refer to Section 25-10.
(17) Install the instrument panel cover. Refer to Section 25-10.
Doc # 6.02.15 Page 209
Rev. 2 34-10-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 210 Doc # 6.02.15
15 Apr 2013 34-10-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Section 34-20
Attitude and Direction
with G1000 System Installed
1. General
This Section tells you about the attitude and direction systems with the Garmin G1000 system
installed. The main attitude and direction systems are integral with the Integrated Cockpit System
(ICS). Refer to Section 31-40 for more data about the ICS.
The DA 40 NG has the usual magnetic compass. The magnetic compass is installed in the instrument
panel at the top, on the right-hand side. There is also an artificial horizon installed in the instrument
panel at the top, arranged centrally.
2. Description and Operation
A. Magnetic Compass
The magnetic compass shows the heading of the airplane related to magnetic north. Fluid in the
compass bowl gives damping. Each graduation of the compass is 5°.
A compass deviation card is located next to the compass on the instrument panel. You must do a
test for the correct operation of the compass (compass swing).
) After replacing a major component.
) After replacing the compass.
) After a major modification to the airplane.
) After a lightning strike has been reported.
) If the airplane has been parked for more than 90 days.
Doc # 6.02.15 Page 1
Rev. 2 34-20-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
B. Attitude Gyro (Artificial Horizon)
The artificial horizon is an electrically-powered gyroscopic instrument. It operates when the
essential bus is powered and the HORIZON circuit-breaker is closed. It can also receive power
from the emergency battery, see Section 24-32. A warning flag drops into view to indicate that the
gyro motor is not receiving sufficient power to operate.
The artificial horizon incorporates a moving display that simulates the earth's horizon and provides
the pilot with a real time visual indication of the airplane pitch and roll attitude relative to the
indicator symbolic airplane. The instrument can function as a primary or standby indicator.
The attitude gyro incorporates pitch and roll displays that are mechanically linked to a spinning
mass gyroscope. The horizon bar moves behind the symbolic airplane. Precession error is
corrected by the internal erection system or by pulling the PULL TO CAGE knob.
The artificial horizon employs an efficient electrically driven internal vertical gyroscope assembly
incorporating a special air erection mechanism. This mechanism simultaneously erects the pitch
and roll axes of the gyroscope. Movement of the airplane generates a reaction of the display that
simulates the visual reference seen by the pilot when looking outside at the earth's true horizon
line.
Page 2 Doc # 6.02.15
15 Apr 2013 34-20-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the magnetic compass. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair given
in the Repair column.
A. Magnetic Compass
Trouble Possible Cause Repair
Magnetic compass damping Defective compass housing. Replace the compass.
fluid leaking.
Compass deviation more than Residual magnetism of a metal Do a test for residual
10°. component in the airplane. magnetism using a hand-held
compass. If necessary,
degauss the component.
Defective compass. Replace the compass.
Compass out of calibration. Do a compass swing.
B. Attitude Gyro (Artificial Horizon)
Trouble Possible Cause Repair
Warning flag in view. HORIZON circuit-breaker open Close or replace the circuit-
or defective. breaker.
Indication of instrument not Power supply wiring defective. Do a test for the correct voltage
reliable. at the instrument. Repair the
power supply wiring/connector.
Ground connection defective. Do a test for correct ground
connection. Repair the ground
wiring/connector.
Instrument defective. Replace the instrument.
Instrument is sluggish. Mechanism worn or dirty. Replace the instrument.
Doc # 6.02.15 Page 101
Rev. 2 34-20-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 34-20-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to remove/install the magnetic compass as well as the attitude gyro (artificial
horizon). It also tells you how to test and adjust the magnetic compass (compass swing).
2. Remove/Install the Magnetic Compass
A. Remove the Magnetic Compass
Detail Steps/Work Items Key Items/References
(1) Make sure that the ELECTRIC MASTER key Instrument panel, left side.
switch is set to OFF.
(2) Remove the instrument panel cover. Refer to Section 25-10.
(3) Disconnect the electrical cables.
(4) Remove the 4 screws that attach the compass Hold the compass!
to the instrument panel.
(5) Move the compass forward and clear of the Remove and discard the compass
instrument panel. deviation table.
B. Install the Magnetic Compass
Detail Steps/Work Items Key Items/References
(1) Make sure that the ELECTRIC MASTER key Instrument panel, left side.
switch is set to OFF.
(2) Move the magnetic compass into position at the Hold the compass in position.
instrument panel.
(3) Install the 4 screws that attach the compass to
the instrument panel.
(4) Connect the electrical cables.
(5) Install the instrument panel cover. Refer to Section 25-10.
(6) Do a compass swing. Refer to Paragraph 3.
Doc # 6.02.15 Page 201
Rev. 2 34-20-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
3. Test/Adjust the Magnetic Compass (Compass Swing)
You must do a test for correct operation of the compass (compass swing):
) After replacing a major component.
) After replacing the compass.
) After a major modification to the airplane.
) After a lightning strike has been reported.
) If the airplane has been parked for more than 90 days.
CAUTION: USE ONLY NON-MAGNETIC TOOLS TO ADJUST THE COMPASS.
CAUTION: DO NOT WEAR OR CARRY METALLIC OBJECTS (WATCHES,
BRACELETS ETC) WHEN YOU ADJUST THE COMPASS
COMPENSATING MAGNETS OR OPERATE THE LAND COMPASS.
METALLIC OBJECTS NEAR THE COMPASS CAN CAUSE ERRORS.
Note: If possible, use a compass swing area that has been tested for magnetic
interference. In any case, you must use a level area that is away from metal
structures, underground pipes, reinforced concrete, other airplane and ground
servicing equipment.
A. Equipment
Item Quantity Part Number
Calibrated land compass. 1 Commercial.
Page 202 Doc # 6.02.15
15 Apr 2013 34-20-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
B. Compass Swing
Detail Steps/Work Items Key Items/References
(1) Adjust the compensating magnets in the Refer to the compass manufacturer's
compass to a neutral position. instructions.
(2) Start the engine and set all electrical loads to Refer to the Airplane Flight Manual.
ON.
(3) Use the land compass to align the airplane to Adjust the N-S compensator magnet so
magnetic north. that the airplane compass indicates a
heading of 0°.
(4) Use the land compass to align the airplane to Adjust the E-W compensator magnet so
magnetic east. that the airplane compass indicates a
heading of 90°.
(5) Use the land compass to align the airplane to Adjust the N-S compensator magnet to
magnetic south. remove half of the error between the
indicated heading and 180°.
(6) Use the land compass to align the airplane to Adjust the E-W compensator magnet to
magnetic west. remove half of the error between the
indicated heading and 270°.
(7) Turn the airplane through 360°, record the If large deviations occur when you
deviation at each 30° radial. Prepare a deviation operate electrical equipment/systems,
table that shows the corrections that must be the deviation table must also show the
applied to each of the 30° radials. corrections to apply to each 30° radial
when that particular equipment/system
is operating.
(8) Install the new deviation table in the compass
card holder next to the compass.
Doc # 6.02.15 Page 203
Rev. 2 34-20-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
4. Remove/Install the Attitude Gyro (Artificial Horizon)
CAUTION: GYROS ARE DELICATE AND CAN NOT WITHSTAND THE SHOCK OF
BEING DROPPED, JARRED OR STRUCK BY PIECES OF EQUIPMENT.
DO NOT PLACE GYROS ON ANY HARD SURFACE. PAD WITH
GENEROUS FOAM.
A. Precautions
) To prevent damage to a gyro, the instrument should be transported to and from the airplane in
its original shipping container. If this is impractical, the gyro should be hand carried carefully in
an upright position.
) A gyro should never be removed while it is spinning or running down. The instrument normally
operates at high RPM and may take 10 minutes or longer to run down. If it is removed while
running and tilted more than 20 degrees, the gyro can develop a gimbal lock. The gimbal will
tumble and start to spin. If gimbal lock occurs while the rotor is turning, the gimbal may spin fast
enough to damage the gimbal bearings, requiring overhaul.
) A malfunctioning gyro should be handled with the same care given a new instrument. Most
malfunctioning instruments can be repaired and returned to service. Using proper handling
procedures during removal prevents additional damage and helps ensure possible reuse.
Page 204 Doc # 6.02.15
15 Apr 2013 34-20-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
B. Remove the Attitude Gyro
Detail Steps/Work Items Key Items/References
(1) Pull the HORIZON circuit-breaker. Instrument panel, right side.
(2) Remove the instrument panel cover. Refer to Section 25-10.
(3) Dis-connect the connector at the rear of the
instrument.
(4) Remove the screws which attach the instrument Hold the instrument!
to the instrument panel.
(5) Remove the instrument from the instrument Handle with care.
panel.
C. Install the Attitude Gyro
Detail Steps/Work Items Key Items/References
(1) Insert the indicator into the instrument panel Upper instrument panel, arranged
cutout. centrally.
(2) Install the screws which attach the instrument to
the instrument panel.
(3) Connect the connector at the rear of the
instrument.
(4) Install the instrument panel cover. Refer to Section 25-10.
(5) Set the HORIZON circuit-breaker. Instrument panel, right side.
Doc # 6.02.15 Page 205
Rev. 2 34-20-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 206 Doc # 6.02.15
15 Apr 2013 34-20-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Section 34-21
Attitude and Direction
with Conventional Cockpit Installed
1. General
This Section tells you about the equipment which shows attitude and flight direction.
Refer to these Sections for data about the systems:
Section 34-22. Magnetic compass.
Section 34-25. Gyro instruments (turn & bank indicator, attitude gyro (artificial horizon), directional
gyro).
Doc # 6.02.15 Page 1
Rev. 2 34-21-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 34-21-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Section 34-22
Magnetic Compass
with Conventional Cockpit Installed
1. General
This Section tells you about the magnetic compass which is used to show airplane flight direction.
Refer to the manufacturer's manuals for more data about the magnetic compass.
2. Description and Operation
The magnetic compass shows the heading of the airplane related to magnetic north. Fluid in the
compass bowl gives damping. Each graduation of the compass is 5°.
A compass deviation card attaches to the compass. Compensating magnets for compass adjustment
are located behind the deviation card holder. The compass lighting comes on when the instrument light
potentiometer is switched on.
You must do a test for correct operation of the compass (compass swing):
) After replacing a major component.
) After replacing the compass.
) After modification to the airplane.
) After a lightning strike has been reported.
) If the airplane has been parked for more than 90 days.
Doc # 6.02.15 Page 1
Rev. 2 34-22-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 34-22-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the magnetic compass. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair given
in the Repair column.
Trouble Possible Cause Repair
Magnetic compass leaking Defective compass housing. Replace the compass.
fluid.
Compass deviation more than Residual magnetism of a metal Do a test for residual
10°. component in the airplane magnetism using a hand-held
compass. If necessary,
degauss the component.
Defective compass. Replace the compass.
Compass out of calibration. Do a compass swing. Refer to
the Maintenance Practices in
this Section.
Doc # 6.02.15 Page 101
Rev. 2 34-22-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 34-22-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to remove/install the magnetic compass. It also tells you how to test and
adjust the magnetic compass (compass swing).
2. Remove/Install the Magnetic Compass
A. Remove the Magnetic Compass
Detail Steps/Work Items Key Items/References
(1) Disconnect the electrical plug for the compass
light.
(2) Remove the screws which attach the compass to Hold the compass!
the glare shield.
(3) Remove the compass from the airplane.
B. Install the Magnetic Compass
Detail Steps/Work Items Key Items/References
(1) Put the compass in position on the glare shield.
(2) Install the screws which attach the compass to
the glare shield.
(3) Connect the electrical plug for the compass light.
(4) Do a compass swing. Refer to Paragraph 3.
Doc # 6.02.15 Page 201
Rev. 2 34-22-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
3. Test/Adjust the Magnetic Compass (Compass Swing)
You must do a test for correct operation of the compass (compass swing):
) After replacing a major component.
) After replacing the compass.
) After modification to the airplane.
) After a lightning strike has been reported.
) If the airplane has been parked for more than 90 days.
CAUTION: USE ONLY NON-MAGNETIC TOOLS TO ADJUST THE COMPASS.
CAUTION: DO NOT WEAR OR CARRY METALLIC MATERIAL(WATCHES,
BRACELETS ETC) WHEN YOU ADJUST THE COMPASS
COMPENSATING MAGNETS OR OPERATE THE LAND COMPASS.
METALLIC MATERIALS CAN CAUSE ERRORS.
Note: If possible, use a compass swing area that has been tested for magnetic
interference. In any case, use a level area which is away from steel structure,
underground pipes, cables, reinforced concrete, other airplanes and ground
equipment.
A. Equipment
Item Quantity Part Number
Calibrated land compass. 1 Commercial.
Page 202 Doc # 6.02.15
15 Apr 2013 34-22-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
B. Compass Swing
Detail Steps/Work Items Key Items/References
(1) Adjust the compensating magnets in the
compass to a neutral position.
(2) Start the engine. Set all electrical loads to ON. Refer to the Airplane Flight Manual.
(3) Use a calibrated and reliable land compass to
make sure of the airplane heading.
(4) Align the airplane to magnetic north. Adjust the N-S compensator magnet so
that the compass indicates an airplane
heading of 0°.
(5) Align the airplane to magnetic east. Adjust the E-W compensator magnet so
that the compass indicates an airplane
heading of 90°.
(6) Align the airplane to magnetic south. Adjust the N-S compensator magnet to
remove half of the error between what
is indicated and 180°.
(7) Align the airplane to magnetic west. Adjust the E-W compensator magnet to
remove half of the error between what
is indicated and 270°.
(8) Turn the airplane through 360°, record the If large deviation occur when you
deviation at each 30° radial. Prepare a deviation operate electrical equipment/systems,
table that shows the corrections that must be the deviation table must also show the
applied to each heading. corrections to apply to each 30° radial
when the that particular
equipment/system is operated.
(9) Install the deviation table in the compass card
holder next to the compass.
Doc # 6.02.15 Page 203
Rev. 2 34-22-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 204 Doc # 6.02.15
15 Apr 2013 34-22-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Section 34-25
Gyro Instruments
with Conventional Cockpit Installed
1. General
This Section tells you about the instruments which show attitude and flight direction and which have
integrated gyros. These are:
) Turn coordinator.
) Attitude gyro (horizon).
) Directional gyro.
2. Description and Operation
A. Turn Coordinator
Figure 1 shows the turn coordinator Mid Continent 1394T100-(R). It is located in the left-hand
section of the instrument panel, see Chapter 31.
The turn coordinator is an electrically-powered gyroscopic instrument. It operates when the main
bus is powered and the T&B circuit-breaker is closed. A warning flag shows when there is no power
to the unit. The warning flag goes out of view when the turn coordinator has the correct power.
The turn and bank coordinator shows the rate of rotation of the airplane about the vertical axis. The
turn coordinator has markings for rate 2 turns.
The turn coordinator has a slip indicator. A ball in a curved tube filled with fluid shows when the
airplane is slipping or skidding. When the ball is in the center, the turn is correctly coordinated.
Doc # 6.02.15 Page 1
Rev. 2 34-25-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
D.C.
ELEC. Miniature Airplane
Horizon Line
Standard Rate Turn Line Power Warning Flag
TURN COORDINATOR
L R
2 MIN.
NO PITCH
INFORMATION
Slip Indicator
Figure 1: Mid Continent 1394T100-(R.) Turn Coordinator
Rotating Roll Scale
Fixed Roll Index
Power Warning Flag
20
20
10
10
Display
10
Horizon Line 20
10
20
Miniature Airplane
PULL
TO
CA G E
Caging Knob
Airplane Adjustment Knob
Figure 2: L-3 Communications AIM 1100 Attitude Gyro
Page 2 Doc # 6.02.15
15 Apr 2013 34-25-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
B. Attitude Gyro (Artificial Horizon)
Figure 2 shows the L-3 Communications AIM 1100 attitude gyro.
The attitude gyro is located in the left-hand section of the instrument panel, see Chapter 31.
The attitude gyro is an electrically-powered gyroscopic instrument. It operates when the essential
bus is powered and the HORIZON circuit-breaker is closed. A warning flag shows when there is
no power to the unit. The warning flag goes out of view when the attitude gyro has the correct
power.
The indicator shows pitch and roll data. The display shows a blue area for the sky and a brown area
for the ground. A miniature airplane represents the airplane's nose and wings. Horizontal markings
above and below the horizon show pitch up and down. Each graduation is 5°.
The roll display has markings around the circumference of the instrument. The markings are at 10,
20, 30, 60 and 90 degrees of roll.
The attitude gyro has these controls:
) PULL TO CAGE knob (manual erection). When pulled, rotated and released in the detent
position, it locks roll and pitch gimbals in caged position.
CAUTION: THE INDICATOR MAY BE DAMAGED IF THE 'PULL TO CAGE' KNOB IS
RELEASED WITH A 'SNAP'. RELEASE 'PULL TO CAGE' KNOB
AVOIDING A 'SNAP' RELEASE.
) Airplane adjustment knob. Only the AIM 1100-28L(0F) DIA has this knob, see Figure 2. Turning
the knob moves the miniature airplane up and down a minimum of ± 4° relative to the middle
position.
Doc # 6.02.15 Page 3
Rev. 2 34-25-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Power Warning Flag
24 27
21
30
18
Compass Card
33
15
Miniature Airplane
0
12 3
9 6
PUSH
Course Select Knob
Figure 4: L-3 Communications AIM2051BLD Directional Gyro
C. Directional Gyro
(1) BF-Goodrich AIM2051BLD
Figure 4 shows the L-3 Communications AIM2051BLD directional gyro. It is located in the
left-hand section of the instrument panel, see Chapter 31.
The directional gyro (DG) is an electrically-powered gyroscopic instrument. It operates when the
main bus is powered and the DG circuit-breaker is closed. A warning flag shows when there is
no power to the unit. The warning flag goes out of view when the DG has the correct power.
The directional gyro shows the direction of the airplane related to a preset heading. You set the
heading by pushing and turning the knob on the face of the directional gyro. The display has a
360° compass card with 5° graduations.
Page 4 Doc # 6.02.15
15 Apr 2013 34-25-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the integrated electrical gyro instruments. If you
have the trouble detailed in the Trouble column read across to the Possible Cause column. Then do
the repair given in the Repair column.
Trouble Possible Cause Repair
Warning flag in view. Related circuit-breaker (T&B or Set or replace the
HORIZON or DG) open or circuit-breaker.
defective.
Indication of instrument not Power supply wiring defective. Do a test for the correct voltage
reliable. at the instrument. Repair the
power supply wiring/connector.
Ground connection defective. Do a test for correct ground
connection. Repair the ground
wiring/connector.
Instrument defective. Replace the instrument.
Instrument is sluggish. Mechanism worn or dirty. Replace the instrument.
Doc # 6.02.15 Page 101
Rev. 2 34-25-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 34-25-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to remove/install the gyro instruments.
CAUTION: Be specially careful when you work on or move gyroscopic instruments.
Make sure that the gyro stops turning before you start to remove the
instrument. Use only the correct shock-proof container for shipping. Mark
the container ‘VERY FRAGILE’ ‘HANDLE LIKE EGGS’.
2. Remove/Install a Gyro Instrument
A. Remove a Gyro Instrument
Detail Steps/Work Items Key Items/References
(1) Open the related circuit-breaker. T&B for the turn & bank indicator.
HORIZON for the attitude gyro.
DG for the directional gyro.
(2) Remove the instrument panel cover. Refer to Section 25-10.
(3) Dis-connect the connector at the rear of the
instrument.
(4) Remove the screws which attach the instrument Hold the instrument!
to the instrument panel.
(5) Remove the instrument from the instrument
panel.
Doc # 6.02.15 Page 201
Rev. 2 34-25-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
B. Install a Gyro Instrument
Detail Steps/Work Items Key Items/References
(1) Put the instrument in position in the instrument
panel.
(2) Install the screws which attach the instrument to
the instrument panel.
(3) Connect the connector at the rear of the
instrument.
(4) Install the instrument panel cover. Refer to Section 25-10.
(5) Set the related circuit-breaker. T&B for the turn & bank indicator.
HORIZON for the attitude gyro.
DG for the directional gyro.
Page 202 Doc # 6.02.15
15 Apr 2013 34-25-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Section 34-30
Landing and Taxiing Aids
with G1000 System Installed
1. General
This Section tells you about the landing and taxiing aids of the DA 40 NG.
Refer to the equipment manufacturer’s manuals for more data about other options of landing and
taxiing aids.
2. Description
The DA 40 NG has the following landing and taxiing aids:
) A localizer system which is part of the G1000 integrated avionics system. Refer to Section
31-40 for more data about the G1000 integrated avionics system.
) A glideslope system which is part of the G1000 integrated avionics system. Refer to Section
31-40 for more data about the G1000 integrated avionics system.
) A marker beacon receiver which is part of the G1000 integrated avionics system. Refer to
Section 31-40 for more data about the G1000 integrated avionics system.
Doc # 6.02.15 Page 1
Rev. 2 34-30-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 34-30-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Section 34-31
Landing and Taxiing Aids
with Conventional Cockpit Installed
1. General
This Section tells you about the landing and taxiing aids that can be installed in the DA 40 NG.
Refer to the equipment manufacturers' manuals for more data about other options of landing and
taxiing aids.
2. Description
The DA 40 NG can have the following landing and taxiing aids:
) A localizer system which is part of the VOR/LOC/GS system. Refer to Section 34-52 for more data
about the VOR/LOC/GS system.
Doc # 6.02.15 Page 1
Rev. 2 34-31-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 34-31-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Section 34-40
Independent Position Determining
with G1000 System Installed
1. General
This Section tells you about the independent position determining system that can be installed in the
DA 40 NG:
Section 34-41. Stormscope system.
% Section 34-42. Traffic Advisory System (TAS).
Doc # 6.02.15 Page 1
Rev. 2 34-40-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 34-40-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Section 34-41
Stormscope System
with G1000 System Installed
1. General
This Section tells you about the stormscope system that can be installed in the DA 40 NG. Refer to
the manufacturer’s manual for more data about the equipment.
The stormscope system consists of the following items:
) Stormscope processor.
) Stormscope antenna.
2. Description and Operation
The WX-500 is a passive sensor that listens for electromagnetic signals with a receiving antenna. The
antenna detects intra-cloud, inter-cloud, or cloud-to-ground electrical discharges within a 200 nm
radius of the airplane and sends the resulting 'discharge signals' to the processor. The processor
digitizes, analyzes, and converts the discharge signals into range and bearing data. This information
is stored in the storm buffer.
A. Stormscope Processor
The stormscope processor is tray mounted and is located under the passengers' seat.
The AVIONICS BUS power to the stormscope system. The ELECTRIC MASTER key switch and
the AVIONIC MASTER switch must be set to ON to supply power through the WX-500 circuit
breaker to the stormscope system.
The processor houses the lightning data acquisition circuitry as well as the circuitry necessary to
process heading information and communicate with the G1000 system. All WX-500 functions are
controlled through the MFD of the G1000 system.
B. Stormscope Antenna
The NY-163 stormscope antenna is located on the horizontal stabilizer. The antenna is a combined
cross-loop and sense antenna. The antenna is sealed against environmental extremes and is
non-repairable.
Doc # 6.02.15 Page 1
Rev. 2 34-41-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 34-41-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the stormscope system. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair given in the
Repair column.
Trouble Possible Cause Repair
Stormscope does not operate. Circuit breaker not set. Set the circuit breaker.
Faulty cables/connectors. Do a test for continuity on each
cable. Do a test for short circuit
to ground and between cables.
Replace defective cables.
Doc # 6.02.15 Page 101
Rev. 2 34-41-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 34-41-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to remove/install the components of the stormscope system. It also tells you
how to test the stormscope system.
2. Remove/Install the Stormscope Processor
A. Remove the Stormscope Processor
Detail Steps/Work Items Key Items/References
(1) Remove the passengers seat. Refer to Section 25-10.
(2) Open the WX-500 circuit breaker.
(3) Loosen the screw that attaches the processor to
its mounting tray.
(4) Remove the stormscope processor from the
mounting tray.
B. Install the Stormscope Processor
Detail Steps/Work Items Key Items/References
(1) Put the stormscope processor in position in the
mounting tray.
(2) Tighten the screw that attaches the processor to
its mounting tray.
(3) Install the passengers seat. Refer to Section 25-10.
(4) Close the WX-500 circuit breaker.
(5) Do a test of the stormscope system. Refer to Paragraph 4.
Doc # 6.02.15 Page 201
Rev. 2 34-41-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
3. Remove/Install the Stormscope Antenna
A. Remove the Stormscope Antenna
Detail Steps/Work Items Key Items/References
(1) Open the WX-500 circuit breaker.
(2) Disconnect the connector of the stormscope
antenna.
(3) Remove the screws which attach the stormscope Hold the antenna!
antenna to the mounting bracket.
(4) Remove the stormscope antenna from the
horizontal stabilizer.
B. Install the Stormscope Antenna
Detail Steps/Work Items Key Items/References
(1) Put the stormscope antenna in position on the The arrow must point into flight
horizontal stabilizer. direction.
(2) Install the screws which attach the stormscope
antenna to the mounting bracket.
(3) Connect the connector of the stormscope
antenna.
(4) Close the WX-500 circuit breaker.
(5) Do a test of the stormscope system. Refer to Paragraph 4.
4. Test of the Stormscope System
Perform the installation checkout as outlined in Goodrich Stormscope WX-500 Installation Manual
P/N 009-11500-001 Chapter 3 'Installation Checkout'.
Page 202 Doc # 6.02.15
15 Apr 2013 34-41-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
% Section 34-42
% Traffic Advisory System (TAS)
% 1. General
% This Section tells you about the traffic advisory system that can be installed in the DA 40 NG. Refer
% to the manufacturer´s manual for more data about the equipment.
% The TAS consists of the following items:
% ) Processor.
% ) Transponder coupler.
% ) Top antenna.
% ) Bottom antenna.
% 2. Description and Operation
% The Ryan/Avidyne Traffic Advisory Systems (collectively know as TASs) are actively interrogating
% on-board air traffic detection systems used to identify potential collision threats. The TAS computes
% relative altitude and range of threats from nearby transponder-equipped airplanes. Airplanes with
% non-Mode C transponders can provide range information. The TAS does not detect airplanes without
% an operating transponder.
% A. Processor
% The TAS processor is tray mounted and is located behind the first ring frame.
% The avionics bus supplies power to the traffic advisory system. The ELECTRIC MASTER key
% switch and the AVIONIC MASTER switch must be set to ON to supply power through the TAS
% circuit breaker to the traffic advisory system.
% The TAS processor communicates to the Garmin G1000 system which indicates nearby traffic on
% the MFD. All functions of the TAS are controlled through the MFD.
% B. Transponder Coupler
% The transponder coupler is mounted on the remote avionic box of the Garmin G1000 system. The
% transponder coupler supplies the processor with a signal indicating the on-board transponder is
% transmitting a reply.
Doc # 6.02.15 Page 1
Rev. 2 34-42-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
% C. Antennas
% The TAS has two directional antennas. The top antenna is located on top of the fuselage behind
% the cabin in front of the COM antenna, and the bottom antenna is located on the fuselage bottom
% center between the main bulkheads.
Page 2 Doc # 6.02.15
15 Apr 2013 34-42-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
% Trouble-Shooting
% 1. General
% The table below lists the defects you could have with the traffic advisory system. If you have the trouble
% detailed in the Trouble column read across to the Possible Cause column. Then do the repair given
% in the Repair column.
% Trouble Possible Cause Repair
% TAS does not operate. Circuit-breaker not set. Set the circuit-breaker.
%
% Faulty cables/connectors. Do a test for continuity on each
% cable. Do a test for short circuit
% to ground and between cables.
% Replace defective cables.
% The TAS bearing shows The antenna coaxes for the top Check antenna connections.
% opposite to the traffic forward antenna are backwards.
% and aft, and it shows correctly
% left and right.
% The TAS bearing shows The antenna coaxes for the Check antenna connections.
% opposite to the traffic left and bottom antenna are
% right, and it shows correctly backwards.
% forward and aft.
Doc # 6.02.15 Page 101
Rev. 2 34-42-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
% Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 34-42-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
% Maintenance Practices
% 1. General
% This Section tells you how to remove/install the components of the traffic advisory system.
% 2. Remove/Install TAS Processor
% A. Remove TAS Processor
% Detail Steps/Work Items Key Items/References
% (1) Make sure that the ELECTRIC MASTER key Instrument panel, center.
% switch is set to OFF.
% (2) Remove the aft baggage compartment. Refer to Section 25-50.
% (3) Open the TAS circuit breaker. Instrument panel, right side.
% (4) Disconnect the connectors and antenna cables
% from the TAS processor.
% (5) Loosen the diagonal retaining screws that
% attaches the processor to its mounting tray.
% (6) Slide the TAS processor out of its mounting tray Along the rails.
% and clear of the airplane.
% B. Install TAS Processor
% Detail Steps/Work Items Key Items/References
% (1) Slide the TAS processor into its mounting tray. Along the rails.
% (2) Tighten the diagonal retaining screws that
% attached the processor to its mounting tray.
% CAUTION: WRONG CONNECTION OF THE ANTENNA CABLES WILL LEAD TO
% A WRONG INDICATION.
%
% (3) Connect the connectors and antenna cables to
% the TAS processor.
% (4) Close the TAS circuit breaker.
% (5) Install the aft baggage compartment.
% (6) Do a test of the traffic advisory system. Refer to the TAS Installation Manual,
% latest revision.
Doc # 6.02.15 Page 201
Rev. 2 34-42-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
% 3. Remove/Install Transponder Coupler
% A. Remove Transponder Coupler
% Detail Steps/Work Items Key Items/References
% (1) Make sure that the ELECTRIC MASTER key Instrument panel, center.
% switch is set to OFF.
% (2) Remove the aft baggage compartment. Refer to Section 25-50.
% (3) Open the TAS circuit breaker. Instrument panel, right side.
% (4) Disconnect the antenna cables from the
% transponder coupler.
% (5) Remove the screws and nuts that attach the Hold the transponder coupler!
% transponder coupler to the remote avionics box.
% (6) Remove the transponder coupler from the remote Fit dust caps to all connections.
% avionics box and clear of the airplane.
% B. Install Transponder Coupler
% Detail Steps/Work Items Key Items/References
% (1) Remove the dust-cover(s) from all connections. If necessary, install the dust covers
% from the new transponder coupler onto
% the transponder coupler that you
% removed.
% (2) Move the transponder coupler into position on the Hold the transponder coupler!
% remote avionics box.
% (3) Install the screws and nuts that attach the
% transponder coupler to the remote avionics box.
% (4) Connect the antenna cables to the transponder
% coupler.
% (5) Close the TAS circuit breaker.
% (6) Install the aft baggage compartment. Refer to Section 25-50.
% (7) Do a test of the traffic advisory system. Refer to the TAS Installation Manual,
% latest revision.
Page 202 Doc # 6.02.15
15 Apr 2013 34-42-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
% 4. Remove/Install a TAS Antenna
% A. Remove a TAS Antenna
% Detail Steps/Work Items Key Items/References
% (1) Make sure that the ELECTRIC MASTER key Instrument panel, center.
% switch is set to OFF.
% (2) Open the TAS circuit-breaker. Instrument panel, right side.
% (3) Remove the aft baggage compartment if you will Refer to Section 25-50.
% replace the top mounted antenna. Remove the
% center console between the two main bulkheads Refer to Section 25-10.
% if you will replace the bottom mounted antenna.
% (4) Disconnect the co-axial cables from the antenna At the antenna.
% that you will replace.
% (5) Remove the antenna:
% S Remove the 4 screws that attach the antenna Hold the antenna.
% to the structure.
% S If necessary, use a knife to carefully remove Take care not to damage the airplane
% the sealant that seals the antenna to the surface!
% airplane outer surface.
% S Move the antenna clear of the airplane.
%
Doc # 6.02.15 Page 203
Rev. 2 34-42-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
% B. Install a TAS Antenna
% Detail Steps/Work Items Key Items/References
% (1) Make sure that the contact surfaces of the
% antenna and the ground plane where the
% antenna will be installed are clean and free of
% grease.
% (2) Move the antenna into position.
% (3) Install the 4 screws that attach the antenna to
% the airplane.
% (4) Seal the outer edge of the antenna where it Refer to the AMM for an approved
% contacts the airplane surface with sealant. sealant.
% (5) Remove the excess sealant that has been
% forced out of the joint between the antenna and
% the airplanes surface.
% CAUTION: WRONG CONNECTION OF THE ANTENNA CABLES WILL LEAD TO
% A WRONG INDICATION.
%
% (6) Connect the co-axial cables to the antenna. At the antenna.
% (7) Install the aft baggage compartment or center Refer to Section 25-10 or 25-50.
% console panel that you removed in Paragraph A.
% (8) Reset the TAS circuit-breaker. Instrument panel, right side.
% (9) Do a test of the traffic advisory system. Refer to the TAS Installation Manual,
% latest revision.
Page 204 Doc # 6.02.15
15 Apr 2013 34-42-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Section 34-50
Dependent Position Determining
with G1000 System Installed
1. General
The DA 40 NG has an integrated cockpit system (ICS). The ICS has all the usual dependent position
determining systems. Refer to Section 31-40 for more data about the dependent positioning
determining systems that are integral with the ICS.
This Section tells you how to replace the antennas for the dependent position determining systems.
2. Description
The DA 40 NG has these dependent position determining systems and antennas:
) Transponder.
) DME.
) GPS (x2).
) ADF.
) Marker.
) VOR.
Flexible co-axial cables connect the antennas to their related equipment. You can replace the co-axial
cables. The VOR antenna is integral with the horizontal stabilizer and you can not replace the VOR
antenna. The other antennas are all attached to the surface of the airplane and can be replaced.
Refer to Section 31-40 for more data about the dependent position determining systems and their
related displays.
Doc # 6.02.15 Page 1
Rev. 2 34-50-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 34-50-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the dependent positioning determining system
antennas. Refer to Section 31-40 for trouble-shooting data for the dependent positioning determining
systems.
If you have the trouble listed in the Trouble column read across to the Possible Cause column. Then
do the repair given in the Repair column.
Trouble Possible Cause Repair
ATC reports no transponder Low output power. Examine and repair/replace
reply. Transponder reply defective antenna connections.
symbol operates.
Replace antenna.
ATC reports no transponder Poor received signal. Examine and repair/replace
reply. Transponder reply defective antenna connections.
symbol not operating.
Replace antenna.
DME/GPS/ADF/MARKER Poor received signal. Examine and repair/replace
systems give poor related defective antenna
performance. connections.
Replace related antenna.
Doc # 6.02.15 Page 101
Rev. 2 34-50-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 34-50-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Maintenance Practices
1. General
The Maintenance Procedures in this Section tell you how to replace the antennas of the dependent
position determining systems. Refer to Section 31-40 for more data about the dependent position
determining systems. Refer to Paragraph 3 for more information on the used types of co-axial cables.
Further particulars on the antenna sealant are given in Paragraph 4.
2. Replace a Dependent Position Determining System Antenna
A. Replace the Transponder or DME Antenna
Detail Steps/Work Items Key Items/References
(10) Make sure that the ELECTRIC MASTER key Instrument panel, center.
switch is set to OFF.
(11) Pull the XPDR/DME circuit-breaker. Instrument panel, right side.
(12) Remove the pilot’s seat if you will replace the Refer to Section 25-10.
transponder antenna. Remove only the co-pilot’s
seat if you will replace the DME antenna.
(13) Disconnect the co-axial cable from the antenna At the antenna.
that you will replace.
(14) Remove the antenna:
S Remove the 2 nuts and washers that attach Hold the antenna.
the antenna to the structure.
S If necessary, use a knife to carefully remove Take care not to damage the airplane
the sealant that seals the antenna to the surface!
airplane outer surface.
S Move the antenna clear of the airplane.
Doc # 6.02.15 Page 201
Rev. 2 34-50-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(15) Install the antenna:
S Make sure that the contact surfaces of the
antenna and the airplane surface where the
antenna will be installed are clean and free
of grease.
S Move the antenna into position under the Use sealant. Refer to Paragraph 4.
fuselage.
S Seal the outer edge of the antenna where it
contacts the airplane surface with sealant.
S Install the 2 washers and nuts that attach the
antenna to the airplane structure.
S Remove the excess sealant that has been
forced out of the joint between the antenna
and the airplane surface.
(16) Connect the co-axial cable to the antenna. At the antenna.
(17) Install the seat(s) that you removed. Refer to Section 25-10.
(18) Reset the XPDR/DME circuit-breaker. Instrument panel, right side.
(19) Do a test of the transponder. Only if you replaced the transponder
antenna.
(20) Do an operational test of the DME on the next Only if you replaced the DME antenna.
flight.
Page 202 Doc # 6.02.15
15 Apr 2013 34-50-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
B. Replace a GPS Antenna
Detail Steps/Work Items Key Items/References
(1) Make sure that the ELECTRIC MASTER key Instrument panel, center.
switch is set to OFF.
(2) Pull the GPS/NAV1 and/or GPS/NAV2 circuit- Instrument panel, right side.
breaker.
(3) Remove the reading/map light(s) as necessary Refer to Section 33-10.
to gain access to the antenna that you will
replace.
(4) Disconnect the co-axial cable from the antenna At the antenna.
that you will replace.
(5) Remove the antenna:
S Remove the 4 screws, nuts and washers that Hold the antenna.
attach the antenna to the airplane.
S Remove the ground-plate.
S If necessary, use a knife to carefully remove Take care not to damage the airplane
the sealant that seals the antenna to the surface!
airplane outer surface.
S Move the antenna clear of the airplane. From the outside.
(6) Install the antenna:
S Make sure that the contact surfaces of the
antenna and the airplane surface where the
antenna will be installed are clean and free
of grease.
S Move the antenna into position on the top of Use sealant. Refer to Paragraph 4.
the fuselage.
S Seal the outer edge of the antenna where it
contacts the airplane surface with sealant.
S Install the ground-plate.
S Install the 4 screws, washers and nuts that
attach the antenna to the airplane.
(7) Connect the co-axial cable to the antenna. At the antenna.
Doc # 6.02.15 Page 203
Rev. 2 34-50-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(8) Install the reading/map light(s) that you removed
at step 3.
(9) Set the GPS/NAV1 and/or GPS/NAV2 Instrument panel, right side.
circuit-breaker.
(10) Do a test of the GPS system(s). Refer to Section 31-40.
C. Replace a Marker or ADF Antenna
Detail Steps/Work Items Key Items/References
(1) Make sure that the ELECTRIC MASTER key Instrument panel, center.
switch is set to OFF.
(2) Remove the rear passengers' seats. Refer to Section 25-10.
(3) Disconnect the co-axial cable from the antenna At the antenna.
that you will replace.
(4) Remove the antenna:
S Remove the 3 screws, nuts and washers that Hold the antenna.
attach the antenna to the airplane.
S Remove the ground-plate.
S If necessary, use a knife to carefully remove Take care not to damage the airplane
the sealant that seals the antenna to the surface!
airplane outer surface.
S Move the antenna clear of the airplane. From the outside.
Page 204 Doc # 6.02.15
15 Apr 2013 34-50-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Detail Steps/Work Items Key Items/References
(5) Install the antenna:
S Make sure that the contact surfaces of the
antenna and the airplane surface where the
antenna will be installed are clean and free
of grease.
S Move the antenna into position on the
bottom of the fuselage.
S Seal the outer edge of the antenna where it Use sealant. Refer to Paragraph 4.
contacts the airplane surface with sealant.
S Install the ground-plate.
S Install the 3 screws, washers and nuts that
attach the antenna to the airplane.
(6) Connect the co-axial cable to the antenna. At the antenna.
(7) Install the rear passengers' seats. Refer to Section 25-10.
(8) Do a post-installation operational test of the ADF Only if you replaced the ADF antenna.
system. Refer to Paragraph 5.
(9) Do an operational test of the marker system on Only if you replaced the marker antenna.
the next flight.
Doc # 6.02.15 Page 205
Rev. 2 34-50-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
3. Used Types of Flexible Co-Axial Cables
Antenna/Receiver Co-Axial Cable
(1) Transponder RG 142
(2) DME RG 142
(3) GPS RG 400
(4) ADF RG 142
(5) Marker RG 400
4. Sealant Specification
Use an adhesive bonding compound on the basis of polyurethane or acrylic to seal the antennas to
the airplane outer surface. Make sure the sealant is free of silicone and it is temperature resistant from
-40 °C ( -40 °F) to +60 °C (+140 °F).
5. Post-Installation Check of the ADF System
A. General
After installing the equipment, check the indicator reading is correct and determine whether or not
quadrantal error correction is necessary. If so, correction should be first carried out on the ground,
then in the air. It is also necessary to establish whether any equipment in the airplane electrical
system is generating interference.
Page 206 Doc # 6.02.15
15 Apr 2013 34-50-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
B. Operational Check
Detail Steps/Work Items Key Items/References
(1) Locate the airplane on the correction platform
and using the bearing compass point the nose of
the airplane to a radio beacon in boundary
range.
(2) Switch on the ADF, adjust to the correct The indicator should read 0 relative
frequency and observe the indication in the ADF bearing.
operating mode.
(3) Turn the airplane about its vertical axis to a The indicator should move to the left.
larger heading.
(4) Turn the airplane about its vertical axis to a The indicator should move to the right.
smaller heading.
Note: If the reading is incorrect or should the indicator move in the wrong direction,
check the wiring of the equipment for agreement with the wiring diagram and
correct if necessary.
Note: If the airplane is accurately aligned with the NBD beacon, but a relative bearing
reading of 0° is not indicated, this is an indication that the antenna has been
wrongly installed. Recheck the antenna for agreement with the centerline of the
airplane and correct if necessary.
Refer to the manufacturer's manual for detailed information on the quadrantal error correction.
Note: It is recommended to proceed in accordance with FAA AC 43-13-1A and
FAA AC 43.13-2A requirements.
Doc # 6.02.15 Page 207
Rev. 2 34-50-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 208 Doc # 6.02.15
15 Apr 2013 34-50-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Section 34-51
Dependent Position Determining
with Conventional Cockpit Installed
1. General
This Section tells you about the equipment which shows dependent position determining.
Refer to these Sections for data about the systems:
Section 34-52. VHF omnidirectional range (VOR), localizer (LOC), and glideslope (GS).
Section 34-56. Transponder (XPDR).
Doc # 6.02.15 Page 1
Rev. 2 34-51-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 34-51-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Section 34-52
VOR/Localizer/Glideslope (VOR/LOC/GS)
with Conventional Cockpit Installed
1. General
This Section tells you about the VOR/LOC/GS (VHF omnidirectional range/localizer/glideslope) system
that can be installed in the DA 40 NG. Refer to the manufacturer's manuals for more data about the
equipment.
The VOR/LOC/GS system consists of the following items:
) NAV receiver. The NAV receiver is part of the NAV/COM system. Refer to Section 23-11 for more
data about the NAV/COM system.
) Display:
) VOR and LOC information is displayed by the NAV/COM receiver. Refer to Section 23-11 for
more data about the NAV/COM receiver.
) NAV (VOR/LOC/GS) antenna. Refer to Section 23-11 for more data about the NAV antenna.
2. Description and Operation
The VHF omnidirectional range (VOR) gives bearing information, ground station identification, and
reception of FSS reports in the VHF band.
Localizer (LOC) circuits are automatically energized when an ILS frequency is selected on the NAV.
Station identification and ATIS information can be received.
Glideslope (GS) circuits are automatically energized when an ILS frequency is selected on the NAV.
Doc # 6.02.15 Page 1
Rev. 2 34-52-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 34-52-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the VOR/LOC/GS system. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair given
in the Repair column.
Trouble Possible Cause Repair
NAV flag on both NAV receiver Faulty NAV receiver. Repair or replace the NAV
display and VOR/LOC receiver.
instrument.
Transmitting station is off the Tune to a new station.
air.
Poor co-ax connections. Examine co-ax connections
for condition and security.
Faulty NAV antenna. Replace the horizontal
stabilizer.
Faulty NAV antenna coupler. Replace the NAV antenna
coupler.
LOC indication not accurate on Faulty NAV receiver. Repair or replace the NAV
NAV receiver display. receiver.
VOR/LOC instrument correct.
LOC indication not accurate on LOC centering adjustment Adjust LOC centering. Refer to
VOR/LOC instrument. NAV needed. manufacturer's documentation.
receiver display correct.
Faulty VOR/LOC instrument. Repair or replace the
VOR/LOC instrument.
VOR indication not accurate on Faulty NAV receiver. Repair or replace the NAV
NAV receiver display. receiver.
VOR/LOC instrument correct.
VOR indication not accurate on VOR centering adjustment Adjust VOR centering. Refer to
VOR/LOC instrument. NAV needed. manufacturer's documentation.
receiver display correct.
Faulty VOR/LOC instrument. Repair or replace the
VOR/LOC instrument.
Doc # 6.02.15 Page 101
Rev. 2 34-52-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Trouble Possible Cause Repair
GS indication not accurate on GS centering adjustment Adjust GS centering. Refer to
GS instrument. needed. manufacturer's documentation.
Faulty NAV/GS receiver. Repair or replace the NAV/GS
receiver.
Faulty GS instrument. Repair or replace the GS
instrument.
Poor co-ax connections. Examine co-ax connections for
condition and security.
Faulty NAV antenna. Replace the horizontal
stabilizer.
Faulty NAV antenna coupler. Replace the NAV antenna
coupler.
Page 102 Doc # 6.02.15
15 Apr 2013 34-52-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Maintenance Practices
1. General
Refer to Section 23-11 for Maintenance Practices for the NAV/COM receivers and antennas.
Doc # 6.02.15 Page 201
Rev. 2 34-52-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 202 Doc # 6.02.15
15 Apr 2013 34-52-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Section 34-56
Transponder (XPDR)
with Conventional Cockpit Installed
1. General
This Section tells you about the transponder system which can be installed in the DA 40 NG. Refer to
the manufacturer's manuals for more data about the equipment. Refer to Chapter 92 for the wiring
diagrams.
The transponder system consists of the following items:
) Transponder. The following transponder can be installed in the DA 40 NG:
) Garmin GTX 328.
) Blind altitude encoder. The following blind altitude encoder can be installed in the DA 40 NG:
) Sandia SAE5-35.
Doc # 6.02.15 Page 1
Rev. 2 34-56-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
A. Garmin GTX 328 Mode S Transponder
Figure 4 shows the Garmin GTX 328 transponder. It is located in the instrument panel on the
bottom side, see Chapter 31.
The essential avionics bus supplies power to the transponder. The ELECTRIC MASTER key switch
and the AVIONIC MASTER switch must be set to ON to supply power through the XPDR
circuit-breaker to the transponder.
The transponder has a display which shows the following:
) FUNC window. The FUNC button changes the FUNC window shown on the right side of the
display. Displayed data includes pressure altitude, flight time, count up timer, count down timer,
and may include contrast, and display brightness, depending on configuration.
) Code window. The transponder code, set by the code selection keys, is shown in the center of
the display.
) Reply indicator. The reply indicator blinks to indicate that the GTX 328 is functioning properly
and replying to interrogations.
) Mode annunciation. The mode annunciation indicates which mode is selected.
GTX 328
ON
IDENT FUNC CRSR
ALT
ALT
7000 FLIGHT TIME
ST
01:23:20
F
START
OF
CLR
BY
VFR STOP
0 1 2 3 4 5 6 7 8 9
Figure 1: Garmin GTX 328 Mode S Transponder
Page 2 Doc # 6.02.15
15 Apr 2013 34-56-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
The transponder has these controls:
) Mode selection keys. The mode selection keys consist of:
) STBY. Sets the transponder to the standby mode. The transponder receives signals but
does not reply.
) ON. If the transponder receives an interrogation, it transmits the code set by the code
selection keys.
) ALT. If the transponder receives an interrogation, it transmits the code set by the code
selection keys and altitude data from the blind encoder.
) OFF. Turns the unit off when depressed for approximately 2 seconds.
) IDENT key. Pressing the IDENT key activates the Special Position Identification (SPI) pulse for
18 seconds, identifying your transponder return from others on the air traffic controller's screen.
The word 'IDENT' will appear in the upper left corner of the display while the IDENT mode is
active.
) Code selection keys. Use these keys (0-7) to enter the transponder code.
) VFR button. Sets the transponder code to the pre-programmed VFR code selected in
Configuration mode. Pressing the VFR button again will restore the previous identification code.
) FUNC button. Changes the page shown on the right side of the display. Displayed data includes
pressure altitude, flight time, count up timer, count down timer, and may include contrast, and
display brightness, depending on configuration.
) START/STOP button. Starts and stops the altitude monitor, count up, count down, and flight
timers.
) CRSR button. Initiates entry of the starting time for the count down timer and cancels
transponder code entry.
) CLR button. Resets the count up and count down timers and cancels the previous keypress
during code selection.
) 8 button. Reduces contrast and display brightness when the respective pages are displayed.
Also enters the number eight into the count down timer.
) 9 button. Increases contrast and display brightness when the respective pages are displayed.
Also enters the number nine into the count down timer.
Doc # 6.02.15 Page 3
Rev. 2 34-56-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
%
%
%
%
%
% Locknut
%
% Mounting Plate
%
% Screw
%
%
%
%
%
%
%
%
%
% Sandia SAE 5-35
% Static Fitting
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
Figure 2: Sandia Aerospace Altitude Data System SAE5-35 Installation
Page 4 Doc # 6.02.15
15 Apr 2013 34-56-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the transponder system. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair given
in the Repair column.
Trouble Possible Cause Repair
Transponder does not operate. Faulty transponder. Replace the transponder.
Reply indicator does not come
No power. Repair faulty wiring,
on when TST selected.
circuit-breaker etc.
Poor ground connection. Do a test of the ground
connection.
ATC reports no reply. Low output power. Examine the antenna
Transponder reply indicator connections.
flashes.
Replace the transponder.
ATC reports no reply. Airplane out of radar range. Do a test at higher altitude.
Transponder reply indicator
Poor received signal. Examine the antenna
does not flash.
connections.
Faulty transponder. Replace the transponder.
ATC reports Mode A does not Faulty transponder. Replace the transponder.
operate. Mode C operates
correctly.
Encoded altitude is wrong at Data code-bit missing. Do a Mode C fault analysis.
one or more altitudes but is
Faulty encoder. Replace the encoder.
correct at most other altitudes.
Faulty Mode C part of the Replace the transponder.
transponder.
Wiring open-circuit between Repair/replace the wiring.
encoder and transponder. Refer to the wiring diagrams in
Chapter 92.
Doc # 6.02.15 Page 101
Rev. 2 34-56-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
Trouble Possible Cause Repair
Encoded altitude output is too Faulty encoder. Replace the encoder.
high or too low over a steady
Encoder requires calibration. Calibrate the encoder. Refer to
range of altitudes. The airplane
the manufacturers manuals.
altimeter reads correctly.
Altitude read-out is -800 ft. Encoder not warmed-up. Let the encoder warm-up
(Refer to the blind encoder
fault analysis in this Section).
Page 102 Doc # 6.02.15
15 Apr 2013 34-56-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove/install the transponder and the blind altitude
encoder. They also tell you how to adjust/test the transponder and do fault analysis on the blind
encoder.
2. Remove/Install the Transponder
A. Remove the Transponder
Detail Steps/Work Items Key Items/References
(1) Open the transponder circuit-breaker.
(2) Put a 3/32 Allen wrench into the access hole for
the locking screw. Engage the screw.
(3) Turn the screw counter-clockwise until the unit
disengages from the mounting rack.
CAUTION: DO NOT PULL ON THE KNOBS. DO NOT PRY THE FACE-PLATE. IF
YOU PULL ON THE KNOBS, OR PRY THE FACE-PLATE, YOU CAN
DAMAGE THE UNIT.
CAUTION: DO NOT TOUCH THE CONNECTOR CARD AT THE REAR OF THE
UNIT. THE ELECTROSTATIC CHARGE ON YOUR BODY CAN
DAMAGE THE UNIT.
(4) Pull gently on the sides of the unit to remove it
from the mounting rack.
(5) Install the protective covers on the rear
connectors of the transponder.
Doc # 6.02.15 Page 201
Rev. 2 34-56-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
B. Install the Transponder
Detail Steps/Work Items Key Items/References
(1) Remove the protective covers from the
connectors on the replacement unit.
(2) Slide the unit into the rack. Engage the locking
screw so that the latch front-lobe touches the
rack.
(3) Turn the locking screw clockwise so that the rear
lobe engages the mounting rack.
CAUTION: DO NOT OVER-TIGHTEN THE LOCKING SCREW. YOU CAN
DAMAGE THE LOCKING MECHANISM.
(4) Continue to turn the screw until the unit is fully
installed in the mounting rack.
(5) Close the transponder circuit-breaker.
(6) Do an operational test. Refer to Paragraph 4.
Page 202 Doc # 6.02.15
15 Apr 2013 34-56-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
3. Remove/Install the Blind Altitude Encoder
A. Remove the Blind Altitude Encoder
Detail Steps/Work Items Key Items/References
(1) Open the XPDR circuit-breaker.
(2) Remove the instrument panel cover. Refer to Section 25-10.
(3) Disconnect the static hose from the encoder. Put a cap on the static hose!
(4) Disconnect the electrical connector(s).
(5) Release the knurled mounting screw for the
encoder.
(6) Remove the encoder. Remove the SAE5-35 from the
mounting rack.
(7) Install a cover over the static port.
B. Install the Blind Altitude Encoder
Detail Steps/Work Items Key Items/References
(1) Remove the cover from the static port on the
encoder.
(2) If you install a new encoder, install the static
fitting from the old encoder on the new encoder.
(3) Put the encoder in position on the mounting. Slide the SAE5-35 in the mounting rack.
Install the knurled mounting screw.
(4) Connect the electrical connector(s).
(5) Connect the static hose to the encoder.
(6) Close the XPDR circuit-breaker.
(7) Do a low-range static leak check. Refer to Section 34-10.
(8) Do the adjustment/test procedure. Refer to Paragraph 5.
(9) Install the instrument panel cover. Refer to Section 25-10.
Doc # 6.02.15 Page 203
Rev. 2 34-56-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
4. Test the Transponder
Use a transponder test set to make sure that the system operates correctly.
Key Items/References or
Detail Steps/Work Items
Limit Values
(1) Connect the test equipment. Refer to the equipment manufacturers'
manuals.
(2) Measure TX power. 125 W to 500 W.
(3) Measure MTL Mode A. -69 dBm to -77 dBm.
(4) Measure MTL Mode C. -69 dBm to -77 dBm.
(5) Determine MTL A & C difference. Max. 1 dB.
(6) Measure SLS P2 P1. Less than 1 % reply.
(7) Measure SLS P2 -9 dB < P1. More than 90 % reply.
(8) Measure 'ident' time. 15 sec to 30 sec.
(9) Measure interrogation Mode A Less than 10 % at max. 1.0 μs.
retard/advance P3.
(10) Measure interrogation Mode C Less than 10 % at max. 1.0 μs.
retard/advance P3.
(11) Measure framing:
S Retard/advance (F2 light just on).
S Difference between F2 retard and advance. 0.45 ± 0.07 μs.
S Calculate center of F2. Max. ± 0.1 μs. from 0.
(12) Check if 'reply' indicator and dimer are OK.
(13) Check if Mode A coding is OK.
(14) Measure transmitter frequency deviation (from ± 1.5 MHz.
1090 MHz).
(15) If necessary, do a test of the blind altitude Refer to Paragraph 5.
encoder.
(16) Dis-connect the test equipment.
Page 204 Doc # 6.02.15
15 Apr 2013 34-56-00 Rev. 2
DA 40 NG AMM Navigation
AIRCRAFT
Key Items/References or
Detail Steps/Work Items
Limit Values
(17) Do an operation flight test:
S Do a test of each control function. Refer to this Section.
S Contact ATC, ask for a transponder check. Note warm-up period of blind encoding
altimeter (see Paragraph 5).
Doc # 6.02.15 Page 205
Rev. 2 34-56-00 15 Apr 2013
Navigation DA 40 NG AMM
AIRCRAFT
5. Adjust/Test the Blind Altitude Encoder
A. Adjust/Test the SAE5-35
This adjustment ensures that the altitude code generated from the SAE5-35 is within 125 feet of
the altitude displayed to the pilot.
Detail Steps/Work Items Key Items/References
(1) Connect the test equipment. Refer to the equipment manufacturers'
manuals.
(2) Set the airplane altimeter to 1013.25 hPa
(29.92 inHg).
(3) Monitor the altitude code. Decrease the pressure
until the output code just changes to 20,000 ft.
(4) Make sure that the altimeter reading is within Lightly tap the panel next to the
± 125 ft of the encoder reading. If not, press the altimeter to prevent errors due to
increase button (behind slot A) or decrease friction.
button (behind slot B) until the encoder reading is
within 30 ft of the altimeter reading.
(5) Increase the pressure until the output code just
changes to 0 ft.
(6) Make sure that the altimeter reading is within Lightly tap the panel next to the
± 125 ft of the encoder reading. If not, press the altimeter to prevent errors due to
increase button (behind slot A) or decrease friction.
button (behind slot B) until the encoder reading is
within 30 ft of the altimeter reading.
(7) Do steps 2 to 5 again until both 20,000 ft and 0 ft
values are within the ± 125 ft tolerance.
(8) Operate the system through the range -1000 ft to Lightly tap the panel next to the
20,000 ft. Make sure that the altimeter and the altimeter to prevent errors due to
encoder are within the ± 125 ft tolerance. friction.
(9) Disconnect the test equipment and remove it
from the airplane.
Page 206 Doc # 6.02.15
15 Apr 2013 34-56-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
CHAPTER 51
STANDARD PRACTICES AND
STRUCTURES
Doc # 6.02.15 Page 1
Rev. 2 51-TITLE 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 51-TITLE Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
TABLE OF CONTENTS
CHAPTER 51
STANDARD PRACTICES AND STRUCTURE
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Types of Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Laminated Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Sandwich Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. Bonded Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6. Repair Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 51-10
Investigation
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Damage Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Types of Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Inspection Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. Further Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 51-20
Repair Processes
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Center of Gravity Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Control Surface Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Drain/Vent Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5. Holding the Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6. Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7. Workshop Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Doc # 6.02.15 Page 1
Rev. 2 51-CONTENTS 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Resin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Glass and Carbon Cloth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Core Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5. Laminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
6. Bonding Paste (Thickened Resin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
7. Curing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8. Exterior Paint Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
9. Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Section 51-30
Materials
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Approved Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 51-40
Fasteners
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Replace a Quick Release Fastener Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 51-60
Control Surface Balancing
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Page 2 Doc # 6.02.15
15 Apr 2013 51-CONTENTS Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Section 51-80
Electrical Bonding
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Test the Electrical Bonding System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Doc # 6.02.15 Page 3
Rev. 2 51-CONTENTS 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 51-CONTENTS Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
CHAPTER 51
STANDARD PRACTICES AND STRUCTURE
1. General
The DA 40 NG is a single-engine, low-wing monoplane of composite construction. It has a ‘T’ tail and
a fixed tricycle landing gear with a nose wheel that can caster.
The DA 40 NG fuselage has a semi-monocoque structure. Two glass fiber reinforced plastic (GFRP)
half-shells make the fuselage skin. The fuselage shells have many layers of glass cloth. Rigid foam
inserts give stiffness to the fuselage shells where necessary. All of the main structural components are
GFRP rigid moldings. Many layers of glass cloth bond together to make each molding. Some
components have layers of carbon fiber cloth to give more strength and stiffness.
The DA 40 NG has a cantilever wing. The wing has top and bottom shells. It has front and rear spars
and a root rib made in three parts. Each shell has a carbon fiber reinforced plastic (CFRP) outer skin,
a rigid foam core and a GFRP inner skin.
The vertical stabilizer is part of the fuselage. The aft part of the left and right fuselage shells make the
left and right shells of the vertical stabilizer.
Each wing has two I-section spars. The front spar on one side is the same as the rear spar on the
opposite side. Many layers of uni-directional carbon fiber make the spar caps. The number of layers
in the spar caps decreases from root to tip. Each spar has a shear web. The shear web has GFRP
skins and a rigid foam core. Glass cloth fillets attach the spar caps to the shear web.
A rear web closes the trailing edge of the wing. An end rib closes the outboard end of the wing. A
removable GFRP winglet attaches to the wing shells and outer rib with screws.
The flaps and ailerons have top and bottom shells. Each shell has mixture of CFRP and GFRP cloth.
The shells have rigid foam cores and bond together.
The horizontal stabilizer has top and bottom shells. Each shell has GFRP skins. The horizontal
stabilizer has a front spar and a rear spar. Three pairs of ribs give strength to the center area. The
elevator has top and bottom shells. Each shell has GFRP skins with a rigid foam core.
The rudder has left and right shells. Each shell has GFRP skins with a rigid foam core. The shells bond
together at a flange.
The canopy is a CFRP molding with inner and outer frames which bond together. The canopy has a
large one-piece acrylic glass window. The passenger door is a CFRP molding with inner and outer
frames. The frames bond together. The door has an acrylic glass window.
A polyurethane paint finish protects the outside skin of the airplane from ultraviolet rays and humidity.
Doc # 6.02.15 Page 1
Rev. 2 51-00-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
2. Types of Structure
The DA 40 NG is constructed from two main types of composite structure.
A. Glass Fiber Reinforced Plastic (GFRP)
GFRP is very thin glass fibers bonded together by resin. The glass fibers give most of the strength
and the resin maintains the shape. The resin also bonds to other structural components such as
other GFRP parts, metal attachment brackets or metal bushings.
The glass fibers are woven to make glass cloth. The orientation and weave of the glass in the cloth
affects the structural strength of the cloth. A component can have many layers of cloth bonded
together with resin. This is called lamination.
GFRP has very good properties. It is strong and flexible. It is very resistant to chemical attack and
very little maintenance is necessary.
B. Carbon Fiber Reinforced Plastic (CFRP)
CFRP is very thin carbon fibers bonded together by resin. The carbon gives most of the strength
and the resin maintains the shape. The resin also bonds to other structural components such as
other CFRP parts, metal attachment brackets or metal bushings.
CFRP is very similar to GFRP. The main advantage of CFRP is that it is stronger and more rigid
and lighter than GFRP.
3. Laminated Components
A laminated component has two or more layers of glass/carbon cloth. The direction of the fibers in the
cloth is important for the properties for each layer. Extra layers are bonded to areas to give more
strength.
4. Sandwich Structure
Many of the components in the DA 40 NG have a sandwich of two skins and a core. GFRP or CFRP
make the skins and rigid plastic foam makes the core.
The skins must bond to the core of a sandwich structure completely. If the skins do not bond to the
core the component can fail.
Page 2 Doc # 6.02.15
15 Apr 2013 51-00-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
5. Bonded Components
A number of components can bond together to make a larger component. Special thick resin bonds
these components together and fills the gap in a joint.
6. Repair Limitations
Repairs which are categorized as 'Class 1' in accordance with Section 51-10, Paragraph 2, may only
be carried out in accordance with a repair scheme which has been approved by the manufacturer.
Such repairs are not described in this Airplane Maintenance Manual.
Doc # 6.02.15 Page 3
Rev. 2 51-00-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 51-00-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Section 51-10
Investigation
1. General
This Section tells you how to assess the class of the damage. It also tells you how to inspect glass
fiber reinforced plastic (GFRP) and carbon fiber reinforced plastic (CFRP) composite structures.
Damage assessment and repairs must be carried out by approved persons.
Refer to Section 51-00 for the types of structure used in the DA 40 NG and for repair limitations. Refer
to Section 51-20 for general repair procedures.
2. Damage Classification
Damage is divided into the classes described below. In doubtful cases (i.e., if you are not sure about
the classification of a damage), you must contact the airplane manufacturer.
A. Class 1
) Major structural damage that requires the partial replacing of a structural component, or
) Damage to a large area, or
) Damage to a highly stressed component or part.
This type of damage restricts or voids airworthiness.
B. Class 2
Holes and cracks passing through both skins of a sandwich construction component. The core
damage must be able to be covered by a 75 mm (3 in) diameter circle.
C. Class 3
Small holes or cracks in the outer skin where there is no internal damage to the component, the
sandwich material, or the inner skin.
D. Class 4
Minor scratches, abrasions or similar damage which is not a crack or a puncture in the skin.
Doc # 6.02.15 Page 1
Rev. 2 51-10-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
3. Types of Damage
There are two basic types of hidden failure in composite structures:
) Disbonding.
) Delamination.
Disbonding is the failure of a bond between two components. For example between the fuselage skin
and a fuselage frame. Or between a composite component and a metal component. Or between a
composite skin and a sandwich core material.
Delamination is the failure of the bond between layers of glass/carbon cloth in a component.
There are also two main types of cracks:
) Micro cracks which occur in the surface of the resin.
) Major cracks with broken fibers. Major cracks do not occur with normal flight loads or normal
landing loads. You must repair major cracks.
4. Inspection Techniques
A. Examine Visually
Use this method to find all types of damage to composites. Use a bright light to examine visually
the inside of a component. GFRP must be green or brown. If the GFRP has white areas, then it
may be damaged. Look specially at areas where components bond to the GFRP.
CFRP must be black or black/brown. If the CFRP has white areas, then it may be damaged. Look
specially at areas where components bond to the CFRP.
Look carefully at the outer surface of a component. If the paint has cracks or bubbles, then the
composite may be damaged. Refer to Paragraph 5 in this Section.
Also look for dents. Look specially in areas where stones can hit the airplane below the fuselage
and the wings. Look specially in the areas of the walkways.
Page 2 Doc # 6.02.15
15 Apr 2013 51-10-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
B. Light Test
Use the light test to find delamination. Use this test on components which do not have rigid foam
inside.
CAUTION: DO NOT LET THE COMPOSITE GET HOT. HEAT CAN CAUSE
DAMAGE TO THE COMPOSITE.
Point a very bright light at the surface and look at the other side of the surface. Damage shows as
a dark area. You can point the light from the inside of a component or from the outside of a
component.
Note: You can use the light test on thick GFRP but it is difficult to use on CFRP.
C. Coin Tap Test
Use the coin tap test to find delamination and disbonding. Tap a coin on the laminate surface in the
area you will test. The sound of the coin tapping on the surface of the laminate will change as you
move the coin over damaged laminate.
Look specially at the area around the damage for secondary damage, which can remain
undetected.
5. Further Inspection
If you find paint damage when you examine a composite structure then do this further inspection.
Find a way to see the inside of a structure or a component. If necessary, remove panels (or other
components), or you can use remote viewing equipment. For example, remove the wing tip assembly
to see inside the wing. If you can see damage inside the component or structure you must do a repair.
Remove the paint coat in the area that you think is damaged. Remove the paint coat carefully, you
must not damage the cloth under the paint coat.
Look carefully at the surface. If you find cracks in the composite you must repair the structure.
If you do not find cracks in the composite then do this test. Push the middle of the area to be tested
with your thumb. If you can feel the skin hitting the core of a sandwich (or other layer/component), then
the skin is disbonded and you must repair the structure.
In some cases you must cut inspection holes in the structure to do the test correctly. If you must cut
inspection holes you must seek advice from Diamond Aircraft Industries.
Doc # 6.02.15 Page 3
Rev. 2 51-10-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 51-10-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Section 51-20
Repair Processes
1. General
This Section tells you how to repair composite structures. Repairs must be carried out by approved
persons. Refer to Section 51-00 for data about the types of structures. Refer to Section 51-10 for data
about the classification of damage and inspection techniques. Refer to Section 51-30 for data about
approved repair materials.
2. Center of Gravity Limits
When you repair an airplane, it is likely that you change the weight of the airplane and the center of
gravity. The further the distance of a repair from the center of gravity, the greater the effect will be on
the center of gravity. You must always weigh the airplane after a large repair and calculate the center
of gravity. Refer to Section 08-10 for data about weighing the airplane.
3. Control Surface Balancing
When you repair a control surface it becomes heavier. Make an estimate of the new weight of the
control surface after before you do a repair. If the control surface will be too heavy then do not repair
it. You must install a new item.
When you repair a control surface and/or apply a new paint coat you must weigh and balance the
control surface. Refer to Section 06-00 for data about weights and balance. Section 51-60 tells you
how to balance a control surface.
WARNING: YOU MUST WEIGH AND BALANCE A CONTROL SURFACE AFTER
REPAIR OR PAINTING. FAILURE TO BALANCE A CONTROL SURFACE
MAY CAUSE THE AIRPLANE TO FAIL IN FLIGHT.
4. Drain/Vent Holes
You must keep all drain and vent holes in the structure of the DA 40 NG open. If you close a drain or
vent hole doing a repair you must make a new hole in the same position.
Doc # 6.02.15 Page 1
Rev. 2 51-20-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
5. Holding the Component
You must hold a component in the correct position when you do a repair. If you do not hold a
component correctly it may move when you do the repair and cause further damage. It can also
change the airplane alignment.
Hold the component in a special device (jig/fixture) before you cut the repair area. If necessary, lift the
airplane on jacks and level the airplane. Refer to Section 07-10 for data about jacking and
Section 08-20 for data about leveling the airplane.
6. Safety Precautions
Most resins can cause skin disease. When you use resin/hardener use a protective barrier cream on
your hands and exposed skin. You must always wear plastic gloves.
WARNING: DO NOT GET RESIN ON YOUR SKIN. RESIN CAN CAUSE SKIN
DISEASE.
The resins, hardeners and solvents used for composite repairs are poisonous. You must not take food
into the work area. Use a mask to protect your face and use eye-protection.
WARNING: DO NOT GET RESINS, HARDENERS OR SOLVENTS IN YOUR MOUTH
OR IN YOUR EYES. THESE CHEMICALS CAN CAUSE DISEASE.
When you grind composites you make small particles of composite dust. These particles can irritate
the skin and eyes. If you breathe these composite particles, they can cause lung disease.
When you grind composite you must always use a protective cream on your hands and on all exposed
skin. Wear overalls which seal at the wrists, neck and ankles. You must always wear gloves and if
necessary, change them often. Use a suitable mask to protect you face and lungs. Always wear safety
goggles to protect your eyes.
If your skin comes into contact with composite dust, then wash it off with flowing water. Do not rub your
skin while it has dust on it.
WARNING: DO NOT GET COMPOSITE DUST PARTICLES IN YOUR EYES, OR IN
YOUR MOUTH, OR ON YOUR SKIN. THESE PARTICLES CAN CAUSE
DISEASE.
Page 2 Doc # 6.02.15
15 Apr 2013 51-20-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
7. Workshop Conditions
Keep the workshop clean and free from dust. Remove grinding dust as it occurs. The working area
must not be affected by air draughts.
The temperature of the workshop should be maintained between 18 °C (65 °F) and 27 °C (77 °F) and
must not fall below 15 °C (59 °F). The relative humidity during mixing, applying or curing or resins must
not be allowed to rise above 80 %.
Maintain the workshop temperature as near to 25 °C (77 °F) as possible during curing.
Doc # 6.02.15 Page 3
Rev. 2 51-20-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 51-20-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Maintenance Practices
1. General
These Maintenance Practices tell you about composite repair processes and how to repair Class 2,
3 and 4 damage to the composite structure. Refer to Section 51-10 for data about damage
classification. Class 1 damage may only be repaired in accordance with a repair scheme approved by
the manufacturer. All repairs must be carried out by approved persons.
You must only use the materials approved by the manufacturer when repairing the airplane. Refer to
Section 51-30 for data about approved materials.
Inspect the damaged area. Look specially at the adjacent structure. Damage can go a long way under
the surface. Use the techniques given in Section 51-10.
You must take care to do the repair correctly. The outer shell of a composite structure is stressed.
Failure of the structure can cause an accident.
2. Resin
You must use the correct quantity of mixed resin for the repair. Weigh all the cut cloth patches that you
will use for the repair. The ratio for glass cloth to mixed resin is 100 : 70. For example, 100 grams of
dry glass cloth require 70 grams of mixed resin. The ratio for carbon cloth to mixed resin is 100 : 100.
For example, 100 grams of dry carbon cloth require 100 grams of mixed resin.
Measure the quantities of resin and hardener accurately (± 2% by weight). Mix the resin and hardener
thoroughly before laminating, or adding fillers or other additives.
Always use clean containers for mixing resin and only mix as much resin as you can use within its pot
life.
When using a large quantity of resin put it into a shallow container. This will increase the ratio of
surface area to volume which will reduce the risk of an exothermic reaction and can improve pot life.
For parts made from self extinguishing resin use the same resin system for repair (refer to
Section 51-30).
Doc # 6.02.15 Page 201
Rev. 2 51-20-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
3. Glass and Carbon Cloth
CAUTION: Epoxy resin cures in an exothermal reaction. Depending on resin/hardener
combination, and pot life of the combination, and working temperature the
mixture can reach high temperatures. Do not use hot resin. Hot resin can
inflame. Put it to a safe location until hardened.
You must always use the correct cloth for the repair. Refer to the lay-up drawing of the repair area for
data about the type of cloths you must use. The lay-up drawing will tell you:
) The correct type of cloth.
) The fiber direction.
) The dimensions of the layer.
Make sure that the fibers in each layer of cloth point in the direction given in the lay-up drawing. This
gives the correct strength to the laminate. Only use sharp shears or scissors to cut the cloth to size.
Make sure that the fibers in the cut cloth point in the correct relative direction. Make sure that the fiber
strands are not broken or damaged. The cloth must be free of any damage or contamination.
4. Core Material
You must always use the correct sandwich core for the repair. Refer to the lay-up drawing of the repair
area for data about the type of core you must use.
Make sure that the core material is not damaged or contaminated.
Use a sharp knife to cut the core to the exact size for the repair. The edges of the cut must be clean
so that the core will bond correctly. You can profile the core by cutting or sanding.
Page 202 Doc # 6.02.15
15 Apr 2013 51-20-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
5. Laminating
A prescribed stack of resin impregnated cloth makes a laminate. A laminate which is used to repair
an airplane becomes an integral part of the airplane structure once the laminate is hardened and fully
cured.
You can make the laminate in place directly on the repair or you can make the laminate on a work
table and then apply the wet laminate to the repair. When you make the laminate on a table:
) It is easier to do.
) It is easier to control and correct the laminating process.
) You can make sure that the cloth layers in the stack are correct before you apply the resin.
) You can make the repair neater.
) You do not have to work upside down.
Doc # 6.02.15 Page 203
Rev. 2 51-20-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
A. Laminating in Place
Detail Steps/Work Items Key Items/References
(1) Prepare the damaged area for laminating. Make Refer to the relevant repair procedure in
sure that the repair is clean and free this Section.
contamination.
(2) Prepare the layers of cloth that you will use. Refer to the lay-up drawing.
(3) Protect the area of the structure around the repair Use plastic/polythene sheet material
from contamination by the repair materials. held in place by self adhesive tape.
WARNING: DO NOT GET RESIN ON YOUR SKIN. RESIN CAN CAUSE SKIN
DISEASE.
WARNING: DO NOT GET RESINS, HARDENERS OR SOLVENTS IN YOUR
MOUTH OR IN YOUR EYES. THESE CHEMICALS CAN CAUSE
DISEASE.
(4) Apply a thin coat of resin to the repair.
(5) Apply the first layer of cloth to the repair and trim Make sure that the fibers in the cloth
to the correct size. point in the correct direction.
(6) Use a roller, squeegee and a stipple brush to
remove all trapped air. Make sure that the cloth is
completely impregnated with resin. If necessary,
add more resin.
(7) When the excess resin has been brought to the
surface with the rolling and stippling process,
apply the next layer of cloth. Trim the cloth to the Make sure that the fibers in the cloth
correct size. point in the correct direction.
(8) Do steps 6 and 7 as necessary until all the layers
of cloth are in place.
(9) Use the roller and squeegee to remove the
excess resin.
(10) Put a layer of peel ply over the laminate.
(11) If necessary, apply a vacuum bag to the laminate. Refer to the lay-up drawing and/or
repair drawing.
Page 204 Doc # 6.02.15
15 Apr 2013 51-20-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
B. Laminating on a Table
Detail Steps/Work Items Key Items/References
(1) Prepare the damaged area for laminating. Make Refer to the relevant repair procedure in
sure that the repair is clean and free from this Section.
contamination.
(2) Protect the area of the structure around the repair Use plastic/polythene sheet material
from contamination by the repair materials. held in place by self adhesive tape.
(3) Put a layer of clean transparent plastic / Colored sheet should be preferred.
polyethylene sheet over the repair and hold it in
place with self adhesive tape.
(4) Use an indelible felt marker to:
S Trace onto the plastic sheet the extreme The outer layer of the structure must be
outline of the repair. tapered to avoid stress risers and to
give a good finish.
S Trace onto the plastic sheet the contour lines
of each layer of cloth in the structure.
(5) Remove the transparent sheet from the structure
and place it upside down on a work table.
Note: The cloth layers are laid in reverse order when you laminate on a table. You
must take care to put the cut cloth layers in the correct order and that the fibers
in each cloth layer point in the correct direction.
(6) Cut the layers of cloth to fit the contour lines that
you traced onto the transparent sheet.
WARNING: DO NOT GET RESIN ON YOUR SKIN. RESIN CAN CAUSE SKIN
DISEASE.
WARNING: DO NOT GET RESINS, HARDENERS OR SOLVENTS IN YOUR
MOUTH OR IN YOUR EYES. THESE CHEMICALS CAN CAUSE
DISEASE.
(7) Apply a thin coat of resin to the transparent
sheet.
Doc # 6.02.15 Page 205
Rev. 2 51-20-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Detail Steps/Work Items Key Items/References
(8) Apply the first inner layer of cloth to the Make sure that the fibers in the cloth
transparent sheet and trim to the correct size. point in the correct direction.
(9) Use a roller, squeegee and a stipple brush to
remove all trapped air. Make sure that the cloth is
completely impregnated with resin. If necessary,
add more resin.
(10) When the excess resin has been brought to the
surface with the rolling and stippling process,
apply the next layer of cloth. Trim the cloth to the Make sure that the fibers in the cloth
correct size. point in the correct direction.
(11) Do steps 9 and 10 as necessary until all the
layers of cloth are in place.
(12) Apply a thin coat of resin to the area of the repair
on the structure where you will attach the
laminate patch.
(13) Put the laminate patch carefully into position on Make sure that the fibers in the cloths
the structure using the transparent sheet. point in the correct direction.
(14) Carefully remove the transparent sheet from the
laminate patch.
(15) Use a roller to make sure that the laminate patch
is firmly in position and that any excess resin is
removed from the repair laminate.
(16) Put a layer of peel ply over the laminate.
(17) If necessary, apply a vacuum bag to the laminate. Refer to the lay-up drawing and/or
repair drawing.
Table 1 - Bonding Paste Mixing Table
Material Weight in Grams
Mixed Resin 50 100 150 200 250 300 350 400 450
Cotton Flocks 6 11.5 17 23 29 34.5 40 46 52
Aerosil 1.4 2.8 4.2 5.5 6.9 8.3 9.7 11.1 12.5
Page 206 Doc # 6.02.15
15 Apr 2013 51-20-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
6. Bonding Paste (Thickened Resin)
CAUTION: TO BOND PARTS MADE OR REPAIRED WITH SELF EXTINGUISHING
RESIN, YOU MUST USE SELF EXTINGUISHING RESIN TO MIX THE
BONDING PASTE (REFER TO SECTION 51-30).
Use bonding paste to bond GFRP/CFRP components together and in the repair of
sandwich cores. Resin and thickening fillers make bonding paste. Table 1 gives you the
proportions by weight of resin to thickening fillers. You can change the proportions of
Aerosil and Microballoons relative to each other but you must keep the total weight of the
Aerosil/Microballoon mix constant.
7. Curing
You must cure a composite structure to make it strong. If you do not cure a composite structure
correctly it may fail. Curing is a two part process, pre-curing and post-curing. The following procedure
gives a typical curing process.
Detail Steps/Work Items Key Items/References
(1) Maintain the temperature of the repair at 20 °C to If you do not have an oven or a
25 °C (68 °F to 77 °F) for at least 24 hours to warming room you can make a
pre-cure the repair. temporary enclosure around the repair
to trap the heat from a flame proof air
heater.
CAUTION: DO NOT ALLOW A TOO HIGH TEMPERATURE DURING THE CURE.
A TOO HIGH TEMPERATURE CAN DAMAGE THE COMPOSITE
STRUCTURE.
(2) After 24 hours raise the temperature of the repair Monitor the temperature every
to at least 65 °C (149 °F) for a minimum of 15 minutes for the first hour and then
6 hours to complete the first stage of the hourly.
post-cure.
(3) After a minimum of 6 hours raise the temperature The final stage post-cure time can be
of the repair to at least 80 °C (176 °F). Maintain divided into sections but you must make
this temperature for a minimum of 14 hours to sure that the repair has a minimum total
complete the final post-cure. of 14 hours at post-cure temperature.
Doc # 6.02.15 Page 207
Rev. 2 51-20-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
% Zone 1
%
Zone 1a
%
% Zone 2
%
Zone 3
%
%
%
%
%
%
%
%
%
%
%
%
%
Figure 1: Paint Color Scheme
Page 208 Doc # 6.02.15
15 Apr 2013 51-20-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
8. Exterior Paint Finish
A. Paint Color Scheme
CAUTION: YOU MUST PAINT THE AIRPLANE TO THE PAINT COLOR SCHEME. IF
YOU DO NOT PAINT THE AIRPLANE TO THE PAINT COLOR SCHEME,
YOU MAY CAUSE DAMAGE TO THE AIRPLANE STRUCTURE.
Since full strength of the fiber composite structure has only been shown up to a temperature of
54EC (129EF), the outer surface of the airplane must be painted white in accordance with
Chapter 04 of this manual.
Exceptions are registration markings and warning marks, which are subject to the following
restrictions (refer to Figure 1):
) Zone 1. No registration markings or warning markings may be applied here, except for the
placards in accordance with Section 11-20.
) Zone 1a. This zone has the same restrictions as Zone 1, except that registration marks may be
applied here which comply with the restrictions of Zone 2.
) Zone 2. Registration markings and warning markings may be applied here. They may be any
shape and color, provided that the average absorption coefficient of each area measuring
200 mm by 200 mm (8 in by 8 in) does not exceed 0.5. Examples which meet this
criterion are:
Registration markings and warning markings of any shape, provided that colors with
a solar absorptivity not exceeding 0.5 (e.g. light yellow or light green) are used.
Registration markings and warning markings of any color, provided that no area
measuring 200 mm by 200 mm (8 in by 8 in) is covered by more than 50%. One
consequence is that the width of decoration stripes must not exceed 100 mm (4 in).
) Zone 3. Registration markings and warning markings of any shape and color may be applied here
without restrictions.
Doc # 6.02.15 Page 209
Rev. 2 51-20-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
%
%
> 200mm (8 in)
%
%
%
%
%
%
%
%
%
%
%
%
Scarfing 25mm ± 5mm
% (1in ± 0.2in) Anti-static Filler
%
%
%
%
%
% Repair Area
%
%
%
%
%
%
Scarfing 25mm ± 5mm
% (1in ± 0.2in)
%
%
Coating Paint
%
%
%
%
%
Anti-static Filler
%
%
Figure 2: Scarfing the Paint Coat
Page 210 Doc # 6.02.15
15 Apr 2013 51-20-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
B. Painting a Large Repair Area
Refer to Figure 2. This procedure must be followed when the diameter of the area which must be
painted is larger than 200 mm (8 in).
Detail Steps/Work Items Key Items/References
(1) Carefully scarf the edges of the existing paint Do not sand through the existing
finish. anti-static filler.
Minimum scarf length: 25 mm (1 in).
To ensure that the anti-static filler of the
existing paint is electrically connected
to the anti-static filler of the new paint.
WARNING: DO NOT GET ACETONE, FILLER, OR PAINT ON YOUR SKIN.
ACETONE, FILLER, AND PAINT CAN CAUSE SKIN DISEASE.
WARNING: DO NOT BREATHE ACETONE, FILLER, OR PAINT FUMES.
ACETONE, FILLER, AND PAINT FUMES CAN CAUSE DISEASE.
CAUTION: THERE MUST BE NO GREASE OR DUST ON THE REPAIR AREA.
GREASE AND DUST PREVENT A GOOD BOND.
(2) Make sure that the area to be repaired is clean If necessary, use acetone and re-sand
and free from any contaminants. the area.
(3) Apply HS filler to the repair area. Obey the filler manufacturer's
instructions.
(4) Allow the HS filler to cure. 2 hours at 45 °C (113 °F).
(5) Lightly sand the HS filler with 320 grit sanding
paper.
(6) Make sure that the area to be repaired is clean If necessary, use acetone and re-sand
and free from any contaminants. the area.
(7) Apply two layers of anti-static spray filler to the Obey the filler manufacturer's
repair area. instructions.
(8) Allow the anti-static filler to dry. At 20 °C to 25 °C (68 °F to 77 °F),
60 to 75 % relative humidity.
(9) Carefully sand the anti-static filler with 320 grit Remove as little anti-static filler as
sanding paper. possible. Do not sand through the
edges.
Doc # 6.02.15 Page 211
Rev. 2 51-20-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Detail Steps/Work Items Key Items/References
(10) Make sure that the area to be repaired is clean If necessary, use acetone and re-sand
and free from any contaminants. the area.
(11) Apply the coating paint. Obey the paint manufacturer's
instructions.
(12) Allow the coating paint to dry. 90 minutes at 45 °C (113 °F), then
2 days at 20 °C (68 °F).
C. Painting a Small Repair Area
This procedure must be followed when the diameter of the area which must be painted is 200 mm
(8 in) or less.
Detail Steps/Work Items Key Items/References
WARNING: DO NOT GET ACETONE, FILLER, OR PAINT ON YOUR SKIN.
ACETONE, FILLER, AND PAINT CAN CAUSE SKIN DISEASE.
WARNING: DO NOT BREATHE ACETONE, FILLER, OR PAINT FUMES.
ACETONE, FILLER, AND PAINT FUMES CAN CAUSE DISEASE.
CAUTION: THERE MUST BE NO GREASE OR DUST ON THE REPAIR AREA.
GREASE AND DUST PREVENT A GOOD BOND.
(1) Make sure that the area to be repaired is clean If necessary, use acetone and re-sand
and free from any contaminants. the area.
(2) Apply 2 layers of HS filler to the repair area. Obey the filler manufacturer's
instructions.
(3) Allow the HS filler to cure. 2 hours at 45 °C (113 °F).
(4) Lightly sand the HS filler with 320 grit sanding
paper.
(5) Make sure that the area to be repaired is clean If necessary, use acetone and re-sand
and free from any contaminants. the area.
(6) Apply the coating paint. Obey the paint manufacturer's
instructions.
(7) Allow the coating paint to dry. 90 minutes at 45 °C (113 °F), then
2 days at 20 °C (68 °F).
Page 212 Doc # 6.02.15
15 Apr 2013 51-20-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
D. Coated Safety Walk Repair (if OÄM 40-317 is installed)
(1) Equipment
Item Quantity Part Number
Safety walk substrate sprinkler. 1 DAI-9011-20-03_LV.
Plastic spattle. 1 Commercial.
(2) Material
Item Quantity Part Number
Safety walk cover LH. 1 D41-1120-20-01_LV.
Safety walk cover RH. 1 D41-1120-20-02_LV.
Fill-in 2 K 400 ml RAL 7038. 3 22101980.
Safety walk substrate. 0.5 kg DAI-9011-20-03.
Doc # 6.02.15 Page 213
Rev. 2 51-20-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
(3) Repair Procedure
Detail Steps/Work Items Key Items/References
WARNING: WHEN HANDLING CHEMICALS ALWAYS OBSERVE HEALTH AND
SAFETY REGULATIONS GIVEN BY THE MANUFACTURER OF THE
CHEMICALS.
(1) Clean the entire area between fuselage and Refer to Section 12-30.
rootribs (LH and RH sides). Use water to
remove dirt from the surface. If necessary,
add a mild cleaning agent.
(2) Use a commercial solvent to remove grease
from the surface. The surface must be
totally clean from grease or dirt.
(3) Place the safety walk covers (note LH and Refer to Figure 3.
RH sides) on the center wing and mark the
positions with a pencil on the middle wing
surface.
(4) Make sure that the safety walk cover
orientation is parallel to flight direction.
(5) Remove the protective layer from the safety
walk cover.
(6) Place the safety walk cover corresponding
to the marks on center wing (don’t use soap
water) and remove the transfer foil
smoothly.
(7) Remove air bubbles from the edges of the
cutouts with a plastic spattle.
(8) Prepare the surface at the cutouts of the
safety walk cover:
S Carefully roughen the paint with
sandpaper (grit 320), for the ends of
strips use red Scotch-Brite.
(9) Clean the surface at the safety walk cutouts
with a vacuum cleaner and silicon remover.
Page 214 Doc # 6.02.15
15 Apr 2013 51-20-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Detail Steps/Work Items Key Items/References
(10) Cover the airplane’s surface around the
safety walk cover.
(11) Prepare lacquer P/N 22101980 in acc. with
the technical information sheet.
Shake 2 minutes before and after operating
the red button.
Press red button with the ball of your hand
until stop is reached.
(12) Spray a thick film at the cutouts of the safety
walk cover.
(13) Use safety walk substrate sprinkler to apply
safety walk substrate evenly over cutouts.
(14) Apply a second layer of lacquer:
S Make sure the whole substrate is evenly
covered with a sufficient amount of
paint.
(15) Carefully pull off the safety walk cover
starting from one edge. Remove the cover in
direction of the strips within 15 minutes.
(16) Let the system dry for 12 h in a dry and
weather protected area at temperatures
from 20 to 30°C (68 to 86 °F).
(17) Remove the cover from the airplane surface.
Doc # 6.02.15 Page 215
Rev. 2 51-20-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Root Rib
10mm
Place Safety
Walk Cover
to Trailing Edge
Place Safety
Walk Cover
to Trailing Edge
10mm
Root Rib
Figure 3: Safety Walk Cover Positioning
Page 216 Doc # 6.02.15
15 Apr 2013 51-20-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
9. Repairs
A. Class 4 Repairs
The repair of minor scratches, abrasions or similar damage which is not a crack or a puncture in
the skin.
Detail Steps/Work Items Key Items/References
WARNING: DO NOT GET ACETONE ON YOUR SKIN. ACETONE CAN CAUSE
SKIN DISEASE.
WARNING: DO NOT BREATHE ACETONE FUMES. ACETONE FUMES CAN
CAUSE DISEASE.
(1) Sand the repair area with 150 grit sanding paper.
(2) Make sure that the area to be repaired is clean If necessary, use acetone.
and free from any contaminants.
(3) Apply putty to the repair area to fill any damage. Obey the putty manufacturer's
instructions.
Fill to the original contour of the
structure.
(4) Allow the putty to cure. 5 to 20 minutes.
(5) Lightly sand the putty with 150 grit sanding paper.
(6) Apply filler(s) and paint coat. Refer to Paragraph 8.
Doc # 6.02.15 Page 217
Rev. 2 51-20-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Table 2 - Material Specifications
WLB No. Manufacturer Material Weave Weight Thick- Scarf
and Type per unit ness
(German [mm]
area
Aviation [mm]
2
Standard) [g/m ]
8.4548.60 Interglas 92110 glass 2/2 twill 163 0.17 7
8.4551.60 Interglas 92125 glass 2/2 twill 280 0.30 12
8.4554.60 Interglas 92140 glass 2/2 twill 390 0.43 18
8.4520.6 Interglas 92145 glass uni-directional 220 0.23 19
8.4525.60 Interglas 92146 glass uni-directional 425 0.43 35
Interglas 98141,
8.3520.80 Cramer carbon 2/2 twill 200 0.30 18
CCC 452
Cramer carbon with
2/2 twill 220 0.32 20
CCC 459 Al aluminum
SGL Sigratex uni-directional
carbon 380 0.40 80
KDU 1034 tape
Page 218 Doc # 6.02.15
15 Apr 2013 51-20-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
B. Class 3 Repairs
Small holes or cracks in the outer skin where there is no internal damage to the component, the
sandwich material, or the inner skin.
Detail Steps/Work Items Key Items/References
(1) Make sure that the area around the damage is
clean.
(2) Carefully examine the area around the damage. Do a coin tap test to find the extent of
Look specially for disbonding between the inner any disbonding or delamination.
laminate layers and any core material.
(3) Remove damaged/loose laminate until the edges Refer to Figure 4.
of the laminates bond together and to any core Use a sharp knife or grinding disk.
material.
(4) Scarf the edges of the repair area with a grinding Refer to Table 2 for data about the scarf
disk or block. size.
(5) Count the layers of fabric that you will need to Refer to the lay-up drawing for the
replace. related structure for data about the cloth
type and orientation.
WARNING: DO NOT GET ACETONE ON YOUR SKIN. ACETONE CAN CAUSE
SKIN DISEASE.
WARNING: DO NOT BREATHE ACETONE FUMES. ACETONE FUMES CAN
CAUSE DISEASE.
CAUTION: THERE MUST BE NO GREASE OR DUST ON THE REPAIR AREA.
GREASE AND DUST PREVENT A GOOD BOND.
(6) Clean the area of the repair. If you use acetone to remove any
grease or dirt then you must re-sand
the repair area.
Doc # 6.02.15 Page 219
Rev. 2 51-20-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Laminate
Foam Core
Laminate
Remove Damaged /Loose Laminate
Scarf
Scarf the Edges of the Repair Area
New Laminate
Repair the Laminate
New Laminate
Contour the Laminate
Figure 4: Typical Class 3 Repair
Page 220 Doc # 6.02.15
15 Apr 2013 51-20-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Detail Steps/Work Items Key Items/References
WARNING: DO NOT GET RESIN ON YOUR SKIN. RESIN CAN CAUSE SKIN
DISEASE.
WARNING: DO NOT GET RESINS, HARDENERS OR SOLVENTS IN YOUR
MOUTH OR IN YOUR EYES. THESE CHEMICALS CAN CAUSE
DISEASE.
(7) Repair the laminate. Use one of the 2 methods given in
Paragraph 5.
(8) Pre-cure the repair. Refer to Paragraph 7.
(9) Post-cure the repair. Refer to Paragraph 7.
(10) When the repair is fully post cured, remove the
peel ply and sand smooth the surface of the
repair.
(11) Contour the repair so that the final surface level Use 150 grit sanding paper.
of the repair is slightly lower than the original To allow for the paint coat.
surrounding area.
(12) Apply filler(s) and paint coat. Refer to Paragraph 8.
Doc # 6.02.15 Page 221
Rev. 2 51-20-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Laminate
Foam Core
Laminate
Remove Damaged/Loose Laminate
Scarf Scarf
min. 20 mm (0.8 in) min. 20 mm (0.8 in)
Remove Damaged Foam Core and Scarf Laminate
Foam Insert
Laminate
Insert the Laminate and Foam Core into the Repair
Foam Insert
Laminate
Profile the Foam Core Insert
Laminate
Repair the Laminate
Laminate
Contour the Laminate
Figure 5: Typical Class 2 Repair
Page 222 Doc # 6.02.15
15 Apr 2013 51-20-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
C. Class 2 Repairs
Holes and cracks passing through both skins of a sandwich construction component. The core
damage must be able to be covered by a 75 mm (3 in) diameter circle.
Detail Steps/Work Items Key Items/References
(1) Make sure that the area around the damage is
clean.
(2) Carefully examine the area around the damage. Do a coin tap test to find the extent of
Look specially for disbonding between the inner any disbonding or delamination.
laminate layers and the foam core.
(3) Remove exterior laminate which is damaged or Refer to Figure 5.
has become disbonded from the foam core. The
edge of the laminate must bond to the foam core.
(4) Remove the damaged foam core. Remove sufficient foam core to give a
minimum of a 20 mm (0.8 in) edge
around the outside of the damaged
area. Refer to Figure 4.
(5) Scarf the edges of the external laminate repair Refer to Table 2 for data about the scarf
area with a grinding disk or block. size.
WARNING: DO NOT GET ACETONE ON YOUR SKIN. ACETONE CAN CAUSE
SKIN DISEASE.
WARNING: DO NOT BREATHE ACETONE FUMES. ACETONE FUMES CAN
CAUSE DISEASE.
CAUTION: THERE MUST BE NO GREASE OR DUST ON THE REPAIR AREA.
GREASE AND DUST PREVENT A GOOD BOND.
(6) Clean the area of the repair. Use acetone only if any grease or dirt
comes to the surface of the repair.
(7) Cut and shape a piece of foam core to replace Use a sharp knife to cut the foam.
the damaged foam core that you removed in
step 4.
(8) Prepare the layers of cloth that you will need to Refer to the lay-up drawing for the
laminate on the inner surface of the foam core. related structure for data about the cloth
type and orientation.
Doc # 6.02.15 Page 223
Rev. 2 51-20-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Detail Steps/Work Items Key Items/References
WARNING: DO NOT GET RESIN ON YOUR SKIN. RESIN CAN CAUSE SKIN
DISEASE.
WARNING: DO NOT GET RESINS, HARDENERS OR SOLVENTS IN YOUR
MOUTH OR IN YOUR EYES. THESE CHEMICALS CAN CAUSE
DISEASE.
(9) Prepare the foam core for inserting in the repair:
S Apply a thin coat of resin to the foam core.
S Apply a coat of thickened resin to the foam Refer to Paragraph 6.
core.
S Laminate the inner layers of cloth onto the Use one of the 2 methods given in
inner surface of the foam core. Make sure Paragraph 5.
that the fibers in the cloth point in the correct
direction.
(10) Apply a thin coat of resin to the area to be
repaired.
(11) Put the foam core and inner laminate into position
in the repair.
(12) Pre-cure the repair. Refer to Paragraph 7.
(13) Use a sanding disk or block to contour the foam Refer to Figure 5.
core to the correct shape.
(14) Clean the repair.
(15) Apply a coat of thickened resin to the foam core
of the repair.
(16) Apply a thin coat of resin to the scarfed edges of
the outer laminate of the repair.
(17) Repair the outer laminate. Use one of the 2 methods given in
Paragraph 5.
(18) Pre-cure the repair. Refer to Paragraph 7.
(19) Post-cure the repair. Refer to Paragraph 7.
Page 224 Doc # 6.02.15
15 Apr 2013 51-20-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Detail Steps/Work Items Key Items/References
(20) When the repair is fully post cured, remove any
peel ply and sand smooth the surface of the
repair.
(21) Contour the repair so that the final surface level Use 150 grit sanding paper.
of the repair is slightly lower than the original To allow for the paint coat.
surrounding area.
(22) Apply filler(s) and paint coat. Refer to Paragraph 8.
Doc # 6.02.15 Page 225
Rev. 2 51-20-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Intentionally left blank
Page 226 Doc # 6.02.15
15 Apr 2013 51-20-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Section 51-30
Materials
1. General
You must only use approved materials from approved sources to repair the DA 40 NG airplane.
Note: If the approved material for the repair work is not available please contact Diamond
Aircraft Industries for information about alternative materials.
2. Approved Materials
A. Resin System
Resin : L 285
Hardener : H 286
Mixture : 100 parts resin and 40 ± 2 parts hardener (by weight)
CAUTION: THE RESIN SYSTEM L940/ H286 IS A SELF EXTINGUISHING SYSTEM
AND IS APPROVED FOR COWLING PARTS ONLY.
Resin : L 940 (self extinguishing)
Hardener : H 286
Mixture : 100 parts resin and 21 ± 2 parts hardener (by weight)
Supplier : Hexion Speciality Chemicals Stuttgart GmbH
Am Ostkai 21/22
D-70327 Stuttgart, Germany
Phone : +49-711-323081
Fax : +49-711-3280041
Doc # 6.02.15 Page 1
Rev. 2 51-30-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
B. Glass Fiber Cloth
WLB No. Weave Weight per Interglas Type Porcher Type
Unit Area
(German
[g/m²]
Aviation
Standard)
8.4548.60 2/2 twill 163 92110 917
8.4551.60 2/2 twill 280 92125 3063
8.4554.60 2/2 twill 390 92140 1989
8.4520.6 UD 220 92145
8.4525.60 UD 425 92146
All cloth types consist of alkali free E-glass with I 550 or PT 55 finish and comply with LN 9169
(German aviation standard).
Supplier for Interglas fabric : Rudolf Usner GmbH
Am Ausferngenufer 4
A-5400 Hallein, Austria
Phone : +43-6245-81516
Fax : +43-6245-81516-40
Supplier for Porcher fabric : Porcher Industrietextilien GmbH
Holzgraben 13/15
D-52062 Aachen, Germany
Phone : +49-241-48225
Fax : +49-241-48229
Page 2 Doc # 6.02.15
15 Apr 2013 51-30-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
C. Carbon Fiber Cloth
WLB No. Weave Mass per Interglas Cramer Type SGL Type
Unit Area Type
(German
[g/m²]
Aviation
Standard)
8.3520.80 2/2 twill 200 98141 CCC 452
2/2 twill
with 220 CCC 459 Al
aluminum
fibers
Sigratex
UD tape 380
KDU 1034
The cloth complies with LN 9169 (German aviation standard).
Supplier for Interglas fabric : Rudolf Usner GmbH (see above)
Supplier for Cramer fabric : CCC C. Cramer & Co
Postfach 2163
D-48616 Heek-Nienborg, Germany
Phone : +49-2568-9315-34
Fax : +49-2568-9315-93
Supplier for SGL tape : SGL Technik GmbH
Wernen von Siemens-Str. 8
D-86405 Meitingen, Germany
Phone: +49-8271-832152
Fax: +49-8271-831427
Doc # 6.02.15 Page 3
Rev. 2 51-30-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
D. Peel Ply
Type : PA 20-63, compliant with LN 98690
Supplier : Strübel Vertriebs GbR
Herrlingerstr. 36/1
D-89081 Ulm, Germany
Phone : +49-731-388577-1, -2
Fax : +49-731-9387353
E. Sandwich Core Material
Type : PVC rigid foam Divinycell H 60
Thickness : 3 mm, 6 mm, 8 mm
Supplier : Conti Tech Kautschuk- und KunststoffvertriebsgesmbH
Industriestr. 31
A-2353 Guntramsdorf, Austria
Phone: +43-2236-49101-0
Fax: +43-2236-49101-49
Type : Airex C70.55, Airex C71.55
Manufacturer : Alcan
Supplier : Polychem HandelsgesmbH
Markt Allhau Nr. 463
A-7411 Markt Allhau, Austria
Phone: +43-3356-20444
Fax: +43-3356-20445
E-Mail: [email protected]
F. Fillers for Resin
(1) Cotton Flakes FB1/035
Supplier : Rudolf Usner GmbH (see above)
Page 4 Doc # 6.02.15
15 Apr 2013 51-30-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
(2) Silcell 300
Supplier : Joh. Klinglhuber & Söhne Handelsgesellschaft mbH
Wallgasse 21
A-1060 Vienna, Austria
Phone : +43-1-5974712-0
Fax : +43-1-5974712-16
(3) Aerosil 380
Supplier : Polychem HandelsgesmbH
Markt Allhau Nr. 463
A-7411 Markt Allhau, Austria
Phone : +43-3356-20444
Fax : +43-3356-20445
E-Mail : [email protected]
G. Exterior Paint
(1) Putty
(a)
Putty : Sikkens Polysoft
Manufacturer : Akzo Nobel
Supplier : Akzo Nobel Coatings GesmbH
Baudißg. 10
A-1110 Vienna, Austria
Phone : +43-1-7674488
Fax : +43-1-7674488-33
or (b)
Putty : ICI P551-1052
Manufacturer : ICI Paints, Berkshire, Great Britain
Supplier : ICI Autocolor der PPG (Austria) Handels GmbH
Rautenweg 15
A-1220 Vienna, Austria
Phone : +43-1-2562704-53
Fax : +43-1-2562700-47
Doc # 6.02.15 Page 5
Rev. 2 51-30-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
(2) HS Filler
Filler : HS Filler ICI P565-889
Manufacturer : ICI Paints, Berkshire, Great Britain
Supplier : ICI Autocolor (see above)
(3) Antistatic Filler
Antistatic filler : Durodur spray filler 2923-011P
Manufacturer : Morton International GmbH, Strullendorf, Germany
Supplier : Lorenz Industrielacke
Wiener Str. 22
A-3002 Purkersdorf, Austria
Phone : +43-2231-633499
Fax : +43-2231-61503
(4) Coating Paint
(a) Durodur
Coating paint : Durodur 3067-R916g; color: RAL 9016 (white) or DB 147 (white)
Manufacturer : Morton International GmbH, Strullendorf, Germany
Supplier : Lorenz Industrielacke (see above)
or
(b) ICI
Coating paint : ICI Turbo Plus P488-1111; color RAL 9016 (white) or DB 147 (white)
Manufacturer : ICI Paints, Berkshire, Great Britain
Supplier : ICI Autocolor
Bachstr. 75
A-5020 Salzburg, Austria
Phone : +43-662-643681
Fax : +43-662-643686
Page 6 Doc # 6.02.15
15 Apr 2013 51-30-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
H. Interior Paint
(1) Putty
(a)
Putty : Sikkens Polysoft
Manufacturer : Akzo Nobel
Supplier : Akzo Nobel Coatings GesmbH (see above)
or (b)
Putty : ICI P551-1052
Manufacturer : ICI Paints, Berkshire, Great Britain
Supplier : ICI Autocolor (see above)
(2) Coating Paint
Glare shield : Nuvovern DS 10/1 + Nuvovern ACR
Instr. panel cover : Nuvovern DS 10/1 + Nuvovern ACR
Other interior parts : Nuvovern DS 10/1
Manufacturer : Mäder Lacke AG, Killwangen, Switzerland
Supplier : Walter Mäder GmbH
Wiener Str. 99
A-2514 Traiskirchen, Austria
Phone : +43-2252-53038
Fax : +43-2252-52297
Doc # 6.02.15 Page 7
Rev. 2 51-30-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
I. Fire Retardant Paint
(1) Courtaulds
Fire retardant paint: Courtaulds Aerospace N 56582/T508 (white)
Finishing varnish : Courtaulds Aerospace 4232-0303
Hardener : Courtaulds Aerospace N 39/1327 (4:1)
Supplier : PRO-DeSoto Deutschland GmbH
Aerospace Coatings
Lauenburger Landstr. 11
D-21039 Börnsen, Germany
Phone : +49-40-742193-10
Fax : +49-40-742139-69
(2) Hensel
Fire retardant paint: Hensotherm 2 KS (white)
Coating paint : Hensotop 84 f
Supplier : Rudolf Hensel GmbH
Lack- und Farbenfabrik
Süderstraße 235
D-20537 Hamburg, Germany
Phone :+49-40-214093
Fax :+49-40-214783
J. Acrylic Glass Cement
Acrylic glass cement : Polymerization cement Acrifix 92
Manufacturer : Röhm, Darmstadt, Germany
Supplier : Röhm Austria GmbH (see above)
Page 8 Doc # 6.02.15
15 Apr 2013 51-30-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Section 51-40
Fasteners
1. General
This Section tells you about the fasteners used to attach panels and cowlings.
2. Description
The DA 40 NG has two main types of fastener. It has quick release cam-lock fasteners for panels
which you remove often, for example, engine cowling, and screws for all the other access panels.
Figure 1 shows the quick-release cam-lock fastener. The fastener has three parts, a receptacle with
a cam track, a grommet and a stud. Rivets attach the receptacle to the airplane structure. A spring ring
attaches the stud assembly to the access panel and a compression spring holds the stud in the stud
assembly.
The T-shaped end of the stud locates in a slot in the receptacle. When you turn the stud clockwise
through 90° it engages the cam track in the receptacle and pulls the access panel into position. When
the stud is turned fully 90° clockwise the T-shaped end of the stud engages a small detent in the cam
track. The compression spring in the stud assembly holds the stud in position in the detent.
There are different length studs. Short studs for thin panels and longer studs for thicker panels. Not
all airplanes have the same length studs in the same position. This is because composite components
can vary in thickness.
If you replace a fastener, make sure that the new fastener has the correct length stud.
Doc # 6.02.15 Page 1
Rev. 2 51-40-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Receptacle
Airplane Structure
Spring Ring Access Panel
Rivet
Grommet
Stud
Figure 1: Quick Release Fastener
Page 2 Doc # 6.02.15
15 Apr 2013 51-40-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Maintenance Practices
1. General
This Section tells you how to replace a quick release fastener stud in an access panel.
2. Replace a Quick Release Fastener Stud
A. Equipment
Item Quantity Part Number
Stud pliers. 1 Camloc 4 P 3.
B. Procedure
Detail Steps/Work Items Key Items/References
(1) Remove the damaged stud assembly: If fitted.
S Turn the stud 90° counter-clockwise to
release it from the receptacle.
S Place the U-jaw of the Camloc pliers under Refer to Figure 1.
the rim of the stud assembly.
S Compress the stud assembly and remove it Turn the stud assembly approximately
from the grommet. 30° off axis.
(2) Install the new stud assembly:
S Select the correct length stud assembly.
S Put the stud assembly into the U-jaw of the
Camloc pliers.
S Compress the stud assembly with the Camloc Turn the stud assembly approximately
pliers and install into the grommet. 30° off axis.
S Engage the stud in the receptacle and turn
90° clockwise to lock the stud.
Doc # 6.02.15 Page 201
Rev. 2 51-40-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Intentionally left blank
Page 202 Doc # 6.02.15
15 Apr 2013 51-40-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Section 51-60
Control Surface Balancing
1. General
This Section tells you how to weigh and measure the residual moment of the control surfaces.
WARNING: YOU MUST WEIGH AND BALANCE A CONTROL SURFACE AFTER ANY WORK
WHICH COULD AFFECT ITS WEIGHT OR ITS BALANCE. OUT OF BALANCE
CONTROL SURFACES CAN FLUTTER AND CAUSE STRUCTURAL FAILURE.
Correct control surface balance is critical to flight safety. You must remove a control surface to weigh
and balance it after:
) Any repair to the control surface.
) Painting the control surface.
) Any report of control vibration or flutter in flight.
You can use any convenient method to weigh a control surface. If you use anything to connect the control
surface to the weighing device, (for example, a sling) you must weigh it separately. Then subtract its weight
from the total value. For example, you use a rope sling to lift an aileron with a spring balance:
% ) Weight of the aileron and the rope sling = 3.8 kg (8.3 lb)
% ) Weight of the rope sling = 0.7 kg (1.5 lb)
% ) Weight of the aileron = 3.8 kg (8.3 lb) - 0.7 kg (1.5 lb) = 3.1 kg (6.8 lb)
When you balance a control surface, the pivot angle of the control must be as shown in the Weights
and Residual Moments Report.
We recommend that for balancing the flaps, aileron, elevator and elevator trim tab, you put a suitable
size rod through the hinge bearings. Support the rod at two points to keep it horizontal.
To balance the rudder it must be supported at the top pivot pin and the bottom mounting bracket. The
center line of the rudder must be horizontal.
Doc # 6.02.15 Page 1
Rev. 2 51-60-00 15 Apr 2013
Aileron Wing Flap
Page 2
Rudder Elevator Trim Tab
LH RH LH RH
Structures
15 Apr 2013
nominal 3.5 to 4.4 kg 5.7 to 6.9 kg 0.28 to 0.39 kg 2.6 to 3.15 kg 4.0 to 4.8 kg
(7.72 to 9.7 lb) (12.57 to 15.21 lb) (0.617 to 0.860 lb) (5.73 to 6.94 lb) (8.82 to 10.58 lb)
weight
incl. BW
actual
Standard Practices and
balancing Center:
weight
LH: RH:
[kg] or [lb]
51-60-00
r
nominal 35.6 to 45.8 kg.cm -5.0 to 0.0 kg.cm 1.0 to 1.5 kg.cm -5.1 to -2.0 kg.cm 23.4 to 31.1 kg.cm
(30.9 to 39.75 in.lb) (-4.34 to 0.00 in.lb) (0.868 to 1.302 in.lb) (-4.43 to -1.74 in.lb) (20.31 to 26.99 in.lb)
AIRCRAFT
residual
moment
actual
center line horizontal center line horizontal center line horizontal upper surface horizontal upper surface horizontal
M=P*r
P ...[kg] or [lb]
Figure 1: Weights and Residual Moments Report
P P P P P
r ...[cm] or [in] r r r r r
Calculation. M = P * r Where M is the residual moment, r (cm or inches) is the distance between the hinge line
and the point where the force P (kg or lb) acts.
Notes. Positive moments are tail heavy, negative moments are nose heavy.
Rudder - weight and residual moment include lower hinge and trim plate.
Elevator - weight and residual moment include trim tab, horn, and trim tab control rods.
Rev. 2
DA 40 NG AMM
Doc # 6.02.15
Aileron - weight and residual moment include horn, trim plate and hinges.
Wing flaps - Weight and residual moment include horn and hinges.
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Refer to Figure 1 for the weight and residual moment for the DA 40 NG.
Use any suitable method to support the rudder horizontally at the pivot axis.
The rudder must be able to rotate freely around the pivot axis.
Remove the stop bolts from the lower mounting bracket before weighing and balancing.
The residual moment is tail heavy.
Spring
Balance
Mass Balance Moment Arm
Weights
Horizontal
Tape
Pivot Axis
Lower Mounting Bracket
Lower Mounting Bracket
Without Stop Bolts.
Top Pivot
Pivot Axis
Moment
Arm
Figure 2: Rudder Static Balance
Doc # 6.02.15 Page 3
Rev. 2 51-60-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Use any suitable method to support the elevator horizontally at the pivot axis.
The elevator must be able to rotate freely around the pivot axis.
The balance includes the trim tab, trim tab control rod and horn.
Spring Balance
Tape
Horizontal
Pivot Axis
Moment Arm
Balance Weight Balance Weight
Balance Weight Pivot Axis
Figure 3: Elevator Static Balance
Page 4 Doc # 6.02.15
15 Apr 2013 51-60-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Refer to Figure 1 for the weight and residual moment for the DA 40 NG.
Use any suitable method to support the trim tab horizontally at the pivot axis.
The trim tab must be able to rotate freely around the pivot axis.
The residual moment is tail heavy.
Spring
Balance
Tape
Horizontal
Pivot Axis
Moment Arm
Pivot Axis
Moment Arm
Figure 4: Trim Tab Static Balance
Doc # 6.02.15 Page 5
Rev. 2 51-60-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Refer to Figure 1 for the weight and residual moment for the DA 40 NG.
Use any suitable method to support the aileron horizontally at the pivot axis.
The aileron must be able to rotate freely around the pivot axis.
The balance includes the horn, trim plate and hinges.
Moment Arm
Horizontal
Mass Balance Tape
Spring
Balance
Pivot Axis
Mass Balance Weight
Pivot
Axis
Moment
Arm
Figure 5: Aileron Static Balance
Page 6 Doc # 6.02.15
15 Apr 2013 51-60-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Refer to Figure 1 for the weight and residual moment for the DA 40 NG.
Use any suitable method to support the wing flap horizontally at the pivot axis.
The wing flap must be able to rotate freely around the pivot axis.
The balance includes the horn and hinges.
The residual moment is tail heavy.
Spring
Balance
Moment Arm
Horizontal
Pivot
Mass Balance Weight Axis
Mass Balance Weight
Pivot Axis
Moment Arm
Figure 6: Wing Flap Static Balance
Doc # 6.02.15 Page 7
Rev. 2 51-60-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Intentionally left blank
Page 8 Doc # 6.02.15
15 Apr 2013 51-60-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Section 51-80
Electrical Bonding
1. General
The bonding system gives the airplane good lightning protection. A special bonding system is
necessary for the composite structure of the DA 40 NG. Without this special system, the composite
structure would not sufficiently conduct electricity.
Refer to Section 23-60 for details about the static discharge wicks.
2. Description
Figure 1 shows a simplified bonding system schematic.
The lightning conductor system is the main part of the bonding system. High capacity aluminum alloy
tubes and strips make the lightning conductor system.
The lightning conductor system has a longitudinal branch and a lateral branch. The longitudinal branch
runs from the engine block via engine truss, firewall, cabin, aft fuselage and empennage to the
elevator. The horizontal branch connects the left wing tip with the right wing tip. It is connected with
the longitudinal branch at the cabin floor under the forward seats.
Metal braiding and strips connect all conductive components (for example: wing skin, fuel tanks,
control systems, landing gear, engine, etc.) and antenna ground plates to the lightning conductor
system.
Doc # 6.02.15 Page 1
Rev. 2 51-80-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
Figure 1: Airplane Lightning Protection and Bonding System Schematic
Page 2 Doc # 6.02.15
15 Apr 2013 51-80-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
The following design features also give lightning protection:
) The aluminum tubes of the lightning conductor system are also used as conduits for electric wires.
) Carbon fiber material is used for the lower wing skin and parts of the fuselage skin, canopy frame
and rear door frame. Carbon fiber material is conductive.
) Carbon fiber material with interwoven aluminum fibers is used for the upper wing skin and the
engine cowling. Carbon fiber material with interwoven aluminum fibers is conductive.
) The forward wing spar separates the lightning conductor system from the fuel tanks.
) A lightning conductor strip is integrated in the horizontal stabilizer.
) The tail skid has an aluminum bar on the lower edge.
) The propeller is non-conductive (except for the erosion sheath), therefore currents cannot flow in
structural parts of the propeller.
Doc # 6.02.15 Page 3
Rev. 2 51-80-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 51-80-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Maintenance Practices
1. General
This Section tells you how to do a test of the electrical bonding system.
2. Test the Electrical Bonding System
The resistance measurements on the DA 40 NG are divided into three categories:
) Very low resistance measurements for conduits in the direct lightning path and electrical power
grounds.
) Low resistance measurements for bondings of controls.
) High resistance measurements for the static discharge wicks.
Do the low resistance bonding measurements with a milliohmmeter and Kelvin probes. The test current
must be approximately 2 amps.
Do the high resistance measurements with a high voltage megaohmmeter (250 V). Measure the static
discharge wicks and the precautions against static charge of the airplane.
All measurements are referenced to the negative pole connection of the battery, except where noted.
The airplane must be in a serviceable condition during the tests, except that the engine cowlings must
be removed.
A. Very Low Resistance Measurements
Max.
Measured
Item Attachment Point Allowable Passed
[mΩ]
[mΩ]
ENGINE COMPARTMENT
Firewall 4.0
Engine propeller bearing, front 5.0
Heating cooler case 6.0
Oil cooler case 6.0
Water cooler case 6.0
Inter cooler case 6.0
Front landing gear tube 10.0
Engine breather tube 6.0
Engine to firewall engine block - firewall 3.0
Doc # 6.02.15 Page 201
Rev. 2 51-80-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
Max.
Measured
Item Attachment Point Allowable Passed
[mΩ]
[mΩ]
FUSELAGE
COMPONENTS
External power connector outer large pin 3.0
Instrument panel above co-pilot's left knee 3.0
Remote avionic box case 4.0
(if installed)
Relay box sheet metal 4.0
FUEL SYSTEM
Fuel gascolator case 15.0
Fuel pumps bracket 15.0
Fuel transfer pump case 15.0
Fuel drain protector sheet metal 15.0
EXTERNAL CONDUCTIVE
PARTS
LH step grounding point 5.0
RH step grounding point 5.0
OAT sensor 5.0
Main LDG gear LH lower bend, inner side 10.0
Main LDG gear RH lower bend, inner side 10.0
Flap asymmetrical tube LH bond. strap connection 10.0
Flap asymmetrical tube RH bond. strap connection 10.0
ANTENNAS
Top COM antenna mounting screw 6.0
Bottom COM antenna mounting screw 6.0
(if installed)
GPS antennas(s) mounting screw 6.0
% Top TAS antenna mounting screw 6.0
% (if installed)
% Bottom TAS antenna mounting screw 8.0
% (if installed)
Page 202 Doc # 6.02.15
15 Apr 2013 51-80-00 Rev. 2
Standard Practices and
DA 40 NG AMM
AIRCRAFT Structures
Max.
Measured
Item Attachment Point Allowable Passed
[mΩ]
[mΩ]
STABILIZER
Vert. lightning prot. tube upper end 7.0
Hor. stab LH lightning strap tip 15.0
Hor. stab RH lightning strap tip 15.0
Grind spur aluminum strap 15.0
Rudder hinge rudder side 10.0
Vert. stabilizer fairing FWD LH side screw 12.0
Vert. stabilizer fairing FWD RH side screw 12.0
Horizontal stabilizer front bracket 10.0
Horizontal stabilizer rear bracket 10.0
LH WING
Fuel tank drain drain 5.0
Tank refill ring 5.0
Tank vent plate 10.0
Pitot tube base tube base 6.0
Landing/taxi light bracket (screws) 10.0
Tip light assy base plate 8.0
Aileron pushrod attachment bracket, aileron 50.0
Flap pushrod attachment bracket, flap 50.0
RH WING
Fuel tank drain drain 5.0
Tank refill ring 5.0
Tank vent plate 10.0
Tip light assy base plate 8.0
Aileron pushrod attachment bracket, aileron 50.0
Flap pushrod attachment bracket, flap 50.0
Doc # 6.02.15 Page 203
Rev. 2 51-80-00 15 Apr 2013
Standard Practices and
DA 40 NG AMM
Structures AIRCRAFT
B. Low Resistance Measurements
Max.
Measured
Item Attachment Point Allowable Passed
[mΩ]
[mΩ]
Pilot stick tube 50.0
Co-pilot stick tube 50.0
Trim wheel assy frame 10.0
Levers frame 50.0
Pilot pedal assy 150.0
Co-pilot pedal assy 150.0
Canopy hinge LH tube tip 100.0
Canopy hinge RH tube tip 100.0
C. High Resistance Measurements
Use a wet sponge to obtain a constant electrical connection to the static dischargers.
Max.
Measured
Item Attachment point Allowable Passed
[MΩ]
[MΩ]
STATIC WICKS
LH wing 100.0
RH wing 100.0
Rudder 100.0
Horizontal stabilizer LH 100.0
Horizontal stabilizer RH 100.0
TIRES
Nose 100.0
LH 100.0
RH 100.0
Page 204 Doc # 6.02.15
15 Apr 2013 51-80-00 Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
CHAPTER 52
DOORS
Doc # 6.02.15 Page 1
Rev. 2 52-TITLE 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 52-TITLE Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 52
DOORS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 52-10
Canopy and Passenger Door
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Canopy Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Passenger Door Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Gas Spring Strut for the Canopy . . . . . . . . . . . . . . . . . . . . . 203
4. Remove/Install the Passenger Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5. Remove/Install the Gas Spring Strut for the Door . . . . . . . . . . . . . . . . . . . . . . . . 206
6. Test the Door Unlocked Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
7. Examine the Carbon Hinges on the Passenger Door . . . . . . . . . . . . . . . . . . . . . 208
8. Inspection of the Door Locking and Safety Hook Mechanisms . . . . . . . . . . . . . 212
Section 52-40
Access Panels
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Doc # 6.02.15 Page 1
Rev. 2 52-CONTENTS 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 52-CONTENTS Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
CHAPTER 52
DOORS
1. General
The DA 40 NG has two types of doors. Section 52-10 tells you about the canopy and the passenger
access door. Section 52-40 tells you about the maintenance access panels.
2. Description
The canopy is a CFRP molding with inner and outer frames. The frames bond together. The canopy
has a large one-piece acrylic glass window. The window has an emergency window on the left side.
Some airplanes also have an emergency window on the right side. You can open the emergency
windows in flight. Refer to Chapter 56 for data about the window.
The canopy attaches to a tubular steel frame at the front. The frame attaches to two hinges on the rear
face of the firewall. The canopy moves up and forward to open.
A handle on the left of the canopy operates two locking bolts. The indoor and outdoor handles are red.
The locking bolts are at the bottom rear corners of the canopy.
The passenger door is a CFRP molding with inner and outer frames. The frames bond together. The
door has a acrylic glass window.
Two hinges attach the door to the top of the fuselage near the center-line. A gas strut attaches to the
rear of the door and the fuselage. The gas strut holds the door open.
A handle on the left of the door operates two locking bolts. The locking bolts are at the bottom front
and rear corners of the door.
The DA 40 NG has a small number of access panels. Panels which must be used often (for example
the oil filler panel) have quick-release fasteners. Other panels have the usual screws.
Doc # 6.02.15 Page 1
Rev. 2 52-00-00 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 52-00-00 Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
Section 52-10
Canopy and Passenger Door
1. General
This Section tells you about the structure, operation and maintenance of the canopy and the
passenger door. Refer to Chapter 56 for data about the windows in the canopy and door.
Doc # 6.02.15 Page 1
Rev. 2 52-10-00 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
Canopy Frame
Hinges To
Firewall
Hinge Frame
Gas Spring Strut
Hinge Frame
Figure 1: Canopy Installation
Page 2 Doc # 6.02.15
15 Apr 2013 52-10-00 Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
2. Canopy Description and Operation
Figure 1 shows the canopy installation.
A. Canopy Description
The canopy is a CFRP molding with inner and outer frames. The frames bond together with
thickened resin. Each part of the frame has layers of carbon cloth and one layer of glass cloth.
Areas of high stress have extra layers of carbon cloth. Mounting bushes for the handle and locking
bolts bond to the inside of the frame with thickened resin.
The canopy has a large one-piece acrylic glass window. A special flexible adhesive bonds the
window to the canopy frame. A flexible filler seals the small gap between the edge of the window
and the frame.
The window has a an emergency window on the left side. Some airplanes also have an emergency
window on the right side. You can open the emergency windows in flight. Refer to Chapter 56 for
data about the window.
B. Canopy Hinge Frame
The canopy attaches to a tubular steel frame at the front (the hinge frame). The frame attaches to
two hinges on the rear face of the firewall. A gas spring strut attaches to the hinge frame and the
bottom of the firewall. The canopy moves up and forward to open. The gas spring strut holds the
canopy open. A door unlocked warning light (DOOR OPEN or DOORS) on the G1000 or the
annunciator panel operates when the canopy is unlocked.
C. Canopy Attachment
The canopy has two attachment plates on the front edge of the canopy hinge frame. Two bolts
attach each plate to the canopy frame. You can remove the canopy by removing these four bolts.
Doc # 6.02.15 Page 3
Rev. 2 52-10-00 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
D. Canopy Locking Mechanism
(1) MÄM 40-139 Not Implemented
Figure 2 shows the canopy locking mechanism.
A handle on the left of the canopy operates two locking bolts. The handle has a spring assisted
over-center lock which holds the handle in the closed position. The locking bolts are at the
bottom rear corners of the canopy.
The handle has two parts. The inner handle has a double lever. The outer handle is red and
attaches to the inner handle with two roll pins. A connecting rod attaches to the rear of the
double lever. The other end of the connecting rod attaches to the inside of the left locking bolt.
A teleflex cable attaches to the front of the double lever. The teleflex cable goes inside the front
of the canopy frame to the right locking bolt. If you pull the canopy handle away from the canopy
frame, these things happen:
The double lever turns to pull the connecting rod and the teleflex cable.
The connecting rod pulls the left locking bolt forward. The forward movement of the locking bolt
operates the door unlocked warning micro-switch in the left side fuselage shell.
The teleflex cable pulls the right locking bolt forward. The forward movement of the locking bolt
operates the door unlocked warning micro-switch in the right side fuselage shell.
The canopy can be pushed up and forward to open.
With the canopy fully closed, push the canopy handle towards the canopy frame. This engages
the locking bolts in the fuselage holes. The spring assisted over-center lock holds the handle
in the closed position. The left locking bolt operates the micro-switch for the door unlocked
warning light (DOOR OPEN or DOORS). When the handle is flush with the canopy frame, the
canopy is locked. Push up on the rear of the canopy frame to make sure that it is locked.
Page 4 Doc # 6.02.15
15 Apr 2013 52-10-00 Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
(2) MÄM 40-139 Implemented
Figure 3 shows the canopy locking mechanism when the design change MÄM 40-139 is
implemented.
A handle on the left of the canopy operates two locking bolts. The handle has a spring assisted
over-center lock which holds the handle in the closed position. The locking bolts are at the
bottom rear corners of the canopy.
The handle has two parts. The inner handle is red and has a double lever. The outer handle is
red and attaches to the inner handle with a roll pin. A connecting rod attaches to the rear of the
double lever. The other end of the connecting rod attaches to the inside of the left locking bolt.
A teleflex cable attaches to the front of the double lever. The teleflex cable goes inside the front
of the canopy frame to the right locking bolt. It can be removed for servicing. If you pull the
canopy handle away from the canopy frame, these things happen:
The double lever turns to pull the connecting rod and the teleflex cable.
The connecting rod pulls the left locking bolt forward. The forward movement of the locking bolt
operates the door unlocked warning micro-switch in the left side fuselage shell.
The teleflex cable pulls the right locking bolt forward. The forward movement of the locking bolt
operates the door unlocked warning micro-switch in the right side fuselage shell.
The canopy can be pushed up and forward to open.
With the canopy fully closed, push the canopy handle towards the canopy frame. This engages
the locking bolts in the fuselage holes. The spring assisted over-center lock holds the handle
in the closed position. The left locking bolt operates the micro-switch for the door unlocked
warning light (DOOR OPEN or DOORS). When the handle is flush with the canopy frame, the
canopy is locked. Push up on the rear of the canopy frame to make sure that it is locked.
Doc # 6.02.15 Page 5
Rev. 2 52-10-00 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
Figure 2: Canopy Locking Mechanism (MÄM 40-139 not implemented)
Page 6 Doc # 6.02.15
15 Apr 2013 52-10-00 Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
Locking Bolt, RH
Grub Screw Canopy Frame
Blanking Plug
Locking Bolt, LH
Teleflex Cable to Connecting Rod to
Right Locking Bolt Left Locking Bolt
Canopy
Fuselage
Handle
Shell
Inner Canopy Handle PTFE
Fork Connecting Block
End-Fitting Rod
Countersunk Screw
with Internal Hex. Head
Canopy Frame
Teleflex
Cable Locking Bolt
Lock Plate
PTFE Bush
To Right
Locking Bolt
Canopy Frame
Lock Tab Outer Canopy Handle
Lock Assy
Figure 3: Canopy Locking Mechanism (MÄM 40-139 implemented)
Doc # 6.02.15 Page 7
Rev. 2 52-10-00 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
3. Passenger Door Description and Operation
A. MÄM 40-139 Not Implemented
Figure 4 shows the passenger door installation and locking mechanism.
The passenger door is a CFRP molding with inner and outer frames. The frames bond together with
thickened resin. Each part of the frame has layers of carbon cloth and one layer of glass cloth.
Areas of high stress have extra layers of carbon cloth. Mounting bushes for the handle and locking
bolts bond to the inside of the frame with thickened resin.
The door has a acrylic glass window. A special flexible adhesive bonds the window to the door
frame. A flexible filler seals the small gap between the edge of the window and the frame.
Two hinges attach the door to the top of the fuselage near the center-line. The hinges bolt to the
door frame. The front hinge can be removed from inside of the cabin in an emergency. With the
front hinge removed, the passenger door can be forced open from the top. A gas strut attaches to
a bracket at the rear of the door and to the fuselage. The gas strut holds the door open. A door
unlocked warning light (DOOR OPEN or DOORS) on the G1000 or on the annunciator panel
operates when the door is unlocked.
A handle on the left of the door operates two locking bolts. The locking bolts are at the bottom front
and rear corners of the door.
The handle has two parts. The inner handle is black and has a double lever. The outer handle is
red and attaches to the inner handle with two roll pins. A long connecting rod attaches to the rear
of the double lever. The other end of the long connecting rod attaches to the inside of the rear
locking bolt. A safety lock is fitted to prevent accidental movement of the handle.
You must lift the safety handle before you can operate the handle from inside the passenger
compartment. To operate the red handle from the outside you must push the button next to the red
handle to lift the inner safety lock.
A short connecting rod attaches to the front of the double lever. The short connecting rod goes to
the front locking bolt. If you pull the canopy handle away from the canopy frame, these things
happen:
) The double lever turns to pull the both of the connecting rods.
) The long connecting rod pulls the rear locking bolt forward.
) The short connecting bolt pulls the front locking bolt aft. The aft movement of the locking bolt
operates a micro switch for the door unlocked warning light (DOOR OPEN or DOORS) located
on the G1000 or on the annunciator panel.
Page 8 Doc # 6.02.15
15 Apr 2013 52-10-00 Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
The door can be pushed up and out to open. With the door fully closed, push the door handle
towards the door frame. This engages the locking bolts in the fuselage holes. The forward locking
bolt operates the door unlocked micro switch. When the handle is flush with the door frame, the
door is locked. Push outwards on the bottom of the door frame to make sure that it is locked.
B. MÄM 40-139 Implemented
Figure 5 shows the passenger door installation and locking mechanism when the design change
MÄM 40-139 is implemented.
The passenger door is a CFRP molding with inner and outer frames. The frames bond together with
thickened resin. Each part of the frame has layers of carbon cloth and one layer of glass cloth.
Areas of high stress have extra layers of carbon cloth. Mounting bushes for the locking bolts bond
to the inside of the frame with thickened resin.
The door has an acrylic glass window. A special flexible adhesive bonds the window to the door
frame. A flexible filler seals the small gap between the edge of the window and the frame.
Two hinges attach the door to the top of the fuselage near the center-line. The hinges bolt to the
door frame. The front hinge can be removed from inside of the cabin in an emergency. With the
front hinge removed, the passenger door can be forced open from the top. A gas strut attaches to
a bracket at the rear of the door and to the fuselage. The gas strut holds the door open. A door
unlocked warning light (DOOR OPEN or DOORS) on the G1000 or on the annunciator panel
operates when the door is unlocked.
A handle on the left of the door operates two locking bolts. The locking bolts are at the bottom front
and rear corners of the door.
The handle has two parts. The inner handle is red and has a double lever. The outer handle is red
and attaches to the inner handle with two roll pins. A long connecting rod attaches to the rear of the
double lever. The other end of the long connecting rod attaches to the inside of the rear locking
bolt. A safety lock is fitted to prevent accidental movement of the handle.
You must lift the safety handle before you can operate the red handle from inside the passenger
compartment. To operate the red handle from the outside you must push the button next to the red
handle to lift the inner safety lock.
Doc # 6.02.15 Page 9
Rev. 2 52-10-00 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
A short connecting rod attaches to the front of the double lever. The short connecting rod goes to
the front locking bolt. If you pull the canopy handle away from the canopy frame, these things
happen:
) The double lever turns to pull the both of the connecting rods.
) The long connecting rod pulls the rear locking bolt forward.
) The short connecting bolt pulls the front locking bolt aft. The aft movement of the locking bolt
operates a micro switch for the door unlocked warning light (DOOR OPEN or DOORS) located
on the G1000 or on the annunciator panel.
The door can be pushed up and out to open.
With the door fully closed, push the door handle towards the door frame. This engages the locking
bolts in the fuselage holes. The forward locking bolt operates the door unlocked micro switch.
When the handle is flush with the door frame, the door is locked. Push outwards on the bottom of
the door frame to make sure that it is locked.
Page 10 Doc # 6.02.15
15 Apr 2013 52-10-00 Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
Hinges
Gas Spring Strut
Rear Locking Bolt
Passenger Door
Door Handle
Front Locking Bolt Child Safety Lock
Door-Closed Switch
Locking Clip Fuselage Shell
Long PTFE Block
Inner Fork Connecting Rod
Door Handle End-Fitting
Door Frame
Short
Connecting Rod Rear
Locking Bolt
PTFE Bush
Door Frame
Locking Clip
Front Fork Outer Door
Locking Bolt End-Fitting Handle
PTFE Bush Door-Handle
Spring
Door-Closed Microswitch
Figure 4: Passenger Door (MÄM 40-139 not implemented)
Doc # 6.02.15 Page 11
Rev. 2 52-10-00 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
Hinges
Gas Spring Strut
Rear Locking Bolt
Passenger Door
Door Handle
Front Locking Bolt Child Safety Lock
Door-Closed Switch
Fuselage Shell
Fork End-Fitting
Inner PTFE Block
Countersunk Screw Long Connecting Rod
Door Handle
with Internal Hex. Head
Door Frame
Short Connecting Rod
Locking Bolt
PTFE Bush
Locking Clip Door Frame
PTFE Bush Outer Door Handle Lock Plate
Fork End-Fitting
Front Locking Bolt
Lock Tab
Door-Closed Microswitch Lock Assy
Figure 5: Passenger Door (MÄM 40-139 implemented)
Page 12 Doc # 6.02.15
15 Apr 2013 52-10-00 Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
Trouble-Shooting
1. General
This table below lists the defects you could have with the canopy and passenger door. If you have the
trouble detailed in the Trouble column, read across to the Possible Cause column. Then do the repair
in the Repair column.
Trouble Possible Cause Repair
Canopy/door is difficult to Canopy/door frame damaged. Replace the canopy/door.
move.
Canopy/door hinges damaged. Replace the damaged parts.
Gas spring strut defective. Replace the gas spring strut.
Canopy/door handle is difficult Locking bolts damaged. Replace the damaged bolt.
to move.
Handle bushes damaged. Replace the canopy/door.
Canopy handle is difficult to Teleflex cable defective. Replace the teleflex cable.
move.
Incorrect operation of door Canopy/door micro-switch Adjust canopy/door micro
unlocked warning on the incorrectly adjusted. switch.
annunciator panel.
Canopy/door micro-switch Replace defective micro
defective. switch.
Defective wiring. Do a continuity test of the
wiring. Refer to Chapter 92 for
the wiring diagrams.
Red button operating the Poor lubrication. Lubricate.
safety hook mechanism is Refer to Section 12-20.
stuck in pushed position.
Doc # 6.02.15 Page 101
Rev. 2 52-10-00 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 52-10-00 Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to install and remove the canopy and passenger door. They
also tell you how to test and adjust the locking mechanism. The standard remove/install procedure is
valid for the standard canopy.
2. Remove/Install the Canopy
A. Remove the Canopy
Detail Steps/Work Items Key Items/References
(1) Open the canopy: Refer to Figure 2.
S Pull the canopy handle away from the canopy
frame.
S Lift the canopy open.
(2) Remove the four nuts, washers and bolts which Refer to Figure 1.
attach the canopy to the hinge frame bracket.
Hold the canopy!
(3) Disconnect the plug for the flood light.
(4) Lift the canopy clear of the airplane. Two persons needed.
Doc # 6.02.15 Page 201
Rev. 2 52-10-00 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
B. Install the Canopy
Detail Steps/Work Items Key Items/References
(1) Lift the canopy into position on the airplane. Two persons needed.
(2) Engage the tapered ends of the hinge frame in Refer to Figure 2.
the tubular brackets on the canopy frame.
(3) Install the four bolts, washers and nuts which
attach the canopy to the hinge frame bracket.
(4) Connect the plug for the flood light.
(5) Close the canopy.
(6) Operate the canopy lock: When the canopy is locked, the canopy
handle must be flush with the canopy
frame.
S Hold the canopy closed.
S Push the canopy handle towards the canopy
frame.
S Push up on the rear of the canopy frame. To make sure that the canopy is locked.
(7) Do a test for correct operation of the door Refer to Paragraph 6.
unlocked warning light (DOOR OPEN or
DOORS).
Page 202 Doc # 6.02.15
15 Apr 2013 52-10-00 Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
3. Remove/Install the Gas Spring Strut for the Canopy
A. Remove the Gas Spring Strut for the Canopy
Detail Steps/Work Items Key Items/References
(1) Remove the canopy. Refer to Paragraph 2.
(2) Remove the nut and washer that attach the strut Refer to Figure 1.
to the hinge frame.
WARNING: MAKE SURE THAT THE STRUT IS FULLY EXTENDED BEFORE YOU
DISCONNECT IT FROM THE HINGE FRAME.
(3) Pull the top of the strut away from the hinge Catch the bush and second washer.
frame.
(4) Remove these items that attach the bottom of the
strut:
S Nut, washer and bolt.
S Bush.
S Two polyamide spacers.
(5) Remove the strut from the airplane.
B. Install the Gas Spring Strut for the Canopy
Detail Steps/Work Items Key Items/References
(1) Put the strut in position in the airplane. The cylinder goes to the top.
(2) Install the bolt, washer and self-locking nut at the Torque: 6.4 Nm (4.7 lbf.ft.).
bottom attachment to the firewall. Use a new self-locking nut.
(3) Put the washer and bush in position on the hinge
frame.
(4) Move the top eye-end of the strut over the bush
on the hinge frame.
(5) Install the washer and self-locking nut to the Torque: 6.4 Nm (4.7 lbf.ft.).
hinge frame. Use a new self-locking nut.
(6) Install the canopy. Refer to Paragraph 2.
Doc # 6.02.15 Page 203
Rev. 2 52-10-00 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
4. Remove/Install the Passenger Door
A. Remove the Passenger Door
Detail Steps/Work Items Key Items/References
(1) Open the passenger door: Refer to Figure 4 and 5.
S Push and hold the safety button next to the
door handle.
S Pull the door handle away from the door
frame.
S Lift the door open.
(2) Remove the gas strut: Hold the door!
S Remove the locking clips from the gas strut
top and bottom ball-end fittings.
S Pull the gas strut off the ball end fittings on
the fuselage and clear of the airplane.
(3) Remove the passenger reading light assembly For access to the front door hinge.
from the top of the cockpit. Refer to Section 33-10.
(4) Remove the bolts and washers which attach the Hold the door!
front and rear door hinges to the fuselage.
(5) Lift the door clear of the airplane.
Page 204 Doc # 6.02.15
15 Apr 2013 52-10-00 Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
B. Install the Passenger Door
Detail Steps/Work Items Key Items/References
(1) Put the door in position in the fuselage.
(2) Install the bolts and washers which attach the
front and rear door hinges to the fuselage.
(3) Install the passenger reading light assembly. Refer to Section 33-10.
(4) Install the gas strut:
S Push the gas strut ball end fittings onto the
fuselage gas strut mounts.
S Install the locking clips which lock the ball end
fittings in place.
(5) Close the door.
(6) Operate the door lock: When the door is locked, the door
handle must be flush with the door
S Hold the door closed.
frame.
S Press the safety button next to the door
handle and push the door handle towards the
door frame.
S Push outwards on the bottom of the door
frame.
(7) Do a test for correct operation of the door Refer to Paragraph 6.
unlocked warning light (DOOR OPEN or
DOORS).
Doc # 6.02.15 Page 205
Rev. 2 52-10-00 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
5. Remove/Install the Gas Spring Strut for the Door
A. Remove the Gas Spring Strut for the Door
Detail Steps/Work Items Key Items/References
(1) Open the passenger door: Refer to Figure 4 and 5.
S Push and hold the button next to the door
handle.
S Pull the door handle away from the door
frame.
S Lift the door open.
(2) Remove the gas strut: Hold the door!
S Remove the locking clips from the gas strut
top and bottom ball-end fittings.
S Pull the gas strut off the ball end fittings on
the fuselage and clear of the airplane.
B. Install the Gas Spring Strut for the Door
Detail Steps/Work Items Key Items/References
(1) Open the passenger door: Refer to Figure 4 and 5.
S Pull the door handle away from the door
frame.
S Lift the door open. Hold the door!
(2) Install the gas strut:
S Push the gas strut ball end fittings onto the
fuselage gas strut mounts.
S Install the locking clips which lock the ball end
fittings in place.
(3) Close the door.
Page 206 Doc # 6.02.15
15 Apr 2013 52-10-00 Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
6. Test the Door Unlocked Warning Light
Detail Steps/Work Items Key Items/References
(1) Make sure that both the front canopy and the Operating handles flush against the
passenger door are fully closed. canopy/door frame.
(2) Test the operation of the door unlocked warning Monitor the door unlocked warning light
light (DOOR OPEN or DOORS) on the PFD of (DOOR OPEN or DOORS) on the PFD
G1000 or annunciator panel: of G1000 or annunciator panel.
S Set the ELECTRIC MASTER key switch to The warning light must be off.
ON.
S Move the passenger door operating handle The warning light must come on when
towards the open position. the operating handle has moved away
from the door frame.
S Move the door operating handle to the fully The warning light must go off.
closed position.
S Move the canopy operating handle towards The warning light must come on when
the open position the operating handle has moved away
from the door frame.
S Move the canopy operating handle to the fully The warning light must go off.
closed position.
S Set the ELECTRIC MASTER key switch to
OFF.
Doc # 6.02.15 Page 207
Rev. 2 52-10-00 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
7. Examine the Carbon Hinges on the Passenger Door
Detail Steps/Work Items Key Items/References
(1) Open the passenger door to carry out the
carbon hinge inspection.
(2) Examine the carbon hinges for cracks and Refer to Figure 6.
delamination on the side faces:
S Hold the passenger door frame with one
hand to the left and one hand to the right of
the hinge.
S Apply torsional test force to the hinge by Apply test force of approx. 8 kg (18 lb)
alternately pulling with one hand and with each hand.
pushing with the other hand.
S If cracks become visible on the side faces of
the hinges when test force is applied, the
hinge is structurally damaged due to
delamination. Contact Diamond Aircraft for
repair instructions.
Page 208 Doc # 6.02.15
15 Apr 2013 52-10-00 Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
Detail Steps/Work Items Key Items/References
(3) Cracks at the outer face of the hinges where Refer to Figure 7.
they meet the door frame may be visible.
If cracks in this area are visible, perform the
following checks:
S Hold the passenger door frame with one
hand to the left and one hand to the right of
the hinge.
S Apply torsional test force to the hinge by Apply test force of approx. 8 kg (18 lb)
alternately pulling with one hand and with each hand.
pushing with the other hand, check the
cracks on the outer face of the hinge.
S Push the passenger door open against the
mechanical stop of the damper with care, do
not use undue force. Check the cracks on
the outer face of the hinge.
If cracks expand extensively when applying test
force, the hinges are structurally damaged.
Contact Diamond Aircraft for repair instructions.
If the cracks do not expand extensively when
applying test force, they are limited to the
painting and do not affect the serviceability of
the door.
Doc # 6.02.15 Page 209
Rev. 2 52-10-00 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
Figure 6: Passenger Door Torsional Hinge Test
Page 210 Doc # 6.02.15
15 Apr 2013 52-10-00 Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
Figure 7: Passenger Door Outer Face Hinge Test
Doc # 6.02.15 Page 211
Rev. 2 52-10-00 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
8. Inspection of the Door Locking and Safety Hook Mechanisms
Detail Steps/Work Items Key Items/References
(1) Make sure the door lock mechanism works
correctly:
S The pins must engage in the guarding plates
of the door frame correctly.
(2) Make sure the safety hook mechanism works
correctly:
S Lubricate the red button of the safety hook Refer to Section 12-20.
mechanism from outside, where it enters the
door frame.
S Operate the button several times. Repeat
lubrication procedure until button moves
smoothly.
S Make sure the safety hook engages
correctly into the retaining block on the
fuselage when the door is closed but
unlatched.
Page 212 Doc # 6.02.15
15 Apr 2013 52-10-00 Rev. 2
DA 40 NG AMM Doors
AIRCRAFT
Section 52-40
Access Panels
1. General
The DA 40 NG has a small number of access panels. Panels which must be used often (for example
the oil filler panel), have quick-release fasteners. Other panels have the usual screws. Refer to Section
71-10 for data about the engine cowlings.
2. Description
Figure 1 shows the location of the access panels on the airplane.
Most panels are GFRP moldings. Screws hold the panels in position. There are no special procedures
for removing or installing access panels.
Doc # 6.02.15 Page 1
Rev. 2 52-40-00 15 Apr 2013
Doors DA 40 NG AMM
AIRCRAFT
Stabilizer Attachment
Stabilizer Fairing
Flap/Aileron Flap/Aileron
Push Rods Push Rods
B-Bolt B-Bolt
Aileron Flap Flap Aileron
Bellcrank Bellcrank Bellcrank Bellcrank
Pitot Probe Main Main Magnetometer
Landing Landing (if installed)
Fuel Tanks Gear Gear Fuel Tanks
Fuel System
Figure 1: Access Panel Locations
Page 2 Doc # 6.02.15
15 Apr 2013 52-40-00 Rev. 2
DA 40 NG AMM Fuselage
AIRCRAFT
CHAPTER 53
FUSELAGE
Doc # 6.02.15 Page 1
Rev. 2 53-TITLE 15 Apr 2013
Fuselage DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 53-TITLE Rev. 2
DA 40 NG AMM Fuselage
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 53
FUSELAGE
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 53-10
Fuselage Structure
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Repair Data for the Fuselage Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Doc # 6.02.15 Page 1
Rev. 2 53-CONTENTS 15 Apr 2013
Fuselage DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 53-CONTENTS Rev. 2
DA 40 NG AMM Fuselage
AIRCRAFT
CHAPTER 53
FUSELAGE
1. General
The DA 40 NG fuselage has a semi-monocoque structure. Two GFRP half-shells make the fuselage
skin. GFRP frames and webs give the fuselage strength and stiffness. The vertical stabilizer is an
integral part of the fuselage.
The fuselage shells have many layers of glass cloth. Some areas have more layers of glass cloth than
other areas. This gives more strength and stiffness where it is needed. Rigid foam inserts give stiffness
where necessary.
The frames and webs also have many layers of glass cloth. Some areas have layers of carbon fiber
cloth or tape to give extra strength. Some components also have rigid inserts of GFRP for attaching
brackets or other components.
Section 53-10 gives the data for the fuselage structure.
Doc # 6.02.15 Page 1
Rev. 2 53-00-00 15 Apr 2013
Fuselage DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 53-00-00 Rev. 2
DA 40 NG AMM Fuselage
AIRCRAFT
Section 53-10
Fuselage Structure
1. General
This Section gives you the data about the fuselage structure. It also includes the vertical stabilizer. See
Chapter 51-00 for data about repair to the structure.
All of the main structural components are GFRP rigid moldings. Many layers of glass cloth bond
together to make each molding. Some components have layers of carbon fiber cloth. This gives more
strength and stiffness.
Most components have rigid GFRP inserts. The inserts give strength and stiffness for attaching other
components such as brackets for controls.
Bonding paste (thickened resin) bonds components to other components. Most of the components in
the fuselage also bond to the fuselage shell.
Doc # 6.02.15 Page 1
Rev. 2 53-10-00 15 Apr 2013
Fuselage DA 40 NG AMM
AIRCRAFT
Floor Panel
Right Shell
Left Shell
Top Hat Profile
Firewall
Figure 1: Fuselage Shells and Front Fuselage Structure
Page 2 Doc # 6.02.15
15 Apr 2013 53-10-00 Rev. 2
DA 40 NG AMM Fuselage
AIRCRAFT
2. Description
Figures 1 to 4 show the fuselage structure.
A. Fuselage Shells
Two GFRP shells make the outer skin of the fuselage. The shells transmit structural loads. The
shells bond to each other at the top and bottom of the fuselage. Each shell has many layers of
glass cloth. Some areas have of the shell have more layers to give more strength and stiffness.
Some areas have rigid foam inserts to give more stiffness.
Thickened resin bonds all other structural components to the fuselage shells. Many small
components bond to the fuselage shells, these include:
) Air inlet and outlet ducts.
) Conduits for electrical wires, antenna cables and fuel pipes.
B. Firewall
The firewall closes the front of the fuselage. It also holds the attachments for the engine mount. It
has holes for the different systems that attach to the engine.
The firewall is a rigid GFRP molding. A special adhesive bonds a fire-resistant ceramic blanket to
the front face of the firewall. The adhesive also bonds a stainless-steel sheet to the front of the
blanket. Components which go through the firewall also hold the stainless-steel sheet and blanket
to the GFRP molding.
C. Top Hat Profile
The top hat profile bonds to the inner bottom skin of the fuselage, behind the firewall. It gives
strength and stiffness to the front fuselage. It has the mounting for the nose landing gear and
channels for fuel pipes.
Doc # 6.02.15 Page 3
Rev. 2 53-10-00 15 Apr 2013
Fuselage DA 40 NG AMM
AIRCRAFT
%
%
%
%
%
%
%
%
%
%
% Top Shell
%
%
%
Rear Outer Rib
% Rear Main Bulkhead
%
Middle Outer Rib
% Bottom Shell
Front Main Bulkhead
%
Front Outer Rib Control Bellcrank
% Mounting Bracket
%
% Rear Closing Rib
% Front Closing Rib Rear Web
%
%
Main Landing Gear Rib
%
%
% Fuel Pipe Channel
% Main Landing Gear Reinforcement Rib
(if installed)
%
%
%
%
%
%
% Figure 2: Fuselage - Center Section
Page 4 Doc # 6.02.15
15 Apr 2013 53-10-00 Rev. 2
DA 40 NG AMM Fuselage
AIRCRAFT
D. Floor Panel
The floor is a rigid GFRP molding. It bonds to the inner bottom skin of the fuselage shell and the
firewall. It goes over the top of the top hat profile. The center part of the floor panel makes the
center console.
The rear part of the floor makes the front support for the pilots' seats. It also holds the front of the
control stick support brackets. The rudder pedal assembly for each pilot attaches to the floor panel.
E. Center Section
Figure 2 shows the center section. The center section has the mountings for the wings and the
main landing gear. It has a front main bulkhead and it has a rear main bulkhead.
The front main bulkhead is a rigid GFRP box-section molding. It has layers of carbon cloth on the
top and bottom faces. The carbon gives cloth gives strength and stiffness to the bulkhead.
The rear main bulkhead has a similar structure. The control bellcrank mounting-bracket is bonded
to the rear face of the rear main bulkhead, in the center.
Front, middle and rear outer ribs bond to the outboard ends of the main bulkheads. The ribs are
rigid GFRP moldings which make the outer face of the wing stub.
Main landing gear ribs bond to the main bulkheads inboard of the middle outer rib. The main
landing gear rib has the outer mounting for the main gear strut.
Front and rear closing ribs bond to the main bulkheads. They are inboard of the main landing gear
ribs. The ribs are rigid GFRP moldings. The middle part of the front closing rib has the inner
mounting for the main landing gear. The rear channels of the top hat profile bond to the front
closing ribs and the front main bulkhead. The rear channels also carry fuel pipes.
A rigid GFRP bottom shell bonds to the lower surface of the center section and makes the bottom
surface of the wing stubs and fuselage. Rigid GFRP top shells bond to the top-outer surface of the
center section and makes the top surface of the wing stubs.
Doc # 6.02.15 Page 5
Rev. 2 53-10-00 15 Apr 2013
Fuselage DA 40 NG AMM
AIRCRAFT
Figure 3: Fuselage Structure - Rear Fuselage
Page 6 Doc # 6.02.15
15 Apr 2013 53-10-00 Rev. 2
DA 40 NG AMM Fuselage
AIRCRAFT
F. Roll Bar
The roll bar is a rigid GFRP molding. Carbon tape gives strength and stiffness to the molding. The
roll bar bonds to the inner face of the fuselage shell and around the canopy, window and passenger
door cut-outs.
G. Baggage Compartment Frame
The baggage compartment frame is a rigid GFRP molding. It closes the rear of the cockpit and
makes a support for the passenger seat (rear seat pan). The frame bonds to the inner fuselage
shells and the center section lower shell.
The lower part of the frame has holes for the rudder cables and trim control. It also has a control
rod guide for the elevator control rod.
H. Ring Frame 1
The ring frame 1 is a rigid GFRP molding. It bonds to the fuselage shells just aft of the baggage
compartment frame. It has holes for the rudder control cables and trim control. It also has a control
rod guide for the elevator control rod.
I. Ring Frame 2
The ring frame 2 is a rigid GFRP molding. It bonds to the fuselage shells aft of ring frame 1. It has
holes for the rudder control cables and trim control. It also has a control rod guide for the elevator
control.
J. Ring Frame 3
The ring frame 3 is a rigid GFRP molding. It bonds to the fuselage shells just forward of the vertical
stabilizer. It has holes for the rudder control cables and trim control.
Doc # 6.02.15 Page 7
Rev. 2 53-10-00 15 Apr 2013
Fuselage DA 40 NG AMM
AIRCRAFT
Vertical Stabilizer
Front Web Reinforcing Rib
Vertical Stabilizer
Rear Web
Vertical Stabilizer
Front Lower Rib
Vertical Stabilizer
Rear Lower Rib
Figure 4: Fuselage Structure - Vertical Stabilizer
Page 8 Doc # 6.02.15
15 Apr 2013 53-10-00 Rev. 2
DA 40 NG AMM Fuselage
AIRCRAFT
K. Vertical Stabilizer Front Lower Rib
The vertical stabilizer front lower rib is a rigid GFRP molding. It bonds to the fuselage shell at the
bottom of the vertical stabilizer. It also bonds to the vertical stabilizer front web. It has a hole for the
flexible control cable for the elevator trim-tab.
L. Vertical Stabilizer Rear Lower Rib
The vertical stabilizer rear lower rib is a rigid GFRP molding. It bonds to the fuselage shell at the
bottom of the vertical stabilizer. It also bonds to the vertical stabilizer front and rear webs. It has a
large slot for the elevator control push-rod.
M. Vertical Stabilizer Front Web
The vertical stabilizer front web is a rigid GFRP molding. It bonds to the fuselage shell. It also
bonds to the vertical stabilizer lower ribs and to the top of the rear web.
The top of the front web is a rigid channel section. GFRP inserts give strength to the area where
the horizontal stabilizer mounts attach.
N. Vertical Stabilizer Rear Web
The vertical stabilizer rear web is a rigid GFRP molding. It bonds to the fuselage shell and it bonds
to the vertical stabilizer front web. The top of the rear web has the top mounting for the rudder. It
also has a reinforcing rib bonded to the rear face.
The vertical stabilizer rear web closes the rear of the vertical stabilizer.
Doc # 6.02.15 Page 9
Rev. 2 53-10-00 15 Apr 2013
Fuselage DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 10 Doc # 6.02.15
15 Apr 2013 53-10-00 Rev. 2
DA 40 NG AMM Fuselage
AIRCRAFT
Maintenance Practices
1. General
This Section gives repair data for the fuselage. Use it to give the data about the fuselage structure.
Refer to Chapter 51 for standard repair procedures.
2. Repair Data for the Fuselage Shells
Figures 5 to 11 show the layers of glass fiber or carbon fiber cloth in the fuselage shells. Use this data
when you need to repair the fuselage. Contact Diamond Aircraft customer support department if more
detailed information (such as further lay up plans) is needed.
The Figures show the main layers of cloth. The cross-hatching on the figure shows the orientation of
the fibers. The orientation is also given in the related table. When you repair the fuselage, you must
use the same type of cloth with the same fiber orientation.
In many areas, uni-directional carbon fiber tape is used. In these cases, the length of the tape is given.
The numbers in circles beside each drawing give the order in which the layers are applied (‘Stages’).
The first stage is a layer of filler and is not shown. Stage 1 is the outer face of the shell.
Where dimensions of layers are given in millimeters (mm), divide by 25.4 to obtain the dimension in
inches (in).
Always do a burn test on a piece of composite from the damaged area before you do a repair. Refer
to Section 51-20 for the burn test.
Doc # 6.02.15 Page 201
Rev. 2 53-10-00 15 Apr 2013
Fuselage DA 40 NG AMM
AIRCRAFT
3
4
4 5
7 6 8
5 6
Item No. Layers Reference No. Type Remarks
4 1 8.4548.60 Glass 92110 twill 2/2 0º/90º Overall
5 2 8.4551.60 Glass 92125 twill 2/2 ±45º
6 1 8.4551.60 Glass 92125 twill 2/2 0°/90º
7 2 8.4551.60 Glass 92125 twill 2/2 15º/105º
8 2 8.4551.60 Glass 92125 twill 2/2 0°/90º
Figure 5: Layers of Cloth in the Fuselage Shells - Stages 3 - 6
Page 202 Doc # 6.02.15
15 Apr 2013 53-10-00 Rev. 2
DA 40 NG AMM Fuselage
AIRCRAFT
9
9
11 10 12 13
RIGHT FUSELAGE SHELL
8
13 12 10 11
LEFT FUSELAGE SHELL
Item No. Layers Reference No. Type Remarks
9 2 8.4525.60 Glass 92146 uni-directional 0º/90º
10 2 8.4551.60 Glass 92125 twill 2/2 ±45º, 250 mm * 600 mm
11 3 KDU 1034 Carbon 100 mm uni-directional 750 mm
12 3 KDU 1034 Carbon 100 mm uni-directional 3250 mm
13 2 8.4525.60 Glass 92146 uni-directional 17º/107º
Figure 6: Layers of Cloth in the Fuselage Shells - Stages 7 & 8
Doc # 6.02.15 Page 203
Rev. 2 53-10-00 15 Apr 2013
Fuselage DA 40 NG AMM
AIRCRAFT
17
16 14
9
RIGHT FUSELAGE SHELL
15
14 16
LEFT FUSELAGE SHELL
19
20 21 22 22 21 20
10
25 24 23 23 24 25
LEFT FUSELAGE SHELL RIGHT FUSELAGE SHELL
Item No. Layers Reference No. Type Remarks
14 3 KDU 1034 Carbon 100 mm uni-directional 1000 mm
15 3 KDU 1034 Carbon 100 mm uni-directional 1400 mm
16 3 KDU 1034 Carbon 100 mm uni-directional 850 mm
17 3 KDU 1034 Carbon 100 mm uni-directional 1200 mm
19 3 KDU 1034 Carbon 100 mm uni-directional 1200 mm
20-22 1 each KDU 1034 Carbon 100 mm uni-directional 600 mm, 700 mm, 800 mm
23-25 1 each KDU 1034 Carbon 100 mm uni-directional 600 mm, 700 mm, 800 mm
Figure 7: Layers of Cloth in the Fuselage Shells - Stages 9 & 10
Page 204 Doc # 6.02.15
15 Apr 2013 53-10-00 Rev. 2
DA 40 NG AMM Fuselage
AIRCRAFT
28
VIEW FROM BELOW
27
34
LEFT FUSELAGE SHELL
32 31 30 29
11
34
VIEW FROM ABOVE
36
35
42
RIGHT FUSELAGE SHELL
37 38 39 40
Item No. Reference No. Type Remarks
27-32 H 60 8 mm rigid foam
34-36 H 60 3 mm rigid foam
37-42 H 60 8 mm rigid foam
Figure 8: Rigid Foam Inserts in the Fuselage Shells - Stage 11
Doc # 6.02.15 Page 205
Rev. 2 53-10-00 15 Apr 2013
Fuselage DA 40 NG AMM
AIRCRAFT
43
12
44, 45
13
44, 45
Item Layers Reference No. Type Remarks
No.
43 2 8.4551.60 Glass 92125 twill 2/2 ±45º
44 2 8.4554.60 Glass 92140 twill 2/2 ±45º
45 1 8.4554.60 Glass 92140 twill 2/2 0º/90º
Figure 9: Layers of Cloth in the Fuselage Shells - Stages 12 & 13
Page 206 Doc # 6.02.15
15 Apr 2013 53-10-00 Rev. 2
DA 40 NG AMM Fuselage
AIRCRAFT
2 3 4
4
2 3
5 6
5 6 7
8 7 9
Item Layers Reference No. Type Remarks
No.
2 1 8.4548.60 Glass 92110 twill 2/2 0º/90º
3 1 8.4551.60 Glass 92125 twill 2/2 ±45º
4 2 8.4551.60 Glass 92125 twill 2/2 0º/90º
5 3 8.4525.60 Glass 92146 uni-directional 0º, 900 mm
6 2 8.4551.60 Glass 92125 twill 2/2 200 mm * 200 mm
7&8 H 60 8 mm rigid foam
9 3 8.4548.60 Glass 92125 twill 2/2 ±45º
Figure 10: Layers of Cloth in the Center Section Bottom Shell
Doc # 6.02.15 Page 207
Rev. 2 53-10-00 15 Apr 2013
Fuselage DA 40 NG AMM
AIRCRAFT
2 3 4
3 4 5
5 6 6 9 8 7 12
11 10 7
Item Layers Reference No. Type Remarks
No.
3 1 8.4548.60 Glass 92110 twill 2/2 0º/90º
4 2 8.4551.60 Glass 92125 twill 2/2 0º/90º
5 2 8.4551.60 Glass 92125 twill 2/2 ±45º
6 3 8.4525.60 Glass 92146 uni-directional 0º
7 - 11 H 60 8 mm rigid foam
12 2 8.4551.60 Glass 92125 twill 2/2 0º/90º
Figure 11: Layers of Cloth in the Center Section Top Shells
Page 208 Doc # 6.02.15
15 Apr 2013 53-10-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
CHAPTER 55
STABILIZERS
Doc # 6.02.15 Page 1
Rev. 2 55-TITLE 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 55-TITLE Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 55
STABILIZERS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 55-10
Horizontal Stabilizer
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Horizontal Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Repair Data for the Horizontal Stabilizer Shells . . . . . . . . . . . . . . . . . . . . . . . . . 205
Section 55-20
Elevator
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Elevator Trim Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Repair Data for the Elevator Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Doc # 6.02.15 Page 1
Rev. 2 55-CONTENTS 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
Section 55-30
Lower Fin
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Lower Fin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 55-40
Rudder
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Rudder and the Upper Bearing . . . . . . . . . . . . . . . . . . . . . . 201
3. Repair Data for the Rudder Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Page 2 Doc # 6.02.15
15 Apr 2013 55-CONTENTS Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
CHAPTER 55
STABILIZERS
1. General
The DA 40 NG has the usual stabilizers. The vertical stabilizer is part of the fuselage. The aft part of
the left and right fuselage shells make the left and right shells of the vertical stabilizer. See
Section 53-10 for data on the fuselage structure.
The horizontal stabilizer has top and bottom shells. Each shell has GFRP skins. The horizontal
stabilizer has a front spar and a rear spar. Both spars have mounting brackets. Three pairs of ribs give
strength to the center area. Two trailing edge webs hold the hinges for the elevator.
The elevator has top and bottom shells. Each shell has GFRP skins with a rigid foam core. The bottom
shell also makes the leading edge spar. The hinges attach to the bottom shell. A large horn with the
mass balance weight attaches to the bottom shell at the center. The trailing edge carries a trim tab.
The lower fin is a GFRP molding. Bolts attach the lower fin to the bottom of the fuselage.
The rudder has left and right shells. Each shell has GFRP skins with a rigid foam core. The shells bond
together at a flange. The hinges attach to the top face of the rudder and a flat face near the bottom of
the leading edge. The horn near the top makes the rudder mass balance.
Trim Tab
Horizontal Stabilizer
Elevator
Rudder
Lower Fin
Figure 1: Stabilizers
Doc # 6.02.15 Page 1
Rev. 2 55-00-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 55-00-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
Section 55-10
Horizontal Stabilizer
1. General
The DA 40 NG has the usual horizontal stabilizer. The horizontal stabilizer attaches to the top of the
vertical stabilizer. The elevator attaches to the trailing edge of the horizontal stabilizer. See
Section 55-20 for data about the elevator structure.
2. Description
Figure 1 shows the horizontal stabilizer structure.
The horizontal stabilizer has top and bottom shells. Each shell has GFRP skins. The top shell has no
cut-outs. The bottom shell has a large cut-out at the rear for the elevator horn and mass balance. It
also has two smaller holes forward and aft of the front spar.
The horizontal stabilizer has two spars. The spars have GFRP skins with rigid GFRP inserts at the
main mounting points. They also have top and bottom caps. The ends of the front spar turn back to
join the aft spar at mid span. The rear spar goes almost to the tip of the horizontal stabilizer. The spars
bond to the top and bottom shells with resin.
Each spar has four holes for a mounting bracket. You can get access to the attachment bolts from
below. The mounting brackets go down through the cut-outs in the bottom shell. Four more holes in
the bottom part of each mounting bracket attach to the vertical stabilizer front web.
Three pairs of ribs give strength to the center area on each side of the access holes. All are rigid
GFRP moldings. They bond to the other components with resin. The rear 'box' ribs make a box round
the large cut-out in the bottom skin. A short rear rib at mid-span gives strength to the area between
the rear spar and the trailing edge web.
The rear box rib has sides with bends and a top face which joins the sides. It closes the sides of the
large cut-out in the bottom shell. The aft part has three holes on each side for the anchor bracket for
the trim-tab mechanism.
Two trailing edge webs close the trailing edges of the top and bottom shells. The outboard end of each
web is a 'J' shape which goes round the outboard balance weight of the elevator. It extends aft at the
outer side to close the elevator cut-out. The webs also holds the hinges for the elevator. The webs
bond to the top and bottom shells and the rear and rear 'box' ribs with resin.
A rigid GFRP fairing goes around the joint between the horizontal stabilizer and the vertical stabilizer.
Four screws attach the fairing to the vertical stabilizer.
Doc # 6.02.15 Page 1
Rev. 2 55-10-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
Top Shell
Center Rib
Rear 'Box' Rib
Trailing Edge Web
Bottom Shell
Rear Spar
Rear Rib
Front Spar
Front Rib
Front Mounting Bracket
12
Rear Mounting Bracket
Horizontal Stabilizer Tip
Figure 1: Horizontal Stabilizer Structure
Page 2 Doc # 6.02.15
15 Apr 2013 55-10-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove and install the horizontal stabilizer.
2. Remove/Install the Horizontal Stabilizer
A. Remove the Horizontal Stabilizer
Note: Two persons needed to remove/install the horizontal stabilizer.
Detail Steps/Work Items Key Items
(1) Remove the horizontal stabilizer fairing.
S Remove 4 screws.
(2) Release the 2 ball-end fittings from the trim-tab Under the elevator.
operating links.
(3) Release the trim-tab mechanism from its Refer to Section 27-31.
mounting bracket.
(4) Move the trim-tab mechanism forward through
the hole in the vertical stabilizer web, clear of the
mounting bracket.
(5) Remove the bolt which connects the elevator
vertical push rod to the elevator horn.
(6) Remove the 8 bolts which attach the horizontal Hold the horizontal stabilizer.
stabilizer to the front and rear mounting brackets.
(7) Disconnect the VOR antenna.
(8) Lift the horizontal stabilizer clear of the airplane.
Doc # 6.02.15 Page 201
Rev. 2 55-10-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
12
Earthing Strip
Balance Weight
12
Elevator Actuating Lever
Large Washer Elevator Lever Rib
Collar Bush
Horizontal Stabilizer
Rear Spar Distance Bush
Horizontal Stabilizer
Front Spar
Elevator Push Rod
Front Rear
Mounting Bracket Mounting Bracket
12
Vertical Stabilizer
Front Web
Figure 2: Horizontal Stabilizer Installation
Page 202 Doc # 6.02.15
15 Apr 2013 55-10-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
B. Install the Horizontal Stabilizer
Detail Steps/Work Items Key Items
(1) Examine the horizontal stabilizer attachments.
Look specially for:
S Corrosion or wear of the bolts.
S Distortion of the mounting brackets.
S Cracks in the mounting brackets.
S Damage to the mounting holes.
(2) Put the horizontal stabilizer in position on the Hold the horizontal stabilizer.
vertical stabilizer.
(3) Connect the VOR antenna.
(4) Install the 8 bolts which attach the horizontal Use new self-locking nuts.
stabilizer to the front and rear mounting brackets.
(5) Install the bolt which connects the elevator Torque: 1.7 Nm (1.2 lbf.ft.).
vertical push rod to the elevator horn. Use a new self-locking nut.
(6) Move the trim-tab mechanism aft through the
hole in the vertical stabilizer web, through the
mounting bracket for the trim mechanism.
(7) Attach the trim-tab mechanism to its mounting Use a new self-locking nut.
bracket:
S Install 2 bolts.
(8) Connect the 2 ball-end fittings to the trim-tab Under the elevator.
operating links.
(9) Do a test for correct, full and free movement of Refer to Section 27-30.
the elevator control. If necessary, adjust the
elevator control.
(10) Do a test for correct, full and free movement of Refer to Section 27-31.
the trim control. If necessary, adjust the trim
control.
Doc # 6.02.15 Page 203
Rev. 2 55-10-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items
(11) Install the horizontal stabilizer fairing:
S Install 4 screws.
Page 204 Doc # 6.02.15
15 Apr 2013 55-10-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
5
1
1 5
6
7
2
2 6
3
8
3 7
Item No. Layers Reference No. Type Remarks
1 1 8.4548.60 Glass 92110 twill 2/2 0/90º
2 1 8.4551.60 Glass 92125 twill 2/2 0/90º
3, 4, 5 1 each 8.4525.60 Glass 92146 uni-directional 0/180º
6, 7 8 each 8.4525.60 Glass 92146 uni-directional 0/180º, 50 mm x 500 mm
stepped 20 mm
8 2 8.4551.60 Glass 92125 twill 2/2 0/90º
Figure 3: Layers of Cloth in the Horizontal Stabilizer Bottom Shell
Doc # 6.02.15 Page 205
Rev. 2 55-10-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
3. Repair Data for the Horizontal Stabilizer Shells
Figures 3 and 4 show the layers of glass fiber cloth in the horizontal stabilizer shells. Use this data
when you need to repair the horizontal stabilizer.
The Figures show the main layers of cloth. The cross-hatching on the Figure shows the orientation of
the fibers. The orientation is also given in the related table. When you repair the horizontal stabilizer,
you must use the same type of cloth with the same fiber orientation.
The numbers in circles beside each drawing give the order in which the layers are applied (‘Stages’).
The first stage (0 for the horizontal stabilizer) is a layer of filler and is not shown. Stage 1 is the outer
face of the shell.
Always do a burn test on a piece of composite from the damaged area before you do a repair. Refer
to Section 51-20 for the burn test.
Page 206 Doc # 6.02.15
15 Apr 2013 55-10-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
4
1
1 4
2 5
2 5
3
6
3 6
Item No. Layers Reference No. Type Remarks
1 1 8.4548.60 Glass 92110 twill 2/2 0/90º
2 2 8.4551.60 Glass 92125 twill 2/2 0/90º
3, 4, 5 1 each 8.4525.60 Glass 92146 uni-directional 0/180º
6 2 8.4551.60 Glass 92125 twill 2/2 0/90º
Figure 4: Layers of Cloth in the Horizontal Stabilizer Top Shell
Doc # 6.02.15 Page 207
Rev. 2 55-10-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 208 Doc # 6.02.15
15 Apr 2013 55-10-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
Section 55-20
Elevator
1. General
The DA 40 NG has the usual elevator. The elevator attaches to the rear web of the horizontal
stabilizer. See Section 27-30 for data about the elevator controls.
Doc # 6.02.15 Page 1
Rev. 2 55-20-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
Top Shell
Trim Tab Hinge
End Bearing Trim Tab
Bottom Shell
Hinge Rod
Elevator Hinge
Assembly
Elevator Horn
Elevator Hinge
Assembly
Bearing Rib
End Bearing
Spherical Bearing
Bonded Bush
Figure 1: Elevator Structure
Page 2 Doc # 6.02.15
15 Apr 2013 55-20-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
2. Description
Figure 1 shows the elevator structure. Figure 2 shows the installation of the elevator on the horizontal
stabilizer. Figure 3 shows the trim tab installation.
The elevator has top and bottom shells. Each shell has GFRP skins with a rigid foam core. The leading
edge of each shell has a curve. The shells bond together where the curves overlap. The shells also
bond together at the ends and at the trailing edge.
The elevator has a horn rib in the middle. It is a strong box with an open front. The elevator horn goes
into the horn rib. Two bolts attach the horn to the elevator.
The horn has a hole with a bush for the elevator push rod. The front of the horn has elevator mass
balance weight. More mass balance weight is attached at the front of the elevator tips.
Five bearings hold the elevator. The elevator horn has a plain bearing. A bolt and spacer attach the
elevator horn to the trailing edge webs of the horizontal stabilizer.
A small bearing rib at mid-span on each side holds an elevator hinge assembly. The hinge assembly
has an eye-end with a plain shank. The eye-end has a spherical bearing. The shank engages in a
bush in the trailing edge web.
The outer end of the elevator on each side has an end bearing. A reinforcing block holds a bonded
bush. The bush aligns with a bonded bush in the horizontal stabilizer trailing edge web. A pivot pin
goes through both bushes to make the outer bearing. A roll pin locks the pivot pin in the bonded bush.
A GFRP trim tab attaches to the trailing edge of the elevator. The trim tab has six GFRP hinges. The
front half of each hinge bonds to the trailing edge of the elevator. The rear half of each hinge bonds
to the leading edge of the trim tab. Two hinge rods go through the hinges. Lock wires hold the hinge
rods in place.
Doc # 6.02.15 Page 3
Rev. 2 55-20-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
Elevator Horn Rib
Elevator Horn Removable Tip
Balance Weight
Trailing Edge Web
Bonded
Bush Elevator Roll
Pin
Rear Rib Pivot
Bonded
Trailing Edge Web Pin
Bush
Figure 2: Elevator Installation on the Horizontal Stabilizer
Page 4 Doc # 6.02.15
15 Apr 2013 55-20-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove and install the elevator and trim tab. Refer to
Sections 27-30 and 27-31 for data on the elevator and trim tab control setting.
2. Remove/Install the Elevator
A. Remove the Elevator
Detail Steps/Work Items Key Items
(1) Remove the horizontal stabilizer fairing:
S Remove 4 screws.
(2) Release the 2 ball-end fittings from the trim-tab Under the elevator.
operating links.
(3) Remove the horizontal stabilizer tips.
(4) Remove 2 bolts, nuts and washers which attach Refer to Figure 2.
the elevator horn rib to the elevator.
(5) Remove the pivot pins from the end bearings: Hold the elevator.
S Remove the roll pin.
S Pull the pivot pin out of the end bearing.
(6) Pull the elevator aft to release the elevator horn
and hinge assemblies.
(7) Put the elevator in a stand or on a padded
surface.
Doc # 6.02.15 Page 201
Rev. 2 55-20-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
Attaching Bolt
Trim Tab
Cranked Actuating Lever RH
Trim Tab Horn
Trim Damper Cranked Actuating Lever LH
Hinge Trim Tab
Rod
Elevator
Trim Tab Operating Cable
Hinge Rod
Trim Tab Hinge
Lock Wire
Trim Tab
Elevator
Trim Tab Hinge
Hinge Rod
(6)
Figure 3: Trim Tab Installation
Page 202 Doc # 6.02.15
15 Apr 2013 55-20-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
B. Install the Elevator
Detail Steps/Work Items Key Items
(1) Put the elevator in position aft of the horizontal Refer to Figure 2.
stabilizer:
S Align the elevator with the horn.
S Move the elevator forward over the horn.
S Align the shanks of the hinge assemblies at
mid-span with the bushes in the trailing edge
web of the horizontal stabilizer.
S Push the elevator forward to engage the
shanks in the bushes.
S Align the end bearings with the bushes in the
trailing edge spar of the horizontal stabilizer.
(2) Install the pivot pins in the end bearings and lock
the pivot pins in position with a roll pin.
(3) Install the bolts, washers and nuts which attach Torque: 6.4 Nm (4.7 lbf.ft.).
the elevator to the elevator horn. Use new lock nuts.
(4) Install the 2 ball-end fittings for the trim-tab Under the elevator.
operating links.
(5) Install the horizontal stabilizer tips.
(6) Install the horizontal stabilizer fairing:
S Install 4 screws.
(7) Do a test for correct range of movement of the Refer to Section 27-30.
elevator control.
(8) Do a test for correct range of movement of the Refer to Section 27-31.
elevator trim control.
Doc # 6.02.15 Page 203
Rev. 2 55-20-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
3. Remove/Install the Elevator Trim Tab
A. Remove the Elevator Trim Tab
Detail Steps/Work Items Key Items
(1) Remove the bolt which attaches the cranked Refer to Figure 3.
actuating levers to the trim tab.
CAUTION: DO NOT USE FORCE TO REMOVE THE LOCK WIRE FROM THE
TRIM TAB HINGE. YOU CAN DAMAGE THE GFRP HINGE.
(2) Remove the lock wire at the outer hinge on each
side of the trim tab.
(3) Move the hinge rods out of the hinges. Hold the trim tab.
(4) Remove the trim tab from the elevator.
B. Install the Elevator Trim Tab
Detail Steps/Work Items Key Items
(1) Put the trim tab in position on the elevator. Refer to Figure 3.
(2) Align the hinges.
(3) Install the hinge rods in each side.
CAUTION: DO NOT USE FORCE TO INSTALL THE LOCK WIRE IN THE TRIM
TAB HINGE. YOU CAN DAMAGE THE GFRP HINGE.
(4) Lock the hinge rods in position with wire. Use new lock wire.
(5) Align the cranked actuating levers with the trim
tab.
(6) Install the bolt which attaches the cranked
actuating levers to the trim tab.
(7) Do a test for correct range of movement of the Refer to Section 27-31.
elevator trim control.
Page 204 Doc # 6.02.15
15 Apr 2013 55-20-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
Center
Line
2
4
5
4
6 7
5
Item No. Layers Reference No. Type Remarks
2 2 8.4548.60 Glass twill 2/2 ±45º
3 2 8.4548.60 Glass twill 2/2 ±45º
4 2 8.4548.60 Glass twill 2/2 ±45º, 125 mm x 135 mm
5 3 8.4554.60 Glass twill 2/2 ±45º, 90 mm x 220 mm
6 1 H 60 3 mm Rigid foam
8 1 8.4548.60 Glass twill 2/2 ±45º
Figure 4: Layers of Cloth in the Top and Bottom Elevator Shells
Doc # 6.02.15 Page 205
Rev. 2 55-20-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
4. Repair Data for the Elevator Shells
Figure 4 shows the layers of glass fiber cloth in the elevator shells. Use this data when you need to
repair the elevator.
The Figures show the main layers of cloth. The cross-hatching on the Figure shows the orientation of
the fibers. The orientation is also given in the related table. When you repair the elevator, you must
use the same type of cloth with the same fiber orientation.
The numbers in circles beside each drawing give the order in which the layers are applied (‘Stages’).
The first stage is a layer of filler and is not shown. Stage 1 is the outer face of the shell.
Always do a burn test on a piece of composite from the damaged area before you do a repair. Refer
to Section 51-20 for the burn test.
Page 206 Doc # 6.02.15
15 Apr 2013 55-20-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
Section 55-30
Lower Fin
1. General
The DA 40 NG has a removable lower fin. The lower fin is a GFRP molding. Screws attach the lower
fin to the bottom of the rear fuselage.
2. Description
The lower fin is a GFRP molding. It has a left shell and a right shell. The shells bond together with
resin.
The lower fin has a hole at the rear for a tie down rope. It also has a flat area at the bottom for a tail
skid.
Doc # 6.02.15 Page 1
Rev. 2 55-30-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
Attaching Screw Holes
Attaching Screw Holes
Tie-Down Hole
Lower Fin
Attaching Screw Hole
Figure 1: Lower Fin
Page 2 Doc # 6.02.15
15 Apr 2013 55-30-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove and install the lower fin.
2. Remove/Install the Lower Fin
A. Remove the Lower Fin
Detail Steps/Work Items Key Items
(1) Remove the sealing tape from the joint between
the lower fin and the fuselage.
(2) Remove 5 screws which attach the lower fin to Refer to Figure 1.
the rear fuselage and cut sealant. Hold the fin.
(3) Remove the lower fin from the airplane.
B. Install the Lower Fin
Detail Steps/Work Items Key Items
(1) Clean the area of the fuselage where the lower
fin attaches.
(2) Put the lower fin in position below the fuselage. Hold the lower fin.
(3) Install the 5 screws with washers which attach
the lower fin. Seal with PU-based sealant.
(4) Apply sealing tape to the joint between the lower
fin and the fuselage.
Doc # 6.02.15 Page 201
Rev. 2 55-30-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 202 Doc # 6.02.15
15 Apr 2013 55-30-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
Section 55-40
Rudder
1. General
The DA 40 NG has the usual rudder. The rudder attaches to the rear web of the vertical stabilizer. See
Section 27-20 for data about the rudder controls.
Doc # 6.02.15 Page 1
Rev. 2 55-40-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
Top Pivot Pin
Insert
Mass Balance
Right Shell
Left Shell
Bottom Mounting Bolts
Figure 1: Rudder Assembly
Page 2 Doc # 6.02.15
15 Apr 2013 55-40-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
2. Description
Figure 1 shows the rudder structure. Figure 2 shows the installation of the rudder on the vertical
stabilizer.
The rudder has left and right shells. Each shell has GFRP skins with a rigid foam core. The leading
edge of each shell has a curve and a flange. The shells bond together at the flanges. The shells also
bond together at the top, bottom and at the trailing edge.
The rudder has a flat face at the bottom of the leading edge. The flat face has two bonded bolts. The
bolts attach the rudder to the rudder lower mounting bracket. Refer to Section 27-20 for data about the
rudder lower mounting bracket.
The rudder has a mass balance weight bonded into the leading edge near the top. You cannot adjust
the mass balance.
Two bearings hold the rudder. A pivot pin bonds into the leading edge near the top. It engages with
a bearing installed in a bearing sleeve attached to the rear web of the vertical stabilizer. On the pivot
pin a bushing and if necessary for adjustment a washer is bonded with Loctite 680. This bushing is
installed to adjust the clearance between rudder and bearing.
Pivot Pin
Pivot Bearing
Figure 2: Clearance Bushing between Rudder and Rudder Bearing
Doc # 6.02.15 Page 3
Rev. 2 55-40-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
Vertical Stabilizer
Rear Web
Top Pivot Pin
Washer Bottom
Nut
Mounting Bolts
Rudder Stop Bolt
Rudder Pedestal
Figure 3: Rudder Installation
Page 4 Doc # 6.02.15
15 Apr 2013 55-40-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove and install the rudder. Refer to Section 27-20
for data on the rudder control setting.
2. Remove/Install the Rudder and the Upper Bearing
A. Remove the Rudder
Detail Steps/Work Items Key Items
(1) Remove 2 nuts and washers which attach the Refer to Figure 3.
rudder to the rudder lower mounting bracket. Hold the rudder.
(2) Pull the bottom of the rudder aft to disengage the
bottom bolts.
(3) Lower the rudder to disengage the top pivot.
(4) Put the rudder in a stand or on a padded surface.
B. Remove the Upper Bearing
Detail Steps/Work Items Key Items
(1) Remove circlip and spacer of the bearing sleeve
from the top side.
(2) Remove the bearing in an upward direction by
pushing from the bottom side.
C. Install the Upper Bearing
Detail Steps/Work Items Key Items
(1) Press bearing into bearing sleeve from the top
side.
(2) Install spacer and circlip into bearing sleeve from
the top side.
Doc # 6.02.15 Page 201
Rev. 2 55-40-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
D. Install the Rudder
Detail Steps/Work Items Key Items
(1) Put the rudder in position aft of the vertical
stabilizer rear web.
(2) Check the bushing is installed and bonded on
pivot.
(3) Align the top pivot pin with the bearing in the top
face of the rear web. Lift the rudder to engage the
top pivot pin.
(4) Move the bottom of the rudder forward to engage
the bottom mounting bolts in the holes in the
rudder lower mounting bracket.
(5) Check clearance between top of bushing and the 1.6 mm to 3.2 mm (1/16" to 1/8").
bottom of the bearing. Adjust if necessary.
(6) Install the washers and nuts on the bottom Torque: 6.4 Nm (4.7 lbf.ft.).
mounting bolts.
(7) Do a test for correct range of movement of the Refer to Section 27-20.
rudder control.
Page 202 Doc # 6.02.15
15 Apr 2013 55-40-00 Rev. 2
DA 40 NG AMM Stabilizers
AIRCRAFT
2 3 4 5 6
2
5
4
6
9 10
9 11
Item Layers Reference No. Type Remarks
No.
2 2 8.4548.60 Glass twill 2/2 ±45º
3 6 8.4548.60 Glass twill 2/2 ±45º, 120 mm x 120 mm
4 4 8.4548.60 Glass twill 2/2 ±45º, 200 mm x 150 mm
5 1 8.4525.60 Glass uni-directional 0º/180º, 100 mm x 920 mm
6 1 8.4525.60 Glass uni-directional ±45º, 265 mm x 100 mm
9 1 H 60 3 mm rigid foam
11 1 8.4548.60 Glass twill 2/2 ±45º
Figure 4: Layers of Cloth in the Rudder Shells
Doc # 6.02.15 Page 203
Rev. 2 55-40-00 15 Apr 2013
Stabilizers DA 40 NG AMM
AIRCRAFT
3. Repair Data for the Rudder Shells
Figure 4 shows the layers of glass fiber cloth in the rudder shells. Use this data when you need to
repair the rudder.
The Figures show the main layers of cloth. The cross-hatching on the Figure shows the orientation of
the fibers. The orientation is also given in the related table. When you repair the rudder, you must use
the same type of cloth with the same fiber orientation.
The numbers in circles beside each drawing give the order in which the layers are applied (‘Stages’).
The first stage is a layer of filler and is not shown. Stage 1 is the outer face of the shell.
Always do a burn test on a piece of composite from the damaged area before you do a repair. Refer
to Section 51-20 for the burn test.
After repair weigh and make sure mass and moments are within limits.
Page 204 Doc # 6.02.15
15 Apr 2013 55-40-00 Rev. 2
DA 40 NG AMM Windows
AIRCRAFT
CHAPTER 56
WINDOWS
Doc # 6.02.15 Page 1
Rev. 2 56-TITLE 15 Apr 2013
Windows DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 56-TITLE Rev. 2
DA 40 NG AMM Windows
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 56
WINDOWS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 56-10
Flight Compartment Windows
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Replace a Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Window Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Doc # 6.02.15 Page 1
Rev. 2 56-CONTENTS 15 Apr 2013
Windows DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 56-CONTENTS Rev. 2
DA 40 NG AMM Windows
AIRCRAFT
CHAPTER 56
WINDOWS
1. General
The DA 40 NG has three windows. All of the windows are molded acrylic glass (plexiglass). The
one-piece canopy window covers the pilots’ cockpit. It is also the windscreen. The passenger door has
a window. The right side of the fuselage has a window for the passenger compartment.
A high-performance elastic adhesive bonds each window to the structure.
Section 56-10 gives the data for all of the windows. Refer to Section 52-10 for data about the canopy
and door structure.
Doc # 6.02.15 Page 1
Rev. 2 56-00-00 15 Apr 2013
Windows DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 56-00-00 Rev. 2
DA 40 NG AMM Windows
AIRCRAFT
Section 56-10
Flight Compartment Windows
1. General
This Section tells you about the windows in the canopy, passenger door and fuselage. Refer to Section
52-10 for data about the canopy and door structure.
Doc # 6.02.15 Page 1
Rev. 2 56-10-00 15 Apr 2013
Windows DA 40 NG AMM
AIRCRAFT
Figure 1: Windows
Page 2 Doc # 6.02.15
15 Apr 2013 56-10-00 Rev. 2
DA 40 NG AMM Windows
AIRCRAFT
2. Description and Operation
Figure 1 shows the windows.
A. General
The DA 40 NG has 3 windows. Each window is polycast molded acrylic glass (plexiglass). This
material gives good optical characteristics. It is also strong. It can be accurately formed into
3-dimensional shapes. A high-performance elastic adhesive bonds each window to the structure.
A flexible white sealant fills the small gap between the edge of the window and the structure.
Each window has a band of white paint over the area where it bonds to the structure. The canopy
window also has a screened area above the pilots’ heads. This is a sun-shade. New windows are
painted by the manufacturer.
B. Front Canopy and Emergency Windows
The one-piece canopy window covers the pilots’ cockpit. It is also the windscreen. It has a small
emergency window (direct-vision panel) on the left side. Some airplanes also have an emergency
window on the right side. The emergency windows have a hinge. You can open the emergency
windows in flight.
C. 'Pop out' Windows (OÄM 40-086)
The emergency windows can be furnished with optional small 'pop out' windows for ventilation
(OÄM 40-086).
D. Rear Windows
The passenger door has a window for the left side of the passenger compartment. The right side
of the fuselage also has a window for the passenger compartment.
Doc # 6.02.15 Page 3
Rev. 2 56-10-00 15 Apr 2013
Windows DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 56-10-00 Rev. 2
DA 40 NG AMM Windows
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to replace or repair damaged windows. See Section 12-30 for data on
cleaning windows.
2. Replace a Window
You must cut the window to replace it!
A. Equipment.
Item Quantity Part Number
High-speed rotary grinder. 1 Commercial.
Terostat adhesive. A/R 9280.
White sealant. A/R
B. Procedure
Detail Steps/Work Items Key Items/References
(1) Remove the canopy or door. Put the canopy or Only if you will replace the canopy or
door on a firm working surface. door window. Refer to Section 52-10.
(2) Put protective covers over the inside of the Only if you will replace the right
cockpit. fuselage window.
(3) Cut the damaged window from the frame. Use the high-speed rotary grinder.
(4) Grind the frame to remove the remaining window
material and adhesive.
(5) Put the window in position in the frame. Align the
2 holes in the window (center front and back) with
the holes in the canopy frame.
Doc # 6.02.15 Page 201
Rev. 2 56-10-00 15 Apr 2013
Windows DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(6) Carefully remove the protective coating from the
new window only where it will bond to the frame.
(7) Grind the bonding surface of the window. Use 120 grade abrasive paper.
(8) Make sure that the viewing area of the window is Use masking tape with paper.
protected.
(9) Apply adhesive to the frame. Use Terostat 9380.
(10) Put the window in position in the frame. Hold the
window with 3 mm pins through the 2 holes in the
canopy.
(11) Removed unwanted adhesive.
(12) Allow the adhesive to cure for 24 hours.
(13) Remove the 2 pins.
(14) Apply a bead of white sealant to the gap between Use Terostat 9380.
the edge of the window and the frame.
(15) Allow the sealant to cure. Follow the manufacturer’s instructions.
(16) Remove the protective covering from the window.
(17) Install the canopy or door. Only if you have replaced the canopy or
door window.
Refer to Section 52-10.
Page 202 Doc # 6.02.15
15 Apr 2013 56-10-00 Rev. 2
DA 40 NG AMM Windows
AIRCRAFT
3. Window Repairs
A. Damage Limits
Maximum crack length: 150 mm (6 in).
Do not repair cracks which are more than 150 mm (6 in) from the edge of the window.
B. Equipment
Item Quantity Part Number
Small high-speed rotary grinder. 1 Commercial.
Filler: Acryfix 92 or Tensol cement No. 70. A/R Commercial.
Masking tape. A/R Commercial.
Plastic adhesive tape. A/R Commercial.
Cold ultra-violet light source (only for Acryfix 92). A/R Commercial.
Note: Fillers become smaller when they cure. Apply enough filler to be above the level
of the window surface. Cut the filler back when it has cured.
If you repair a vertical crack, keep the filler in place with plastic adhesive tape.
Apply a second coat of filler after the first coat has cured.
C. Temporary Repairs to Windows
Stop-drill the ends of short cracks. Use a 2.5 mm (3/32 in) drill. Refer to Figure 2.
Doc # 6.02.15 Page 203
Rev. 2 56-10-00 15 Apr 2013
Windows DA 40 NG AMM
AIRCRAFT
Masking
Crack Window
Tape 60-90° >2/3 Thickness
Outer
Surface
Inner
Surface
STEP 1
Cold UV Light
Filler
(Acryfix Filler Only)
STEP 2
Stop-drill 2.5 mm (3/32 in)
Outer >1/3 Thickness
Surface
Inner
Surface 60-90°
Masking
Tape STEP 3
Filler
Cold UV Light
(Acryfix Filler Only)
STEP 4
Grind to Contour and
Polish with Fine Abrasive Paper
STEP 5
Figure 2: Window Repairs
Page 204 Doc # 6.02.15
15 Apr 2013 56-10-00 Rev. 2
DA 40 NG AMM Windows
AIRCRAFT
D. Permanent Repairs to Windows
Detail Steps/Work Items Key Items/References
(1) Remove the canopy or door. Put the canopy or Only if you will repair the canopy or
door on a firm working surface with the crack door window. Refer to Section 52-10.
horizontal.
(2) Put protective covers over the inside of the Only if you will repair the right fuselage
cockpit. window.
(3) Mask the area around the crack on both inner
and outer surfaces.
(4) Cut a groove along the crack in the outer surface Refer to Figure 2, step 1.
of the window.
(5) Countersink temporary stop-drill holes.
(6) Seal the stop-drill holes on the inner surface. Use plastic adhesive tape.
(7) Apply filler to the groove and the stop-drill holes. Step 2. Use Acryfix 92 or Tensol
cement No. 70.
(8) Let the filler cure. Refer to the manufacturer’s data.
(9) If possible, turn the window so that the inner
surface is up. Remove any plastic adhesive tape.
(10) Cut a groove along the crack in the inner surface Refer to Figure 2, step 3.
of the window.
Note: This groove is less deep than the outer surface groove. It must cut into the outer
layer of filler. This prevents holes in the filler.
(11) Countersink the filler in the stop-drill holes on the
inner surface to 1 mm (0.04 in).
(12) Apply filler to the groove and the stop-drill holes. Step 4.
(13) Let the filler cure. Refer to the manufacturer’s data.
(14) Remove the masking materials.
(15) Grind the filler to the profile of the surface. Grind both sides. Step 5.
(16) Polish the repair area with fine abrasive paper.
Doc # 6.02.15 Page 205
Rev. 2 56-10-00 15 Apr 2013
Windows DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 206 Doc # 6.02.15
15 Apr 2013 56-10-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
CHAPTER 57
WINGS
Doc # 6.02.15 Page 1
Rev. 2 57-TITLE 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 57-TITLE Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 57
WINGS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 57-10
Wing Structure
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Wings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the A or B-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
4. Remove/Install Control Surface Hinge Brackets . . . . . . . . . . . . . . . . . . . . . . . . . 216
5. Repair Data for the Wing Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Section 57-50
Flaps
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Repair Data for the Flap Shells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Doc # 6.02.15 Page 1
Rev. 2 57-CONTENTS 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
Section 57-60
Aileron
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install an Aileron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Repair Data for the Aileron Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Page 2 Doc # 6.02.15
15 Apr 2013 57-CONTENTS Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
CHAPTER 57
WINGS
1. General
The DA 40 NG has cantilever wings. The wings are set low on the fuselage. Each wing has a flap
attached to the inboard trailing edge. An aileron attaches to the outboard trailing edge.
The wings have a monocoque structure. Each wing has top and bottom shells. The shells have CFRP
outer skins, a rigid foam core and GFRP inner skins. Each wing has two I-section spars.
Uni-directional carbon fiber cloth makes the spar caps. Each wing also has GFRP ribs and webs.
The flaps and ailerons have a mixture of CFRP and GFRP cloth in the shells. The shells have rigid
foam cores.
This Chapter gives the repair data about the layers of cloth used in the structure of the wings flaps and
ailerons. Refer to Chapter 51 for general composite repair data. Refer to Chapter 27 for data about
the control systems which operate the flaps and ailerons.
Doc # 6.02.15 Page 1
Rev. 2 57-00-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 57-00-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
Section 57-10
Wing Structure
1. General
This Section gives you the data about the structure of the wings. Refer to Section 57-50 for data about
the structure of the flaps. Refer to Section 57-60 for data about the structure of the ailerons.
Doc # 6.02.15 Page 1
Rev. 2 57-10-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
Top Shell
Middle
Root Rib Rear
Root Rib
Bush
Flap Control Rib
Spar
Stub Rear Web
Front
Root Rib Aileron Control Rib Removable
Winglet
Front Spar Rear Spar
Inner Fuel
Tank Ribs
Outer Fuel
Tank Ribs
Bottom Shell
2 Outer Ribs
Left Wing Shown, (Not all S/Ns)
Right Wing Opposite
End Rib
Figure 1: Wing Structure
Page 2 Doc # 6.02.15
15 Apr 2013 57-10-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
2. Description
Figure 1 shows the wing structure. The wing has top and bottom shells. It has front and rear spars and
a root rib made in three parts. Four ribs hold the fuel tanks between the spars. Flap and aileron control
ribs hold the bellcranks for the control systems.
A rear web closes the trailing edge of the wing. An end rib closes the outboard end of the wing.
A removable GFRP tip attaches to the wing shells and outer rib with screws.
Bonding paste (thickened resin) bonds the wing components to each other. The following section gives
more data about the main parts:
A. Wing Shells
Each wing has top and bottom shells. Each shell has a CFRP outer skin, a rigid foam core and a
GFRP inner skin. The fibers in the layers of cloth which cover the whole wing run at ± 45° to the
lateral axis of the wing. The outer layer is carbon fiber. The inner layer is glass fiber.
Some areas have more layers of cloth to give more strength. For example, the area around each
access hole has extra layers of carbon fiber cloth.
The bottom shell of each wing has seven access holes. These give access to the flap and aileron
bellcranks and fuel tanks. The top shell has a hole for the fuel cap of the outer fuel tank.
B. Spars
Each wing has two I-section spars. The front spar on one side is the same as the rear spar on the
opposite side.
Many layers of uni-directional carbon fiber make the spar caps. The number of layers in the spar
caps decreases from root to tip.
Each spar has a shear web. The shear web has GFRP skins and a rigid foam core. Glass cloth
fillets attach the spar caps to the shear web.
The inboard end of each spar (the ‘stub’) goes past the root rib. The spar stub is a box-section with
many layers of glass cloth wrapped round the spar caps. Two large bushes bond into the spar stub.
The wing main bolts engage these bushes and attach the wing to the fuselage center section. The
bushes and bolts transmit the wing bending loads into the center section. Figure 3 shows the main
bolt installation.
Doc # 6.02.15 Page 3
Rev. 2 57-10-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
C. Root Rib
Each wing has a three-piece root rib. Each piece is a GFRP molding with many layers of glass fiber
cloth. The front root rib bonds to the top and bottom shells and the front face of the front spar. It has
a housing for the A-bolt. The A-bolt transmits lift loads into the center section.
The middle part of the root rib bonds to the top and bottom shells, the aft face of the front spar and
the front face of the rear spar. It has a large oval access panel for removing the fuel tanks.
The rear root rib bonds to the top and bottom shells, the aft face of the rear spar and the rear web.
It has a housing for the B-bolt. The B-bolt transmits lift loads into the center section. It also has
guide rollers for the flap and aileron push rods.
D. Fuel Tank Ribs
Four ribs hold the fuel tanks in each wing. Each rib is a GFRP molding with a large oval hole. The
hole has a flat inner flange to hold the tank. The ribs bond to the top and bottom shells, the aft face
of the front spar and the front face of the rear spar.
E. Flap and Aileron Control Ribs
Each wing has two flap and one aileron control rib. The ribs are GFRP moldings. Each rib has a
bend with a solid insert. The insert gives extra strength where the control bellcrank attaches. The
ribs bond to the top and bottom shells, the aft face of the rear spar and the rear web.
F. Rear Web
Each wing has a rear web. The web closes the trailing edge of the wing. The web bonds to the top
and bottom shells. It also bonds to the rear faces of the rear root rib, the flap control ribs and the
aileron control rib. The rear web has extra layers where the flap and aileron hinges attach. Rivets
hold anchor-nut plates to the forward face of the rear web where the hinges attach.
G. Wing End Rib
Each wing has an end rib. The end rib is a GFRP molding. The end rib has eight anchor-nuts which
attach the wing tip. It also has a threaded strong-point for a tie-down ring.
H. Wing Tip
The wing tip is a GFRP molding with top and bottom shells. The wing tip holds the external lights.
Page 4 Doc # 6.02.15
15 Apr 2013 57-10-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove and install the wings. They also tell you how to
remove and install the wing tips and other small components.
2. Remove/Install the Wings
A. Equipment
Item Quantity Part Number
Padded wing trestles. 4 Commercial.
Main bolt removal tool. 1 -
Wing stand (not essential). 1 per wing Commercial.
Doc # 6.02.15 Page 201
Rev. 2 57-10-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
B. Remove the Wings
Use this procedure to remove the left wing or the right wing. Where a part of the procedure applies
to only one wing it will tell you so.
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE AREA AROUND THE FLAPS IS CLEAR OF
PERSONS AND EQUIPMENT BEFORE YOU LOWER THE FLAPS. IF
NOT, THE FLAPS CAN INJURE PERSONS OR BE DAMAGED BY
EQUIPMENT.
(1) Lower the flaps.
(2) Disconnect the battery. Refer to Section 24-31.
(3) Defuel the airplane. Refer to Section 12-10.
(4) Remove these items for access:
S The left/right pilots’ seats. As necessary. Refer to Section 25-10.
S Main landing gear access panel.
S Center section rear access panel.
S Inboard fuel tank access panel.
(5) Put trestles under both wing tips. Under the end rib.
(6) Disconnect the flap push-rod: At the wing root.
S Remove the nut, washer and bolt. Through the center section rear panel.
(7) Disconnect the aileron push-rod: At the wing root.
S Remove the nut, washer and bolt. Through the center section rear panel.
(8) Disconnect the electrical connector in the wing Left wing: connector P2400, under the
harness. pilot's seat.
Right wing: connector P2401, under the
co-pilot's seat.
Page 202 Doc # 6.02.15
15 Apr 2013 57-10-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
Detail Steps/Work Items Key Items/References
(9) Disconnect these items under the left pilot’s seat: For left wing only.
S The Pitot hose. The hose is 8 mm (5/16 in) diameter
(green color).
S The stall warning hose. The hose is 10 mm (3/8 in) diameter
(transparent).
WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE DISEASE.
WARNING: DO NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN CAUSE
INJURY TO PERSONS AND DAMAGE TO EQUIPMENT.
(10) Disconnect the fuel hose(s) in the stub wing. Put a container to catch a small quantity
of fuel. Remove spilt fuel.
(11) Remove the locking tube from the inboard and
outboard main bolts:
S Remove the nut, washer and bolt.
S Move the tube over the long end piece.
S Remove the short end piece.
S Remove the tube and the long end piece.
WARNING: THREE PERSONS NEEDED TO LIFT THE WING. IF YOU DO NOT,
YOU CAN CAUSE INJURY.
CAUTION: DO NOT LIFT ON THE FLAP. YOU CAN DAMAGE THE FLAP.
Note: For the rest of this procedure, one person must lift the wing tip. One person
must lift the leading edge at the root rib. One person must lift the trailing edge
at the root rib.
Doc # 6.02.15 Page 203
Rev. 2 57-10-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(12) Remove the main bolts:
S Take the weight off the wing. If necessary, move the wing tip a small
amount up and down to help release
the main bolts.
S For each bolt:
S Install the main bolt removal tool.
S Extract the bolt.
(13) Lift the wing away from the center section. Make sure that the electrical cables do
not catch on the center section conduit.
(14) Put the wing on trestles or a wing stand.
Note: If you use trestles, put one trestle under the spar stubs. Put the second trestle
under the wing end rib.
Page 204 Doc # 6.02.15
15 Apr 2013 57-10-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
Rear Main Bulkhead Bushes
Rear Spar
Locking Tube
Locking Bolt
Front Main Bulkhead
Bushes
Short
End-Piece Rear Spar Bush
Main Bolt
Long
End-Piece
Front
Main Bolt
Front Spar Spar Bush
Figure 2: Wing Main Bolt Installation
Doc # 6.02.15 Page 205
Rev. 2 57-10-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
C. Pre-Installation Check
Do this check before you install the wings.
Detail Steps/Work Items Key Items/References
(1) Examine the inner faces of the front and rear Refer to the manufacturer if you find
main bulkheads. Look specially for: damage in any of these areas.
S Damage to the main bolt bushes. Clean the bushes.
S Damage to the structure round the bushes.
S Looseness between the bushes and the main
bulkhead.
S Damage to the top and bottom shells of the
center section (where the spar stubs can
touch the shells during wing removal).
S Delamination between the main bulkheads
and the shells.
(2) Examine the front, middle and rear end ribs in the Refer to the manufacturer if you find
center section. Look specially for: damage in any of these areas.
S Damage to the A and B-bolt bushes. Clean the bushes.
S Looseness between the A and B-bolt bushes
and the end ribs.
S Delamination between the end ribs, the main
bulkheads and the shells.
(3) Examine the wing spar stubs. Look specially for: Refer to the manufacturer if you find
damage in any of these areas.
S Damage to the main bolt bushes. Clean the bushes.
S Damage to the spar stub around the bushes.
S Looseness between the bushes and the spar
stub.
S Delamination between the spars and the
shells.
Page 206 Doc # 6.02.15
15 Apr 2013 57-10-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
Detail Steps/Work Items Key Items/References
(4) Examine the wing root ribs. Look specially for: Refer to the manufacturer if you find
damage in any of these areas.
S Damage to the A and B-bolts and bushes. Clean the bolts and bushes.
S Damage to the front and rear root ribs around
the bushes.
S Looseness between the bushes and the root
ribs.
S Delamination between the root ribs, the spars
and the shells.
(5) Examine the main bolt assemblies. Look Clean the main bolt assembly.
specially for:
S Corrosion of the end-pieces or tube. Remove corrosion. Repair the surface
finish. Refer to Section 51-20.
S Corrosion of the main bolts. No corrosion permitted.
S Scratches on the bearing surfaces. Maximum depth 0.1 mm (0.004 in).
S Deformation. No deformation permitted.
S Damage to the threads for the removal tool. Replace the bolt if you cannot attach
the removal tool correctly.
(6) Measure the radial play of each main bolt in the Maximum radial play 0.2 mm (0.008 in).
related main bulkhead bushes.
(7) Measure the radial play of each main bolt in the Maximum radial play 0.2 mm (0.008 in).
related spar stub bush.
(8) Lubricate these items: Refer to Section 12-20.
S Main bolts.
S Front and rear main bulkhead bushes.
S Spar bushes.
S A and B-bolt bushes in the end ribs.
S A and B-bolts in the wing root ribs.
Doc # 6.02.15 Page 207
Rev. 2 57-10-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(9) Examine the flap torsion tube and transfer lever
in the center section. Look specially for damage
to the transfer pins.
(10) Examine the flap. Look specially for damage to
the inner end rib.
Page 208 Doc # 6.02.15
15 Apr 2013 57-10-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
D. Install the Wings
Use this procedure to install the left wing or the right wing. Where a part of the procedure applies
to only one wing it will tell you so.
Detail Steps/Work Items Key Items/References
(1) Do the pre-installation check. Refer to Paragraph C.
WARNING: THREE PERSONS NEEDED TO LIFT THE WING. IF YOU DO NOT,
YOU CAN CAUSE INJURY.
CAUTION: DO NOT LIFT ON THE FLAP. YOU CAN DAMAGE THE FLAP.
CAUTION: DO NOT LET THE SPAR STUBS TOUCH THE CENTER SECTION
SHELLS. YOU CAN DAMAGE THE SHELLS.
Note: Until you install the main bolts, one person must lift the wing tip. One person
must lift the leading edge at the root rib. One person must lift the trailing edge
at the root rib.
(2) Lift the wing into position:
S Move the spar stubs part way into the front Hold the wing in position.
and rear main bulkheads.
S Put the electrical cable, Pitot, static and stall Hold the wing in position.
warning tubes through the conduit in the
leading edge of the center section.
S Align the flap inner rib with the transfer pins Hold the wing in position.
on the transfer lever.
S Move the wing fully into the center section to
engage the A and B-bolts and the flap
transfer pins.
(3) Install the main bolts: If necessary, move the wing tip a small
amount up and down to help install the
S Hold the weight of the wing.
main bolts.
S Install each bolt.
Doc # 6.02.15 Page 209
Rev. 2 57-10-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(4) Install the locking tubes on the inboard and Refer to Figure 3.
outboard main bolts:
S Install the long end piece in one main bolt.
S Move the tube over the long end piece.
S Install the short end piece in the other main
bolt.
S Move the tube over the short end piece.
S Install the bolt, washer and self-locking nut Torque: hand tight.
through the tube and the long end piece.
(5) Connect these items under the left pilot’s seat: For left wing only.
S The Pitot hose. The hose is 8 mm (5/16 in) diameter.
(Green color).
S The stall warning hose. The hose is 10 mm (3/8 in) diameter.
(Transparent).
(6) Connect the electrical connector in the wing Left wing: connector P2400, under the
harness. pilot's seat.
Right wing: connector P2401, under the
co-pilot's seat.
(7) Connect the fuel hose(s) in the stub-wing.
(8) Connect the flap push-rod: Through the center section rear panel.
S Install the bolt, washer and self-locking nut. Torque: 6.4 Nm (4.7 lbf.ft.).
(9) Connect the aileron push-rod: Through the center section rear panel.
S Install the bolt, washer and self-locking nut. Torque: 6.4 Nm (4.7 lbf.ft.).
(10) If you must also install the other wing, do steps
1 to 9 again for that wing.
(11) Connect the battery. Refer to Section 24-31.
(12) Do a test for correct operation and range of Refer to Section 27-50.
movement of the flap system. If necessary, adjust
the flap system.
Page 210 Doc # 6.02.15
15 Apr 2013 57-10-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
Detail Steps/Work Items Key Items/References
(13) Do an inspection of the flap controls which you
have connected or adjusted.
S If necessary for your Airworthiness Authority,
do a second inspection of the controls.
(14) Do a test for correct operation and range of Refer to Section 27-10.
movement of the aileron system. If necessary,
adjust the aileron system.
(15) Do an inspection of the aileron controls which
you have connected or adjusted.
S If necessary for your Airworthiness Authority,
do a second inspection of the controls.
(16) Do a functional check of these lights: Refer to Section 33-40.
S Navigation lights.
S Strobe lights (ACLs).
Left wing only.
S Taxi light.
Left wing only.
S Landing light.
(17) Do a functional check of the Pitot heating system. Left wing only.
Refer to Section 34-10.
(18) Do a Pitot and static system leak test. Left wing only.
Refer to Section 34-10.
(19) Refuel the airplane to the unusable fuel level. Refer to Section 12-10.
(20) Install these items after access:
S The left/right pilots’ seats. As necessary. Refer to Section 25-10.
S Main landing gear access panel.
S Center section rear access panel.
S Inboard fuel tank access panel.
(21) Do an air test. Refer to the Airplane Flight Manual.
Doc # 6.02.15 Page 211
Rev. 2 57-10-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
3. Remove/Install the A or B-Bolts
A. Remove the A or B-Bolts
Detail Steps/Work Items Key Items/References
(1) Remove the wing Refer to Paragraph 2.
(2) Remove the A or B-bolt: Refer to Figure 4.
S Hold the flats on the flange of the bolt with a
wrench.
S Remove the self-locking nut from the A or Access for the A-bolt through the hole
B-bolt. in the front root rib.
Access for the B-bolt through the
access panel in the bottom shell.
S Remove the A or B-bolt.
Page 212 Doc # 6.02.15
15 Apr 2013 57-10-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
Rear
Root Rib
Front
Root Rib
Bonded
Bush
Access
Hole Access B-Bolt
Bonded Panel
Bush RIGHT SHOWN LEFT OPPOSITE
A-Bolt
Figure 3: A and B-Bolt Installation
Doc # 6.02.15 Page 213
Rev. 2 57-10-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
B. Install the A or B-Bolts
Detail Steps/Work Items Key Items/References
(1) Examine the A or B-bolt. Look specially for:
S Corrosion. No corrosion permitted.
S Scratches on the bearing surfaces. Maximum depth 0.1 mm (0.004 in).
S Deformation. No deformation permitted.
S Damage to the threads. No damage permitted.
(2) Examine the A or B-bolt bush. Look specially for:
S Looseness between the A or B-bolt bush and
the root rib.
S Damage to the root rib where the bush
attaches.
S Damage to the bush.
(3) Install the A or B-bolt: Refer to Figure 4.
S Install the bolt in the bush. Access for the A-bolt through the hole
in the front root rib.
S Hold the flats on the flange of the bolt with a Access for the B-bolt through the
wrench. access panel in the bottom shell.
S Install the washer and self-locking nut. Torque: 32 Nm (23.6 lbf.ft.).
(4) Install the wing. Refer to Paragraph 2.
Page 214 Doc # 6.02.15
15 Apr 2013 57-10-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
Figure 4: Control Surface Hinge Bracket Installation
Doc # 6.02.15 Page 215
Rev. 2 57-10-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
4. Remove/Install Control Surface Hinge Brackets
A. Remove Control Surface Hinge Brackets
Detail Steps/Work Items Key Items/References
(1) Remove the control surface. Refer to Sections 57-50 and 57-60.
(2) For brackets at the control horn hinge: The flap brackets have 3 bolts.
S Remove the control bell-crank access panel The aileron brackets have 2 bolts.
under the wing.
S Remove the attaching nuts and large
washers.
S Remove the bolts and small washers. From inside of the wing.
S Remove the bracket.
(3) For brackets not at the control horn hinge: All brackets have 2 bolts.
S Remove the bolts and small washers.
S Remove the bracket.
Page 216 Doc # 6.02.15
15 Apr 2013 57-10-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
B. Install Control Surface Hinge Brackets
Detail Steps/Work Items Key Items/References
(1) For brackets at the control horn hinge: The flap brackets have 3 bolts.
The aileron brackets have 2 bolts.
S Put the bracket in position on the rear web.
S Install the bolts with small washers. From inside of the wing.
Torque: 3.6 Nm (2.7 lbf.ft.).
S Install the large washers and self-locking
nuts.
S Install the control bellcrank access panel
under the wing.
(2) For brackets not at the control horn hinge: All brackets have 2 bolts.
S Put the bracket in position on the rear web.
S Install the bolts and small washers. Torque: 3.6 Nm (2.7 lbf.ft.).
(3) Install the control surface. Refer to Sections 57-50 and 57-60.
5. Repair Data for the Wing Shells
Figures 6 through 9 show the layers of glass fiber cloth in the wing shells. Use this data when you
need to repair the wing.
The Figures show the main layers of cloth. The cross-hatching on the figure shows the orientation of
the fibers. The orientation is also given in the related table. When you repair the wing, you must use
the same type of cloth with the same fiber orientation.
The numbers in circles beside each drawing give the order in which the layers are applied (‘Stages’).
The first stage is a layer of filler and is not shown. Stage 1 is the outer face of the shell.
Always do a burn test on a piece of composite from the damaged area before you do a repair. Refer
to Section 51-20 for the burn test.
Doc # 6.02.15 Page 217
Rev. 2 57-10-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
Item Layers Reference No. Type Remarks
No.
1 1 8.4503.60 Interglas 02037 0o/90o
2, 3 1 CCC 459 Al carbon/aluminum 0°/90º - lightning protection.
6 2 8.3520.80 carbon cloth 0°/90º, 100 mm wide.
7 1 8.3520.80 carbon cloth ±45º
10 - 13 3 each 8.3520.80 carbon cloth ±45º, 200 mm x 200 mm
14, 15 3 each 8.3520.80 carbon cloth ±45º, 200 mm x 250 mm
16 3 each 8.3520.80 carbon cloth ±45º, 160 mm x 160 mm
Figure 5: Layers of Cloth in the Wing Bottom Shell - Stages 2 - 6
Page 218 Doc # 6.02.15
15 Apr 2013 57-10-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
Item No. Layers Reference No. Type Remarks
18, 20 1 each H 60 6 mm rigid foam
22 2 8.4551.60 glass twill 2/2 ±45º, 90 mm wide.
23 1 8.4551.60 glass twill 2/2 ±45º
Figure 6: Layers of Cloth in the Wing Bottom Shell - Stages 7 - 9
Doc # 6.02.15 Page 219
Rev. 2 57-10-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
Item No. Layers Reference No. Type Remarks
2, 3 1 CCC 459 Al carbon/aluminum 0°/90º - lightning protection.
6 2 8.3520.80 carbon cloth 0°/90º, 100 mm wide.
7 2 8.3520.80 carbon cloth ±45º 200 mm x 200 mm.
10 3 8.3520.80 carbon cloth ±45º 220 mm x 220 mm.
11 3 8.3520.80 carbon cloth ±45º 250 mm x 300 mm.
Figure 7: Layers of Cloth in the Wing Top Shell - Stages 2 - 6
Page 220 Doc # 6.02.15
15 Apr 2013 57-10-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
13 15
17
Item Layers Reference No. Type Remarks
No.
13, 15 1 each H 60 6 mm rigid foam
17 1 8.4551.60 glass twill 2/2 ±45º
Figure 8: Layers of Cloth in the Wing Top Shell - Stages 7 and 8
Doc # 6.02.15 Page 221
Rev. 2 57-10-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 222 Doc # 6.02.15
15 Apr 2013 57-10-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
Section 57-50
Flaps
1. General
This Section tells you about the flap structure. Refer to Section 27-50 for data about the flap control
system.
2. Description
Figure 1 shows the flap structure. Each flap has these components:
A. Bottom Shell
The bottom shell has inner and outer GFRP skins. It also has one layer of carbon fiber cloth in the
outer skin. The skins bond to a rigid plastic foam core. The leading edge of the shell bends up to
form a web. It then curves forward to form a shroud which seals the gap between flap and wing
when the flap is down.
The outboard end of the bottom shell also bends up to close the end of the flap. The leading edge,
the ends, and the area where the horn attaches have more carbon fiber cloth to give more strength
and stiffness.
B. Top Shell
The top shell has inner and outer GFRP skins. It also has one layer of carbon cloth in the outer
skin. The skins bond to a rigid plastic foam core. The top shell bonds to the bottom shell and the
inner end rib.
C. Inner End Rib
The inner end rib is a CFRP molding. The rib has two holes with flanged bushes. The bushes
engage with the transfer pins on the transfer levers of the flap control system. The end rib bonds
to the top and bottom shells.
D. Flap Horn
The flap horn is an aluminum alloy component. Three bolts attach the horn to the bottom surface
of the flap. A small hole in the leading edge of the flap gives access to the front attaching nuts and
washers. The horn also makes one of the flap hinges. Two flanged bushes in the front of the horn
make the hinge.
E. Flap Hinges
Each flap has five hinges (as well as the flap horn). Two bolts attach each hinge to the leading edge
of the flap. A small hole in the middle of the hinge gives access to the attaching nuts and washers.
Each hinge has a flanged bush at the inboard end. A plastic plug seals the outboard end.
Doc # 6.02.15 Page 1
Rev. 2 57-50-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
Top Shell
Inner
End Rib
Bottom Shell
Flap Structure
Access
Hole
Mass
Balance
Flap Horn
Access
Hole
Flanged
Bush
Flap Leading Edge
Flap Hinge Plastic Plug
Figure 1: Flap Structure and Assembly
Page 2 Doc # 6.02.15
15 Apr 2013 57-50-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove and install the flaps. Refer to Section 27-50 for
the flap setting procedure.
2. Remove/Install a Flap
A. Remove a Flap
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE AREA AROUND THE FLAPS IS CLEAR OF
PERSONS AND EQUIPMENT BEFORE YOU LOWER THE FLAPS. IF
NOT, THE FLAPS CAN INJURE PERSONS OR BE DAMAGED BY
EQUIPMENT.
(1) Lower the flaps:
S Set the ELECTRIC MASTER key switch to
ON.
S Set the flap selector to LDG.
S When the flaps stop moving.
S Set the ELECTRIC MASTER key switch to
OFF.
(2) Open the circuit-breaker for the flap control. Instrument panel. Right side.
(3) Disconnect the flap push rod from the flap horn: Hold the flap.
S Remove the nut and washer from the bolt
which attaches the push rod to the horn.
S Remove the attachment bolt and washer from
the horn.
Doc # 6.02.15 Page 201
Rev. 2 57-50-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(4) Remove the 6 hinge pins from the flap hinges Support the flap assembly!
and the flap horn:
S Remove the roll pins which locate the flap
hinge pins.
S Move the hinge pins inboard, and clear of the
hinges.
(5) Carefully move the flap aft, and clear of the
airplane.
B. Install a Flap
Detail Steps/Work Items Key Items/References
(1) Make sure that the hinge pins are clean and not
damaged.
(2) Put the flap into position on the airplane.
(3) Install the 6 hinge pins in the hinges and flap Make sure that there is a gap of 0.5 -
horn: 2.5 mm (0.002 - 0.010 in) between the
faces of the hinge at the horn and a gap
S Push the hinge pins into position from the
of 1 - 3 mm (0.004 - 0.012 in) between
inboard side.
the faces at the other hinges.
S Align the holes in the hinges with the holes in
the hinge pins and install the roll pins.
(4) Install the bolt which attaches the flap push rod to
the flap horn:
S Install a washer on the bolt.
S Push the bolt through the horn and the push
rod.
S Install the washer and the nut on the bolt.
(5) Do a test for correct adjustment of the flaps. Refer to Section 27-50.
(6) If necessary for your Airworthiness Authority, do
a second inspection of the flap controls.
Page 202 Doc # 6.02.15
15 Apr 2013 57-50-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
3. Repair Data for the Flap Shells.
Figures 2 and 3 show the layers of glass/carbon fiber cloth in the flap shells. Use this data when you
need to repair the flap.
The Figures show the main layers of cloth. The cross-hatching on the figure shows the orientation of
the fibers. The orientation is also given in the related table. When you repair the flap, you must use the
same type of cloth with the same fiber orientation.
The numbers in circles beside each drawing give the order in which the layers are applied (‘Stages’).
The first stage is a layer of filler and is not shown. Stage 1 is the outer face of the shell.
Always do a burn test on a piece of composite from the damaged area before you do a repair. Refer
to Section 51-20 for the burn test.
Doc # 6.02.15 Page 203
Rev. 2 57-50-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
2 2
6 8
3 3
7
9 10 11 12 13 14
7
4 4
15
8
5
5
Item No. Layers Reference No. Type Remarks
2 1 8.4548.60 glass twill 2/2 ±45º
3 1 8.3520.8 carbon ±45º
4 1 8.3520.8 carbon ±45º, 80 mm x 270 mm.
5 1 H 60 3 mm rigid foam
7 1 8.3520.8 carbon ±45º, 70 mm x 230 mm.
8 1 8.3520.8 carbon ±45º, 90 mm wide.
9 - 14 1 each 8.3520.8 carbon ±45º, 30 mm x 70 mm.
15 1 8.4548.60 glass twill 2/2 ±45º
Figure 2: Layers of Cloth in the Flap Bottom Shell
Page 204 Doc # 6.02.15
15 Apr 2013 57-50-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
2 5
2 5
3
3 6
4 8
4 7
Item No. Layers Reference No. Type Remarks
2 1 8.4548.60 glass twill 2/2 ±45º
3 2 8.3520.8 carbon ±45º, 80 mm x 80 mm.
4 1 8.3520.8 carbon ±45º
5 1 H 60 3 mm rigid foam
7 1 8.3520.8 carbon ±45º
8 1 8.4548.60 glass twill 2/2 ±45º
Figure 3: Layers of Cloth in the Flap Top Shell
Doc # 6.02.15 Page 205
Rev. 2 57-50-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 206 Doc # 6.02.15
15 Apr 2013 57-50-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
Section 57-60
Aileron
1. General
This Section tells you about the aileron structure. Refer to Section 27-10 for data about the aileron
control system.
2. Description
Figure 1 shows the aileron structure. Each aileron has these components:
A. Bottom Shell
The bottom shell has inner and outer GFRP skins. A layer of carbon fiber cloth covers a large part
of the inboard area of the outer skin. The skins bond to a rigid plastic foam core. The leading edge
of the shell bends up to form a web. It then curves forward to form a shroud which seals the gap
between aileron and wing when the aileron moves down.
The ends of the bottom shell also bend up to close the ends of the aileron. The leading edge, the
ends and the area where the horn attaches have more carbon fiber cloth to give more strength and
stiffness.
B. Top Shell
The top shell has inner and outer GFRP skins. A layer of carbon fiber cloth covers a large part of
the inboard area of the outer skin. The skins bond to a rigid plastic foam core. The top shell bonds
to the bottom shell.
C. Aileron Horn
The aileron horn is an aluminum alloy component. Three bolts attach the horn to the bottom surface
of the aileron. A small hole in the leading edge of the aileron gives access to the front attaching
nuts and washers. The horn also makes one of the aileron hinges.
D. Aileron Hinges
Each aileron has three hinges (as well as the aileron horn). Two bolts attach each hinge to the
leading edge of the aileron. A small hole in the middle of the hinge gives access to the attaching
nuts and washers. Each hinge has a flanged bush at the inboard end. A plastic plug seals the
outboard end.
E. Aileron Mass Balance
Each aileron has a paddle on the outboard end. To balance the mass of the aileron behind the
hinge line, the leading edge of the paddle is made from heavy metal.
Doc # 6.02.15 Page 1
Rev. 2 57-60-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
Top Shell
Bottom
Shell
Aileron
Structure
Access
Hole
Aileron Horn Mass
Balance
Access
Hole
Flanged
Bush
Aileron Leading Edge
Aileron Hinge Plastic Plug
Figure 1: Aileron Structure and Assembly
Page 2 Doc # 6.02.15
15 Apr 2013 57-60-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove and install the ailerons. Refer to Section 27-10
for the aileron control setting procedure.
2. Remove/Install an Aileron
A. Remove an Aileron
Detail Steps/Work Items Key Items/References
(1) Disconnect the aileron push rod from the aileron Hold the aileron.
horn:
S Remove the nut and washer from the bolt
which attaches the push rod to the horn.
S Remove the attachment bolt and washer from
the horn.
(2) Remove the 4 hinge pins from the aileron hinges Support the aileron assembly!
and the aileron horn:
S Remove the roll pins which locate the aileron
hinge pins.
S Move the hinge pins inboard, and clear of the
hinges.
(3) Carefully move the aileron aft, and clear of the
airplane.
Doc # 6.02.15 Page 201
Rev. 2 57-60-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
B. Install an Aileron
Detail Steps/Work Items Key Items/References
(1) Make sure that the hinge pins are clean and not
damaged.
(2) Put the aileron into position on the airplane.
(3) Install the 4 hinge pins in the hinges and aileron Make sure that there is a gap of 0.5 -
horn: 2.5 mm (0.002 - 0.010 in) between the
faces of the hinge at the horn and a gap
S Push the hinge pins into position from the
of 1 - 3 mm (0.004 - 0.012 in) between
inboard side.
the faces at the other hinges.
S Align the holes in the hinges with the holes in
the hinge pins and install the roll pins.
(4) Install the bolt which attaches the aileron push
rod to the aileron horn:
S Install a washer on the bolt.
S Push the bolt through the horn and the push
rod.
S Install the washer and the nut on the bolt.
(5) Do a test for correct adjustment of the aileron. Refer to Section 27-60.
(6) If necessary for your Airworthiness Authority, do
a second inspection of the aileron controls.
Page 202 Doc # 6.02.15
15 Apr 2013 57-60-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
3. Repair Data for the Aileron Shells
Figures 2 and 3 show the layers of glass/carbon fiber cloth in the aileron shells. Use this data when
you need to repair the aileron.
The Figures show the main layers of cloth. The cross-hatching on the figure shows the orientation of
the fibers. The orientation is also given in the related table. When you repair the aileron, you must use
the same type of cloth with the same fiber orientation.
The numbers in circles beside each drawing give the order in which the layers are applied (‘Stages’).
The first stage is a layer of filler and is not shown. Stage 1 is the outer face of the shell.
Always do a burn test on a piece of composite from the damaged area before you do a repair. Refer
to Section 51-20 for the burn test.
Doc # 6.02.15 Page 203
Rev. 2 57-60-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
2 2 6 8
9 10
3 3 7 11 12 13 14
4 4 5 8
15
5
6
Item No. Layers Reference No. Type Remarks
2 2 8.4548.60 glass twill 2/2 ±45º
3 1 8.3520.8 carbon ±45º, 270 mm x 1220 mm.
4 1 8.4548.60 glass twill 2/2 ±45º, 270 mm x 520 mm.
5 3 8.3520.8 carbon ±45º, 80 mm x 270 mm.
6 1 H 60 3 mm rigid foam
8 1 8.3520.8 carbon ±45º, 90 mm x 1670 mm.
9 2 8.4548.60 glass twill 2/2 ±45º, 80 mm x 270 mm.
10 8 8.3520.8 carbon ±45º, 80 mm x 270 mm.
11 - 14 8 each 8.3520.8 carbon ±45º, 20 mm x 70 mm.
15 1 8.4548.60 glass twill 2/2 ±45º
Figure 2: Layers of Cloth in the Aileron Bottom Shell
Page 204 Doc # 6.02.15
15 Apr 2013 57-60-00 Rev. 2
DA 40 NG AMM Wings
AIRCRAFT
2 2 5
5
3
3 6
4
8
4 7
Item Layers Reference No. Type Remarks
No.
2 2 8.4548.60 glass twill 2/2 ±45º
3 1 8.3520.8 carbon ±45º 300 mm x 1220 mm.
4 1 8.4548.60 glass twill 2/2 ±45º 300 mm x 480 mm.
5 1 H 60 3 mm rigid foam
7 2 8.3520.8 carbon ±45º 40 mm x 80 mm.
8 1 8.4548.60 glass twill 2/2 ±45º
Figure 3: Layers of Cloth in the Aileron Top Shell
Doc # 6.02.15 Page 205
Rev. 2 57-60-00 15 Apr 2013
Wings DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 206 Doc # 6.02.15
15 Apr 2013 57-60-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
CHAPTER 61
PROPELLER
Doc # 6.02.15 Page 1
Rev. 2 61-TITLE 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2
15 Apr 2013 61-TITLE Doc # 6.02.15
Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 61
PROPELLER
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 61-10
Propeller Assembly
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the MTV-6-R/190-69 Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Propeller Blade Tracking Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4. Check/Adjust the V-Belt Tension of the Additional Alternator (if OÄM 40-314 is
installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
5. Remove/Install the Additional Alternator V-Belt (if OÄM 40-314 is installed) . . . 211
6. Remove/Install the Additional Alternator (if OÄM 40-314 is installed) . . . . . . . . 216
Section 61-20
Propeller Control
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Doc # 6.02.15 Page 1
Rev. 2 61-CONTENTS 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Propeller Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Page 2
15 Apr 2013 61-CONTENTS Doc # 6.02.15
Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
CHAPTER 61
PROPELLER
1. General
This Chapter describes the propeller installation of the DA 40 NG. Refer to Section 61-10 for data
about the propeller and refer to Section 61-20 for data about the propeller control.
For more data on the propeller refer to the propeller manufacturer’s manuals.
Note: Equipment which is certified for installation in the DA 40 NG is listed in Section 6.5
of the Airplane Flight Manual. Such equipment may be installed in accordance with
the Airplane Maintenance Manual.
Any equipment which is not listed in Section 6.5 of the Airplane Flight Manual is
called "Additional Equipment". The installation of Additional Equipment is a
modification which must be handled in accordance with national regulations or a
Service Bulletin.
Doc # 6.02.15 Page 1
Rev. 2 61-00-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
Propeller
Propeller Governor
Spinner
% Figure 1: Propeller Assembly
Page 2
15 Apr 2013 61-CONTENTS Doc # 6.02.15
Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
Section 61-10
Propeller Assembly
1. General
The DA 40 NG has a MTV-6-R/190-69 variable pitch propeller installed. The propeller has three
blades. The blades are made from wood and are covered with GFRP. The blades have an acrylic
lacquer painted finish. The outboard leading-edges of the blades are protected from erosion by a
stainless-steel sheath. The stainless-steel sheath is bonded into position. The inboard section of the
leading-edge is protected by a self-adhesive rubber strip (PU tape).
This Section describes how to remove and install the propeller and how to do a propeller blade
tracking test.
Refer to the propeller and governor manufacturer manuals for more data.
If OÄM 40-314 is installed, a gearbox fan with an additional alternator pulley is installed on the gearbox
flange.
2. Description
Figures 1 and 2 show the propeller. The propeller hub has six studs on the rear face. The propeller
attaches to the engine gearbox flange with six nuts and washers.
If OÄM 40-314 is installed, an additional alternator gearbox fan with an additional alternator pulley is
installed on the gearbox flange using a prop flange pulley support. The six propeller attachment nuts
mount the gearbox fan assy and the propeller to the gearbox flange.
A spinner bulkhead (spinner backplate) attaches to the rear of the hub with six bolts. The bolts are
secured with lock-wire. A front support plate attaches to the front of the hub with six screws. The
screws are also secured with lock-wire. The spinner dome which is made from composite material
attaches to the front/aft bulkhead with screws.
When the engine is running, aerodynamic as well as spring forces push the propeller blades towards
fine pitch.
The engine has an electronic engine control system EECS which includes an electronic engine control
unit (EECU). The EECU controls the propeller pitch via the governor hydraulically. Gearbox oil flows
through the constant speed governor and controls the oil pressure in the propeller pitch change
mechanism. The oil pressure is increased to obtain propeller blade pitch increase and reduced to lower
the blade pitch angles. The oil to govern the propeller blade pitch flows through the hollow propeller
and gearbox hub.
Doc # 6.02.15 Page 1
Rev. 2 61-10-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
Metal Erosion Sheath
Wood/Composite
Blade
PU Tape Spinner Bulkhead
Gearbox Flange
Balance Weights
Attaching Nut
and Washer
Hub
Blade Ferrule
Low
Pitch Stop
Front
Support Plate
Spinner Attaching
Spinner Dome Screws
Figure 1: Propeller Assembly
Page 2 Doc # 6.02.15
15 Apr 2013 61-10-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
2nd Alternator Pulley
Propeller Flange Nut
Fan Wheel
V-Belt
Spinner Bulkhead
Balance Weights
Propeller Flange
Pulley Support
Propeller Flange Pulley
Attaching Bolts
Hub
Spinner Attaching
Screws
Spinner Dome
Figure 2: Propeller Assembly (if OÄM 40-314 is installed)
Doc # 6.02.15 Page 3
Rev. 2 61-10-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
3. Operation
When the propeller is turning aerodynamic and spring forces cause the blades to turn towards fine
pitch.
High pressure oil is used to move the propeller blades to high pitch. Oil from the engine gearbox is
pumped to the governor. The governor directs the oil to the propeller as necessary to control the
propeller pitch.
The propeller pitch control system is integrated into the engine EECS system. The pitch is controlled
automatically by the EECU. Depending on the power setting the propeller pitch is adjusted such that
the required RPM will be obtained as shown in Figure 3.
An adjustable pitch stop limits the amount of blade movement towards coarse pitch.
If the oil pressure fails during normal flight aerodynamic propeller blade forces and spring forces of
the propeller pitch change mechanism pushes the blades into fine pitch.
Page 4 Doc # 6.02.15
15 Apr 2013 61-10-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
Figure 3: Propeller RPM Adjusted by the Engine ECU System
Doc # 6.02.15 Page 5
Rev. 2 61-10-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 6 Doc # 6.02.15
15 Apr 2013 61-10-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the possible defects of the propeller. If you have the trouble detailed in the
Trouble column read across to the Possible Cause column. Then do the repair according to the Repair
column.
Trouble Possible Cause Repair
Engine vibration. Propeller out of balance. Examine the propeller. If you
find damage refer to the
manufacturer’s Owners
Manual.
Spinner out of balance. Replace the spinner.
Propeller mounting loose. Tighten the mounting nuts to
the correct torque. Refer to the
manufacturer’s Owners
Manual. Use new nuts.
Spinner attaching screws Tighten the attaching screws.
loose. Refer to the manufacturer’s
Owners Manual.
Blade tracking not correct. Refer to the manufacturer’s
Owners Manual.
Cracks in the blades. Over-speed. Refer to the manufacturer’s
Owners Manual.
Holes/nicks/dents in the blade. Stone damage. Repair/replace the propeller.
Refer to the manufacturer’s
Owners Manual.
Doc # 6.02.15 Page 101
Rev. 2 61-10-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 61-10-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices describe how to remove and install the propeller, how to conduct a
propeller blade tracking test and how to remove and install the additional alternator pulley assy (if
OÄM 40-314 is installed).
2. Remove/Install the MTV-6-R/190-69 Propeller
A. Remove the Propeller
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE PROPELLER. IF THE ENGINE IS TURNED, THE
PROPELLER CAN CAUSE INJURY OR DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the engine cowling. Refer to Section 71-10.
Note: Mark the propeller, spinner, front support plate and spinner bulkhead, with an
index mark. This will help you install these items in the correct position.
(4) Remove the spinner dome: Refer to Figure 4 or 5.
S Mark the spinner dome and spinner
bulkhead with index marks to aid
installation.
S Release the screws holding the spinner
dome to the spinner bulkhead and move the
spinner dome clear of the airplane.
Doc # 6.02.15 Page 201
Rev. 2 61-10-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(5) Remove the nuts and washers which attach the Hold the propeller!
propeller to the propeller shaft flange.
(6) Pull the propeller forward and clear of the
propeller shaft flange.
(7) Use caps to cover open lines.
Page 202 Doc # 6.02.15
15 Apr 2013 61-10-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
Gearbox Flange
Hub
Oil Seal
OIL SEAL LOCATION IN THE HUB
Spinner Bulkhead
Gearbox Flange
Balance Weights
Nut
Washer
Oil Seal
Attaching Bolts
Hub
Spinner Attaching
Screws
Spinner Dome
Figure 4: Propeller Installation (if OÄM 40-314 is not installed)
Doc # 6.02.15 Page 203
Rev. 2 61-10-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
Propeller Flange
Hub
2nd Alternator Pulley
Oil Seal Propeller Flange Nut
OIL SEAL LOCATION IN THE HUB Fan Wheel
V-Belt
Spinner Bulkhead
Balance Weights
Propeller Flange
Pulley Support
Propeller Flange Pulley
Attaching Bolts
Hub
Spinner Attaching
Screws
Spinner Dome
Figure 5: Propeller Installation (if OÄM 40-314 is installed)
Page 204 Doc # 6.02.15
15 Apr 2013 61-10-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
B. Install the Propeller
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE PROPELLER. IF THE ENGINE IS TURNED, THE
PROPELLER CAN CAUSE INJURY OR DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Verify that the airplane battery is disconnected.
(3) Make sure that the propeller shaft flange and
the propeller flange are clean and dry.
% (4) Make sure that the shipping plug is removed
% and check the inside of the propeller hub area
% for contamination.
(5) Make sure that a new O-ring oil seal is in place Refer to Figure 4 or 5.
in the propeller hub. Lightly oil the seal.
Use clean gearbox oil.
(6) Move the propeller into position on the gearbox Take care not to damage the propeller
flange. O-ring seal.
Note: Make sure that the propeller is pushed into the correct position by hand. Do not
use the nuts to pull the propeller into position.
(7) Install the 6 washers and nuts.
(8) When the propeller is in the correct position, Refer to mt-Propeller Operation and
fully tighten the nuts in opposing pairs. Installation Manual, latest revision.
(9) Check gearbox oil level and refill if necessary. Refer to Section 12-10.
(10) Do a test for correct blade track. Refer to Paragraph 3.
Doc # 6.02.15 Page 205
Rev. 2 61-10-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(11) Install the spinner dome: Align the index mark.
S Loosely install the screws and plastic
washers which attach the spinner dome to
the spinner bulkhead.
S Tighten all the attaching screws. Refer to mt-Propeller Operation and
Installation Manual, latest revision.
(12) Install the engine cowlings. Refer to Section 71-10.
(13) Do an engine run-up. Do a test for correct Refer to Section 71-00.
operation of the propeller.
(14) Check for oil leaks.
(15) Check gearbox oil level and refill if necessary. Refer to Section 12-10.
Page 206 Doc # 6.02.15
15 Apr 2013 61-10-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
3. Propeller Blade Tracking Test
A. Equipment
Item Quantity Part Number
Tracking stand. 1 Commercial.
B. Procedure
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE PROPELLER. IF THE ENGINE IS TURNED, THE
PROPELLER CAN CAUSE INJURY OR DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Put the tracking stand behind the propeller that Do not move the tracking stand during
you will test. the test.
(4) Turn the propeller backwards to align a blade
with the tracking stand.
(5) Measure the distance from the stand to the Measure from the stand to a point on the
blade. trailing edge 10 cm (4 in) from the blade
tip.
(6) Do steps 3 and 4 for the other blades and
record the values.
(7) The difference between any blades must not be
more than 3 mm (1/8 in).
Doc # 6.02.15 Page 207
Rev. 2 61-10-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
4. Check/Adjust the V-Belt Tension of the Additional Alternator (if OÄM 40-314 is installed)
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE ADDITIONAL ALTERNATOR ASSEMBLY. IF THE
ENGINE IS TURNED, THE PROPELLER CAN CAUSE INJURY OR
DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the engine cowling. Refer to Section 71-10.
(4) Check the v-belt tension:
S Pull the v-belt half way between the pulleys
down with 25 N (5.6 lbf) and measure the
deflection.
Page 208 Doc # 6.02.15
15 Apr 2013 61-10-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
Detail Steps/Work Items Key Items/References
% (5) If OÄM 40-314 Rev. ‘j’ or earlier is installed:
% If the deflection is 4 mm to 5 mm (0.16 in to
% 0.20 in):
S Refer to item 6 of this checklist.
% If the deflection is not in between 4 mm and
% 5 mm (0.16 in and 0.20 in):
Remove the safety wires on the alternator
bracket bolts.
S Release the two alternator bracket bolts.
S Adjust the v-belt tension.
S Tighten the bracket bolts.
S Check the v-belt tension. Refer to item 4 of this checklist.
% If the deflection is 4 mm to 5 mm (0.16 in to
% 0.20 in):
S Tighten the bracket bolts.
S Install the safety wires.
% If OÄM 40-314 Rev. ‘k’ or later is installed:
% Check the v-belt tension by conducting one of the
% following test methods:
% S Pull the v-belt half way between the pulleys
% down with 25 N (5.6 lbf) and measure the
% deflection.
% S Measure the natural frequency of the v-belt Recommended tension gauge:
% half way between the pulleys according the CONTI® VSM-1.
% instructions of the tension gauge
%
% manufacturer. Repeat this measurement
% 4 times turning the propeller blade each
% time 90°.
Doc # 6.02.15 Page 209
Rev. 2 61-10-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
% If the deflection is 4 mm to 5 mm
% (0.16 in to 0.20 in) respectively the natural
% frequency is 123 Hz +12/-0:
% S Refer to item 6 of this checklist.
% If the deflection is not in between 4 mm and
% 5 mm (0.16 in and 0.20 in) respectively the
% natural frequency is not 123 Hz +12/-0:
% S Remove the safety wires on the alternator
% bracket bolts.
%
% S Release the two alternator bracket bolts.
%
% S Install Diamond tool. Use Diamond tool
%
% No. D44-6116-00-00-SW
%
% S Adjust the v-belt tension.
%
% S Tighten the accessible bracket bolt.
%
% S Check the v-belt tension. Refer to item 4 of this checklist.
%
% S If the deflection is 4 mm to 5 mm
% (0.16 in to 0.20 in) respectively the natural
% frequency is 123 Hz +12/-0:
% S Remove Diamond tool.
% S Tighten the remaining bracket bolt.
% S Install the safety wires.
(6) Install the engine cowlings. Refer to Section 71-10.
(7) Connect the airplane main battery. Refer to Section 24-31.
(8) Do an engine run-up. Do a test for correct Refer to Section 71-00.
operation of the propeller.
Page 210 Doc # 6.02.15
15 Apr 2013 61-10-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
5. Remove/Install the Additional Alternator V-Belt (if OÄM 40-314 is installed)
A. Remove the Additional Alternator V-Belt
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE ADDITIONAL ALTERNATOR ASSEMBLY. IF THE
ENGINE IS TURNED, THE PROPELLER CAN CAUSE INJURY OR
DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the engine cowling. Refer to Section 71-10.
(4) Remove the safety wires on the alternator
bracket bolts.
(5) Release the two alternator bracket bolts.
(6) Lift the v-belt from the additional alternator pulley.
(7) Remove the six bolts which attach the propeller Refer to Figure 5.
pulley assembly to the propeller flange pulley
support and move the assembly towards the
propeller.
(8) Release the six propeller attachment nuts. Support the propeller.
(9) Remove the propeller, v-belt and the propeller
pulley assembly.
Doc # 6.02.15 Page 211
Rev. 2 61-10-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
B. Install the Additional Alternator V-Belt
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE ADDITIONAL ALTERNATOR ASSEMBLY. IF THE
ENGINE IS TURNED, THE PROPELLER CAN CAUSE INJURY OR
DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Verify that the airplane main battery is Refer to Section 24-31.
disconnected.
(3) Make sure that the propeller shaft, the propeller Refer to Section 71-10.
flange and the propeller flange pulley support are
clean and dry.
(4) Assemble the propeller flange pulley and the fan Use new self locking nuts.
wheel with six bolts, washers and self locking
nuts.
(5) Remove the caps which cover the propeller and
the gearbox hub.
(6) Make sure that a new O-ring oil seal is in place in Refer to Figure 5.
the propeller hub. Lightly oil the seal. Use clean gearbox oil.
(7) Move the v-belt, the propeller pulley assembly Take care not to damage the propeller
and the propeller into position on the propeller O-ring seal.
flange.
Note: Make sure that the propeller is pushed into the correct position by hand. Do not
use the nuts to pull the propeller into position.
(8) Put the propeller flange pulley support into
position and install the six nuts.
Page 212 Doc # 6.02.15
15 Apr 2013 61-10-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
Detail Steps/Work Items Key Items/References
(9) If the propeller is in the correct position fully Refer to mt-Propeller Operation and
tighten the nuts in opposing pairs. Installation Manual, latest revision.
(10) Install the six bolts which attach the propeller
pulley assembly to the propeller flange pulley
support.
(11) Lift the v-belt into position on the additional
alternator and the propeller flange pulley
assembly.
(12) Adjust the additional alternator v-belt tension. Refer to Paragraph 4.
(13) Check the gearbox oil level and refill if necessary. Refer to Section 12-10.
(14) Install the engine cowlings. Refer to Section 71-10.
(15) Connect the airplane main battery. Refer to Section 24-31.
(16) Do an engine run-up. Do a test for correct Refer to Section 71-00.
operation of the propeller.
(17) Check for oil leaks.
(18) Check gearbox oil level and refill if necessary. Refer to Section 12-10.
(19) Check - and if necessary adjust - the tension of Refer to Paragraph 5.
the v-belt.
(20) If the v-belt was replaced check v-belt tension
after 5 hours of operation.
Doc # 6.02.15 Page 213
Rev. 2 61-10-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
2nd Alternator
Voltage Regulator
Bolt
Washer P-Clamp
Voltage
Regulator
Washer Support
Nut Fuse Mounting
Washer
Fuse
Washer
Nut
Washer
Washer
Screw
Bolt Nut/Extension
Nut
Alternator Mounting
Bracket
2nd Alternator
2nd Alternator
Mounting Bolt
Engine Mounting Arm RH
V-Belt
Figure 6: Additional Alternator and Regulator Installation
% (if OÄM 40-314/j or earlier is installed)
Page 214 Doc # 6.02.15
15 Apr 2013 61-10-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
%
%
%
2nd Alternator
% Voltage Regulator
%
%
Bolt
%
% Washer
P-Clamp
%
%
Voltage
Regulator
% Washer Support
% Nut Fuse Mounting
% Washer
% Fuse
Washer
% Nut
Washer
% Washer
Screw
% Bolt
Bolt
%
% Washer Alternator
% Bushing Spray Shield
Lockwire Bolt
%
% Bolt
Washer
%
Alternator Mounting Bracket
%
Washer
%
Nut
% Washer
%
%
2nd Alternator
% Washer
Fan Washer
% Pulley Nut Bolt
% Lock Washer Lockwire Nut/Extension
% Bushing
% Mounting
Bolt Nut
% Nut
Washer
%
% V-Belt
% Engine Mounting Arm RH
%
% Figure 7: Additional Alternator and Regulator Installation (if OÄM 40-314/k or later is installed)
Doc # 6.02.15 Page 215
Rev. 2 61-10-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
6. Remove/Install the Additional Alternator (if OÄM 40-314 is installed)
A. Remove the Additional Alternator
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE ADDITIONAL ALTERNATOR ASSEMBLY. IF THE
ENGINE IS TURNED, THE PROPELLER CAN CAUSE INJURY OR
DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the engine cowling. Refer to Section 71-10.
(4) Remove the safety wires on the additional
alternator bracket bolts.
% (5) Release the two alternator bracket bolts. Refer to Figure 6 or 7.
(6) Lift the v-belt from the additional alternator
pulley.
(7) Remove the two additional alternator bracket Support the additional alternator.
bolts.
% (8) Remove the additional alternator composite Refer to Figure 6 or 7.
cover.
(9) Remove the alternator cooling hose from the
additional alternator.
(10) Remove the electrical wiring harness from the
additional alternator.
% (11) Remove the bolt or bolts attaching the additional Support the additional alternator.
% alternator to the RH engine mounting arm. Refer to Figure 6 or 7.
Page 216 Doc # 6.02.15
15 Apr 2013 61-10-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
Detail Steps/Work Items Key Items/References
(12) Move the additional alternator clear of the
airplane.
B. Install the Additional Alternator
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE ADDITIONAL ALTERNATOR ASSEMBLY. IF THE
ENGINE IS TURNED, THE PROPELLER CAN CAUSE INJURY OR
DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Verify that the airplane main battery is Refer to Section 24-31.
disconnected.
% (3) Position the additional alternator on the forward Refer to Figure 6 or 7.
RH engine mounting arm.
(4) Connect the electrical wiring harness to the Refer to Section 24-33.
additional alternator.
% (5) Install the bolt or bolts which attaches the Refer to Figure 6 or 7.
additional alternator to the forward RH engine Torque: 6.4 Nm (4.7 lbf.ft)
mounting arm.
% (6) If OÄM 40-314 Rev. ‘j’ or earlier is installed:
Measure the gap between the engine mounting
arm and the aft. alternator attachment with the
alternator pushed to the aft. position. If the gap
is more than 0.1 mm, install adequate number
of shim rings (according DIN 988). Use
CA 1000-RRC De Sato.
Doc # 6.02.15 Page 217
Rev. 2 61-10-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
% (7) Install the composite cover to the additional Refer to Figure 6 or 7.
alternator.
(8) Attach and secure the additional alternator
cooling hose.
(9) Install the additional alternator mounting bracket
to the gear box and tighten the bolts.
(10) Position the v-belt on the propeller pulley
assembly and the additional alternator pulley.
(11) Adjust the v-belt tension. Refer to Paragraph 4.
(12) Check the two safety wires on the additional
alternator bracket bolts.
(13) Connect the airplane main battery. Refer to Section 24-31.
(14) Install the engine cowlings. Refer to Section 71-10.
(15) Do an engine run-up. Do a test for correct Refer to Section 71-00.
operation of the propeller.
Page 218 Doc # 6.02.15
15 Apr 2013 61-10-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
Section 61-20
Propeller Control
1. General
The DA 40 NG has a MTV-6-R/190-69 variable pitch propeller with an engine mounted constant speed
governor P-853-16. The constant speed governor is controlled by the engine EECS system. The
constant speed governor controls the propeller blade angle (pitch).
For further information about the constant speed governor unit refer to mt-Propeller Operation and
Installation Manual, latest revision.
Doc # 6.02.15 Page 1
Rev. 2 61-20-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
Figure 1: Propeller RPM Adjusted by the EECU System
Page 2 Doc # 6.02.15
15 Apr 2013 61-20-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
2. Description and Operation
The DA 40 NG has a MTV-6-R/190-69 variable pitch propeller. When the propeller is rotating the
aerodynamic and spring forces causes the blades to move towards fine pitch. The propeller uses oil
pressure to increase the blade angle (pitch).
The constant speed governor is controlled by the engine control units (EECUs). The pilot has only one
lever to control the engine performance. The propeller blade angle is adjusted automatically based on
power lever position. Figure 1 shows the propeller RPM as set by the engine EECU system for a given
load.
As with other constant speed propeller control systems, the EECU senses engine performance and
sets the governor to regulate oil pressure to the propeller to change blade angle as required.
Depending on the power setting the propeller pitch is adjusted such that the required RPM will be
obtained as shown in Figure 1.
Figure 2 shows the propeller control system schematic diagram.
The oil pressure at the governor is approximate 7 bar (100 PSI). If the engine speed is too high, the
constant speed governor operates the pilot valve such that the oil flows in the propeller hub which
increases the propeller pitch and reduces the RPM.
If the engine speed is too low, the governor releases oil flow out of the propeller hub. The piston moves
aft to reduce the blade angle which will increase engine RPM.
For further information of the governor's working principles refer to the mt-Propeller Operation and
Installation Manual, latest revision.
During normal operation a preset coarse-pitch-stop prevents the propeller blades from moving past
a preset maximum blade angle. If the engine fails in flight, or if the propeller oil supply fails in flight,
aerodynamic and spring forces will reduce the blade pitch angle which keeps the propeller rotating.
Doc # 6.02.15 Page 3
Rev. 2 61-20-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
Control
EECU
Motor Governor Propeller
Reduction
Gearbox
Engine
Master
Switch
Propeller Blade
Spring
Oil
Figure 2: Propeller Control System Schematic Diagram
Page 4 Doc # 6.02.15
15 Apr 2013 61-20-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
The specified propeller settings are given as follows:
) Low pitch: 14.5° ± 0.2° (@ 0.75 R)
) High pitch: 35° ± 1° (@ 0.75 R)
Technical data governor:
) Specific installation: DA 40 NG
) Specific engine: Austro Engine E4A
) Max. revolution: 2680 RPM ± 10 RPM
) Min. revolution: 2030 RPM ± 10 RPM
) Rotation: LH
) Control head position: 355°
Doc # 6.02.15 Page 5
Rev. 2 61-20-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 6 Doc # 6.02.15
15 Apr 2013 61-20-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have for the propeller control. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair in the
Repair column.
Trouble Possible Cause Repair
Propeller RPM fluctuating. Engine gearbox oil level low. Replenish gearbox oil level.
Refer to Chapter 72.
Engine gearbox oil Replace engine gearbox oil.
contaminated. Refer to Chapter 72.
Electrical connection between Do a continuity check of the
engine EECU system and wiring between the EECU
governor. system and the governor.
Replace/repair faulty wiring.
Refer to Chapter 92 for the
wiring diagrams.
Governor defective. Replace the governor.
Doc # 6.02.15 Page 101
Rev. 2 61-20-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 61-20-00 Rev. 2
DA 40 NG AMM Propeller
AIRCRAFT
Maintenance Practices
1. General
This Section describes how to remove/install the governor and how to test/adjust the governor.
2. Remove/Install the Propeller Governor
A. Remove the Propeller Governor
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE PROPELLER. IF THE ENGINE IS TURNED, THE
PROPELLER CAN CAUSE INJURY OR DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the engine cowlings. Refer to Section 71-10.
(4) Disconnect the cable connector GOV from the Refer to the AE Maintenance Manual,
governor. latest revision, Chapter 71-50-05.
(5) Release the four nuts which attach the governor Use a container to catch the small
to the drive-pad and remove the governor from amount of oil from the governor.
the gearbox.
(6) Remove and discard the gasket.
(7) Put a blanking cover on the governor drive-pad
and put a cover over the governor mounting
face.
Doc # 6.02.15 Page 201
Rev. 2 61-20-00 15 Apr 2013
Propeller DA 40 NG AMM
AIRCRAFT
B. Install the Propeller Governor
Note: It is prohibited to adjust propeller RPMs.
Detail Steps/Work Items Key Items/References
(1) Compare governor Equipment Log-Sheet with
the settings given in Section 61-20, page 5.
(2) Put the governor and gasket in position on the Use a new gasket. Verify installation
gearbox drive pad. direction.
(3) Install the four washers and nuts which attach Refer to mt-Propeller Operation and
the governor to the drive pad. Installation Manual, latest revision.
Use new self locking nuts.
(4) Connect the propeller control cable connector Refer to the AE Maintenance Manual,
GOV to the governor. latest revision.
(5) Install the engine cowling. Refer to Section 71-10.
(6) Connect the airplane main battery. Refer to Section 24-31.
(7) Do an engine ground run.
(8) Check for oil leaks.
(9) Check the gearbox oil level. Refer to Section 12-10.
Page 202 Doc # 6.02.15
15 Apr 2013 61-20-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
CHAPTER 71
POWER PLANT
Doc # 6.02.15 Page 1
Rev. 2 71-TITLE 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2
15 Apr 2013 71-TITLE Doc # 6.02.15
Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 71
POWER PLANT
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Engine Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Engine Test - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Section 71-10
Engine Cowling
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Engine Cowling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Cleaning and Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Section 71-20
Engine Mounting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Doc # 6.02.15 Page 1
Rev. 2 71-CONTENTS 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Engine Mount (Without Engine Installed) . . . . . . . . . . . . . . . 201
Section 71-50
Electrical Cables in the Engine Compartment
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 71-60
Air Intakes
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Alternate Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Remove/Install the Alternate Air Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . 207
5. Adjust the Alternate Air Valve Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Section 71-70
Engine Drains
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Page 2
15 Apr 2013 71-CONTENTS Doc # 6.02.15
Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Oil Separator Breather Hose . . . . . . . . . . . . . . . . . . . . . . . . 201
Doc # 6.02.15 Page 3
Rev. 2 71-CONTENTS 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4
15 Apr 2013 71-CONTENTS Doc # 6.02.15
Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
CHAPTER 71
POWER PLANT
1. General
This Chapter describes the power plant removal and installation of the DA 40 NG.
For data on conducting an engine test after installation refer also to the Operation Manual for the E4-A
engine. Refer to the DA 40 NG Airplane Flight Manual for engine start/stop procedures. For particular
information on the firmware refer to applicable DAI Service Bulletin.
Refer to these Chapters for data about other engine systems:
) Chapter 72. Engine. Refer to the AE Operation Manual, latest revision for data on the
engine.
) Chapter 73. Engine fuel and control. Refer to the AE Operation Manual, latest revision for
data on the fuel injection system.
) Chapter 76. Engine controls.
) Chapter 77. Engine indicating.
) Chapter 78. Exhaust system.
) Chapter 79. Oil system. Refer to the AE Operation Manual, latest revision for data on the
engine oil system.
) Chapter 80. Starter system control and installation. Refer to the AE Operation Manual,
latest revision for data on the starter.
) Chapter 81. Turbo charger.
Note: Equipment which is certified for installation in the DA 40 NG is listed in Section 6.5
of the Airplane Flight Manual. Such equipment may be installed in accordance with
the Airplane Maintenance Manual.
Any equipment which is not listed in Section 6.5 of the Airplane Flight Manual is
called "Additional Equipment". The installation of Additional Equipment is a
modification which must be handled in accordance with national regulations or a
Service Bulletin.
Doc # 6.02.15 Page 1
Rev. 2 71-00-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Top Cowling
Engine Mounting Frame
Bottom Cowling
Figure 1: Power Plant (if MÄM 40-434 is not installed)
Page 2 Doc # 6.02.15
15 Apr 2013 71-00-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Figure 2: Power Plant (if MÄM 40-434 is installed)
Doc # 6.02.15 Page 3
Rev. 2 71-00-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
2. Description and Operation
The DA 40 NG has an Austro Engine E4-A liquid-cooled, in-line four-stroke four cylinder engine with
a double overhead camshaft (DOHC) with four valves per cylinder. The valves are actuated by the cam
follower. The direct fuel injection is realized by means of a common rail technique and the engine is
charged by a turbo charger in combination with an inter-cooler.
The propeller is activated by a gearbox driven governor which is controlled by the EECUs. All engine
components are controlled by an EECU system.
The power plant is protected by a top and bottom engine cowling. The two halves attach to each other
and to the airframe with Camloc quick release fasteners.
The bottom cowling has air intakes one for engine liquid cooling and one for the engine air intake. The
top cowling has air intakes for cabin heat, engine gearbox cooling and intercooler air intake.
The engine mount attaches to the firewall at five locations. The engine attaches to the engine mount
with four oil-filled rubber elements which make the engine shock-mounts.
The wiring harness is lead through the firewall to connect the engine to the ECUs and give electrical
supply to the engine sensors. Electrical cables from the main battery and from the generator supply
electrical power to the airplane electrical system.
Page 4 Doc # 6.02.15
15 Apr 2013 71-00-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
3. Engine Specification
Note: The engine drives the propeller through a speed-reducing gear. All RPMs are
shown as propeller RPMs.
AE E4-A Engine Specification
Engine manufacturer. Austro Engine GmbH.
Engine model. E4-A.
Engine operating limits:
S Maximum take-off power. 123.5 kW (165.6 DIN-hp) at 2300 RPM.
S Maximum continuous power. 114.0 kW (152.9 DIN-hp) at 2100 RPM.
S Maximum overspeed (max. 20 sec). 2500 RPM.
Oil pressure: Refer to Airplane Flight Manual.
Oil temperature: Refer to Airplane Flight Manual.
Oil consumption:
S Maximum. 0.1 liter/hr. (0.11 US qt/hr.).
Oil quantity: Refer to Airplane Flight Manual.
Coolant temperature: Refer to Airplane Flight Manual.
Fuel consumption: Refer to Airplane Flight Manual.
Gearbox oil capacity: 2.1 liter (2.22 US qts).
Engine weight, bare: 185 kg (407.9 lb).
Fuel grade: Refer to Airplane Flight Manual.
Engine oil: Refer to Airplane Flight Manual.
Coolant: Refer to Airplane Flight Manual.
Gearbox oil: Refer to Airplane Flight Manual.
Doc # 6.02.15 Page 5
Rev. 2 71-00-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 6 Doc # 6.02.15
15 Apr 2013 71-00-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Trouble-Shooting
1. General
The table below lists possible defects of the power plant. It does NOT give information about trouble
shooting for the engine or the engine systems. Refer to the AE Operation Manual, latest revision or
AE Maintenance Manual, latest revision for engine and engine system trouble-shooting.
WARNING: YOU MUST BE CAREFUL WHEN YOU DO POWER PLANT TROUBLE
SHOOTING. OPERATION OF A DAMAGED ENGINE CAN CAUSE MORE
DAMAGE TO THE ENGINE. THIS CAN CAUSE INJURY TO
PERSONNEL.
When experiencing trouble as detailed in the Trouble column read across to the Possible Cause
column. Then do the repair given in the Repair column.
Trouble Possible Cause Repair
Engine vibration. Damaged shock mounts. Replace the shock mounts.
Propeller imbalance. Balance the propeller.
Engine operates with only Refer to the engine
3 fuel injectors. manufacturer.
Engine does not produce full Engine air intake blocked. Examine the air intake.
power.
Air filter blocked. Examine/Replace the air filter.
Sensor signal out of limits. Read AE engine data with
laptop computer via CAN
interface. Refer to the AE
Maintenance Manual, latest
revision.
Doc # 6.02.15 Page 101
Rev. 2 71-00-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 71-00-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove/install the engine.
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER. IF
THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
TURN THE PROPELLER. DISCONNECT THE BATTERY.
WARNING: DO NOT GO BELOW THE ENGINE WHEN YOU LIFT THE ENGINE WITH
THE HOIST. THE HOIST CAN FAIL. THIS CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: DO NOT GET ENGINE OIL, GEAR OIL OR COOLANT ON YOU. THESE
LIQUIDS CAN CAUSE SKIN DISEASE.
WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE. DO
NOT ALLOW FIRE OR SPARKS NEAR FUEL. FUEL BURNS AND
BURNING FUEL CAN CAUSE INJURY TO PEOPLE AND DAMAGE TO
EQUIPMENT.
CAUTION: YOU MUST ATTACH CAPS TO ENGINE OPENINGS AND PIPES WHEN
YOU REMOVE THE ENGINE. IF YOU DO NOT DO THIS,
CONTAMINATION CAN ENTER THE ENGINE OPENINGS AND PIPES.
THIS CAN CAUSE BLOCKAGE TO THE AIRPLANE SYSTEMS AND
DAMAGE FOR THE ENGINE.
2. Remove/Install the Engine
A. Equipment
Item Quantity Part Number
Engine hoist. 1 Commercial.
Engine sling. 1 Commercial.
Tail trestle. 1 Commercial.
Hoisting points. 3 Delivered with engine.
Doc # 6.02.15 Page 201
Rev. 2 71-00-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Oil Pressure Sensor Coolant Level Sensor
Fuel Supply Line Intercooler
Fuel Return Line
Starter Motor Oil Filter
Alternator
Oil Filler
Crankshaft 2 Sensor
Figure 3: Engine Sensors (if MÄM 40-434 is not installed)
Page 202 Doc # 6.02.15
15 Apr 2013 71-00-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Figure 4: Engine Sensors (if MÄM 40-434 is installed)
Doc # 6.02.15 Page 203
Rev. 2 71-00-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
B. Remove the Engine without Cable Harness
Detail Steps/Work Items Key Items/References
(1) Read the engine EECU data out and send them via Refer to Section 72-00.
email to Austro Engine GmbH. Refer to the
AE Maintenance Manual, latest revision.
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE PROPELLER. IF THE ENGINE IS TURNED, THE
PROPELLER CAN CAUSE INJURY OR DEATH.
(2) Set the engine FUEL SELECTOR to OFF.
(3) Make sure that the engine is safe:
S Set ELECTRIC MASTER key switch to OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(4) Disconnect the airplane main battery. Refer to Section 24-31.
(5) Remove the engine cowling. Refer to Section 71-10.
(6) Remove the propeller. Refer to Section 61-10.
(7) Drain the coolant system. Refer to Section 75-00.
(8) Drain the engine oil. Refer to AE Maintenance Manual,
latest revision.
(9) Drain the gearbox oil. Refer to AE Maintenance Manual,
latest revision.
(10) Remove the hose from the alternate air valve to the
turbo charger.
(11) Remove the intercooler with the coolant tank. Refer to Section 75-00.
(12) Disconnect the coolant hoses from the coolant Refer to Section 75-00.
radiator:
S Remove the 8 worm-drive-clamps. 4 on each hose.
S Remove the hoses.
S Remove the forward cooling pipe.
Page 204 Doc # 6.02.15
15 Apr 2013 71-00-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Detail Steps/Work Items Key Items/References
(13) Disconnect the coolant hoses from the heating Refer to Section 75-00.
radiator.
(14) Disconnect the breather line.
(15) Disconnect the electrical cables on the alternator:
S Release all clips and ties holding the cables to the
engine.
(16) Disconnect the electrical cables from the starter motor: Do not remove clips and ties on the
engine mount.
S Disconnect the two control cables at the solenoid.
S Disconnect the main supply cable at the solenoid.
S Release all clips and ties holding the cables to the
engine.
(17) Disconnect all electrical connections (glow plugs, Refer to AE Maintenance Manual,
injectors, etc.). latest revision.
(18) Remove the hose that connects the turbo charger Refer to Section 73-00.
outlet to the inter-cooler:
S Remove the 4 worm-drive-clamps.
S Remove the hose.
(19) Remove the exhaust. Refer to Section 78-00.
(20) Release clips, ties and clamps holding the engine
wire harness to the engine mount.
Move the harness clear of the engine.
(21) Disconnect the fuel supply hose and remove the fuel At the high-pressure fuel pump.
line mounting bracket.
(22) Disconnect the fuel return hose. Behind the rail pressure regulator.
(23) Remove the bonding cable at the engine near each
engine shock-mount.
(24) Support the airplane at the tail. Use the tail trestle. Refer to
Section 07-10.
Doc # 6.02.15 Page 205
Rev. 2 71-00-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(25) Remove the mounting bracket:
S Remove the three bolts located at the upper right
side of the gearbox and engine housing.
(26) Install hoisting points. Refer to AE Installation Manual,
latest revision.
(27) Attach the sling to the engine. There are lifting points at:
Attach the sling to the hoist. S Front right cylinder head.
S Rear left of the cylinder head
near coolant pump.
S Rear right at the alternator
bracket.
Refer to AE Installation Manual,
latest revision.
(28) Support the weight of the engine with the hoist.
(29) Remove the nuts, bolts and washers that attach the
engine support brackets to the engine mount.
(30) Remove the safety rope from the engine.
(31) Lift the engine a small distance, turn it slightly to the Make sure that the engine does not
right side and move it at the same time forward and hit the engine mount.
clear of the engine mount.
(32) Remove the mounting arms from the engine.
(33) Attach the shipping stand to the engine. Refer to AE Installation Manual,
latest revision.
(34) Put caps on the engine openings and pipes.
(35) Prepare engine for shipping. Note TTSO hours and reason for
removal.
(36) Clean firewall and engine mount.
(37) Examine the engine mount for cracks and corrosion.
(38) Check lifetime of the hoses and replace as necessary.
Page 206 Doc # 6.02.15
15 Apr 2013 71-00-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Engine Mount
Safety Rope
Bonding Wire
Washer
Bolt
Engine Mount
Bolt
Spacer
Washer Bolt
Washer Washer
Nut
Engine Mounting Frame
Bonding
Wire
Nut
Spacer
Washer Safety Rope
Washer
Nut
Mounting Arm Mounting Arm
Bolt Washer
Bolt Spacer Washer
Washer Bolt
Washer
Nut
Bolt Washer
Bolt
Engine Safety
Engine Mount Mount Rope
Bolt
Safety Rope
Bonding Washer
Wire
Washer
Washer
Bonding Wire Bolt
Bolt
Figure 5: Engine Shock-Mounts (if MÄM 40-434 is not installed)
Doc # 6.02.15 Page 207
Rev. 2 71-00-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Washer Nut
Safety Rope
Engine Mount
Washer Washer
Bolt
Bolt
Bonding Wire
Nut Engine Mount
Washer
Engine Mounting Frame
Washer
Bolt Bonding
Wire
Washer
Bolt Nut
Washer Bracket
Bolt Nut
Bolt
Washers
Washers Washer Washers
Bushing Bolt
Bolt
Bolt Mounting Arm
Mounting
Safety Arm
Rope Bolt
Safety
Bonding Rope
Engine
Wire
Engine Shock Shock Washers
Mount Mount
Washers
Nut Washer
Bonding Wire
Bolt
Washer
Washer
Bolt
Bolt
Figure 6: Engine Shock-Mounts (if MÄM 40-434 is installed)
Page 208 Doc # 6.02.15
15 Apr 2013 71-00-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
% Figure 7: Engine Shock-Mounts (if MÄM 40-568 is installed)
Doc # 6.02.15 Page 209
Rev. 2 71-00-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
C. Install the Engine
Detail Steps/Work Items Key Items/References
(1) Attach the sling to the engine. There are lifting points at:
Attach the sling to the hoist. S Front right cylinder head.
S Front left of the reduction gear
housing.
S Rear left of the cylinder head
near coolant pump.
S Rear right at the alternator
bracket.
(2) Remove the shipping stand from the engine.
(3) Install the engine shock-mounts at the engine mount. Torque: 16 Nm (11.8 lbf.ft.),
Use Loctite 243.
(4) Install engine mounting arms at the engine. Use Loctite 243.
(5) Carefully move the engine back into position in the
engine mount.
(6) Install the bolts, nuts, and washers that attach the Front bolts:
engine shock-mounts to the engine mounting arms.
Wet installation with CA 1000-PRC
De Soto, Use Loctite 243, Torque:
85 ± 8 Nm (62.7 ± 5.9 lbf.ft.).
Rear bolts:
Use Loctite 243, Torque: 32 Nm
(23.6 lbf.ft.).
(7) Install the bonding cable at the engine near each
shock-mount.
(8) Install the forward cooling pipe with clamps at the
engine mount.
Page 210 Doc # 6.02.15
15 Apr 2013 71-00-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Detail Steps/Work Items Key Items/References
(9) Connect the electrical cables to the starter motor:
S Connect the two control cables at the solenoid.
S Connect the main supply cable at the solenoid.
S Attach all clips and ties holding the cables to the
engine.
(10) Move the engine wire harness into position on the Refer to AE Maintenance Manual,
engine. Connect the engine wire harness and latest revision.
bonding cables to the electrical sensors.
(11) Install clips and ties clamps holding the engine wire
harness to the engine.
(12) Connect the fuel supply hose. At the high pressure pump.
(13) Connect the fuel return hose. At the high pressure pump.
(14) Install the intercooler with coolant tank. Refer to Section 75-00.
(15) Install the coolant hoses to the coolant radiator: Refer to Section 75-00.
S Install the 2 hoses, at the radiator.
S Install the 8 worm-drive-clamps that hold the 4 on each hose.
hoses.
(16) Install the hose which connects the alternate air to
the turbo charger.
(17) Install the hose which connects the intercooler to the
turbo charger.
(18) Connect the breather line. At the oil pre-separator.
(19) Install exhaust. Torque: 25 - 34 Nm
(18.44 - 25.08 lbf.ft.).
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE PROPELLER. IF THE ENGINE IS TURNED, THE
PROPELLER CAN CAUSE INJURY OR DEATH.
Doc # 6.02.15 Page 211
Rev. 2 71-00-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(20) Install the mounting bracket:
S Install the three bolts located at the upper right
side of the gearbox and engine housing.
(21) Install the propeller. Refer to Section 61-00.
(22) Fill and bleed the cooling system. Refer to Section 75-00.
(23) Fill the engine with oil. Refer to Section 12-10.
(24) Fill the gearbox with oil. Refer to Section 12-10.
(25) Connect the airplane main battery. Refer to Section 24-31.
(26) Install the engine cowling. Refer to Section 71-10.
(27) Remove the tail trestle. Refer to Section 07-10.
(28) Do an engine test. Refer to Paragraph 3.
Page 212 Doc # 6.02.15
15 Apr 2013 71-00-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
ft)
3
(3
m
10
3 m (10 ft)
Figure 8: Engine Testing Safety Zone
Doc # 6.02.15 Page 213
Rev. 2 71-00-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
3. Engine Test - General
These procedures describe how to conduct an engine test.
For data on the engine and engine performance testing, refer to the AE Operation Manual, latest
revision.
Note: The engine drives the propeller through a speed-reducing gear. All RPMs
are shown as propeller RPMs.
CAUTION: ONLY AUTHORIZED PERSONNEL MAY READ ENGINE DATA WITH
THE 'ECU OPERATOR' SOFTWARE.
A. Equipment
Item Quantity Part Number
Airplane chocks. 2 Commercial.
Fuel sample kit. 1 Commercial.
Laptop computer. 1 Commercial.
"Wizard 300" software, latest approved revision. n/a n/a.
CAN interface. 1 n/a.
B. Preparation
Detail Steps/Work Items Key Items/References
WARNING: DO NOT LET PERSONS INTO THE SAFETY RANGE OF THE
AIRPLANE. PROPELLERS CAN CAUSE INJURY OR DEATH.
(1) Proceed according to Pre-Flight Inspection Refer to Airplane Flight Manual, latest
given in the AFM. revision.
C. Engine Starting and Warm-Up
Refer to the AE Operation Manual, latest revision for operating limitations.
Detail Steps/Work Items Key Items/References
(1) Conduct Engine Start and Warm Up according Refer to Airplane Flight Manual, latest
to the AFM. revision.
Page 214 Doc # 6.02.15
15 Apr 2013 71-00-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
D. ECU Test, Propeller Control Test and ECU Voter Test
Conduct these tests with the engine warm (see Paragraph C).
Note: The engine drives the propeller through a speed-reducing gear. All RPMs
are shown as propeller RPMs.
WARNING: DO NOT CONTINUE WITH THE TEST IF THE ECU CAUTION LIGHTS DO
NOT GO ON AND OFF WHEN REQUIRED, OR IF A CAUTION LIGHT
STARTS FLASHING. STOP THE GROUND TEST AND FIND THE FAULT.
WARNING: DO NOT OPERATE THE AIRPLANE IF THE ENGINE STOPS RUNNING
DURING THE TEST.
Use the procedures below for the engine/system that will be tested.
Detail Steps/Work Items Key Items/References
(1) Perform an ECU Test according to the AFM. Refer to Airplane Flight Manual, latest
revision.
E. Performance Check
CAUTION: THE ENGINE PARAMETERS MUST BE IN THE GREEN RANGE FOR
THIS CHECK. DO THE PERFORMANCE CHECK IMMEDIATELY AFTER
WARM-UP AND ECU TESTS (SEE PARAGRAPHS C AND D, ABOVE).
Note: The engine is controlled by the EECUs. The performance check is therefore
different from the usual airplane engines. If the values are within the limits
as shown in the AFM and no caution or warning light is illuminated the
engine works properly.
Detail Steps/Work Items Key Items/References
(1) Perform an Available Power Check according to Refer to Airplane Flight Manual, latest
the AFM. revision.
Doc # 6.02.15 Page 215
Rev. 2 71-00-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 216 Doc # 6.02.15
15 Apr 2013 71-00-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Section 71-10
Engine Cowling
1. General
The DA 40 NG cowling is made of two carbon fiber reinforced plastic (CFRP) halves. The cowling
gives aerodynamic shape to the nose of the airplane. The parts are very easy to remove and give good
access to the engine.
Refer to Section 51-20 for repair data for the cowling. Refer to Section 51-60 for data on the
quick-release fasteners.
2. Description
Figures 1 and 2 show the cowling.
Camloc quick-release fasteners attach the cowling halves to each other and to the fuselage. Both
cowling halves are very light and one person can hold them easily.
The top cowling has two air intakes, one on the front right side and one on the front left side of the
cowling. The left opening supplies air to the intercooler and the right one for the cabin heat and
gearbox cooling. The bottom cowling has an air intake at the front to supply air for the coolant radiator.
The side-NACA-intake which is built into the bottom cowling supplies air for the engine intake system.
Doc # 6.02.15 Page 1
Rev. 2 71-10-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Top Cowling
Air Intake,
Cabin Heat
Air Intake,
Gearbox Cooling
Air Intake,
Intercooler Access Panel
Air Intake, Engine
Air Intake, Bottom Cowling
Radiator
Figure 1: Engine Cowling (if MÄM 40-434 is not installed)
Page 2 Doc # 6.02.15
15 Apr 2013 71-10-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Figure 2: Engine Cowling (if MÄM 40-434 is installed)
Doc # 6.02.15 Page 3
Rev. 2 71-10-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 71-10-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Trouble-Shooting
1. General
The table below lists possible defects of the engine cowling. When experiencing trouble detailed in the
Trouble column read across to the Possible Cause column, then do the repair in the Repair column.
Trouble Possible Cause Repair
Outer surface of the cowling Engine overheating. Examine the engine for hot gas
discolored. Paint blistered. leaks. Examine the exhaust for
Hot gas leak.
Black soot on the inner cracks and leaking gaskets.
surface. Engine fire. Replaced damage items.
Repaint the cowling.
Oil/fuel/coolant on the inner Oil, fuel or coolant leak. Examine the engine. Look
surface of the cowling. specially for oil, fuel and
coolant leaks. Correct the
problems which you have
found. Clean the cowling.
Doc # 6.02.15 Page 101
Rev. 2 71-10-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 71-10-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Maintenance Practices
1. General
This Section contains the Maintenance Practices for the cowling. It describes how to remove/install,
clean and paint the cowling.
2. Remove/Install the Engine Cowling
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
WORK NEAR TO THE PROPELLER.
- SET THE ELECTRIC MASTER KEY SWITCH TO "OFF".
- SET THE ENGINE MASTER SWITCH TO "OFF".
- SET THE POWER LEVER TO "0%".
- DISCONNECT THE AIRPLANE MAIN BATTERY.
A. Remove the Top Cowling
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE COWLING. IF THE ENGINE IS TURNED, THE
PROPELLER CAN CAUSE INJURY OR DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Release the quick-release fasteners which hold Refer to Figures 1 and 2.
the top cowling.
(4) Pull the side of the upper cowling gently Take care not to scratch the cowling on
outwards and upwards. the propeller!
(5) Disconnect te cabin heat air intake hose from the
upper cowling.
(6) Move the cowling away from the airplane. Take care not to scratch the cowling on
the propeller!
Doc # 6.02.15 Page 201
Rev. 2 71-10-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
B. Remove the Bottom Cowling
Detail Steps/Work Items Key Items/References
(1) Release the quick-release fasteners which hold Hold the bottom cowling!
the bottom cowling.
(2) Remove the bottom cowling:
S Lower the rear of the cowling. Take care not to scratch the cowling on
the propeller and spinner.
S Move the cowling down and forward. Take care not to damage the engine air
intake duct.
S Move the cowling clear of the airplane.
C. Install the Bottom Cowling
Detail Steps/Work Items Key Items/References
(1) Examine the bottom cowling. Make sure that:
S The cowling is clean.
S The cowling is not damaged. Repair any damage.
S The quick-release fasteners are not Replace missing/damaged fasteners.
missing/damaged.
S Drain holes must be clear.
(2) Lift the cowling into position:
S Move the cowling upwards.
S Lift the cowling fully into position. Take care that the air intake ducts
connect.
S Tighten the quick-release fasteners that
attach the cowling to the engine nacelle.
Page 202 Doc # 6.02.15
15 Apr 2013 71-10-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
D. Install the Top Cowling
Detail Steps/Work Items Key Items/References
(1) Examine the top cowling. Make sure that:
S The cowling is clean.
S The cowling is not damaged. Repair any damage.
S The quick-release fasteners are not Replace missing/damaged fasteners.
missing/damaged.
(2) Move the top cowling into position.
(3) Connect (worm drive clamp) the cabin heat air
intake to the upper cowling.
(4) Gently pull the edges of the cowling apart and
lower the cowling into position.
(5) Tighten the quick-release fasteners.
3. Cleaning and Painting
A. Clean the Cowling
Detail Steps/Work Items Key Items/References
(1) Wash the outer surface with a mixture of water Obey the detergent manufacturer’s
and a mild detergent. instructions.
(2) Wash the inner surface with a mixture of water Obey the detergent manufacturer’s
and a mild detergent. instructions.
CAUTION: DO NOT USE POLISH CONTAINING SILICONE. SILICONE MAKES
CFRP REPAIR DIFFICULT.
(3) Polish the outer surface with wax polish. Obey the polish manufacturer’s
instructions. Do not use silicone polish.
Doc # 6.02.15 Page 203
Rev. 2 71-10-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
B. Paint the Insides of the Cowling
This Paragraph gives the data for painting the inside of the engine cowling with fire protection paint.
Refer to Section 51-20 for repairs and painting the outside of the cowling.
Detail Steps/Work Items Key Items/References
(1) Clean the inside of the cowling.
(2) Make the area rough for painting. Use 150-320 grade wet and dry paper.
WARNING: DO NOT GET ACETONE ON YOUR SKIN. ACETONE CAN CAUSE
SKIN DISEASE.
WARNING: DO NOT BREATHE ACETONE FUMES. ACETONE FUMES CAN
CAUSE ILLNESS.
CAUTION: REMOVE ACETONE AS SOON AS POSSIBLE FROM GFRP.
ACETONE CAN CAUSE THE RESIN TO SOFTEN AND FAIL.
(3) Clean the area for painting. Use acetone.
(4) Paint the inside of the cowling with fire Obey the paint manufacturer’s
protection paint. instructions.
Page 204 Doc # 6.02.15
15 Apr 2013 71-10-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Section 71-20
Engine Mounting
1. General
The engine mount is constructed from tubular steel which is welded at the joints. Powder coating
protects the frame from corrosion. Welded brackets hold components such as the coolant radiator and
the intercooler in position. Rubber lined P-clamps and cable ties hold electrical cables and other
equipment components to the engine mount.
The engine mounting-frame has five small mounting pads at the rear of the frame. Bolts through the
pads attach the engine mount to the firewall.
The engine attaches to the engine mount at four mounting pads. Oil-filled rubber shock-mounts are
built between the engine mounting arms and the engine mount pads and isolate the airframe from
engine vibrations.
Additionally there are safety ropes (steel wire ropes) at each engine mounting pad installed.
Doc # 6.02.15 Page 1
Rev. 2 71-20-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Figure 1: Engine Mount Assembly (if MÄM 40-434 is not installed)
Page 2 Doc # 6.02.15
15 Apr 2013 71-20-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
% A B
%
Firewall
% Bolt
Bolt
Firewall Mounting Pad
% Washer
Washer
% Bushing A Support Bracket
% Washer (if MÄM 40-505 is
NOT installed) Firewall Mounting Pad
%
Nut Firewall
% Bushing B
% A
Nut Washer
% Firewall
Mounting
% Pad Intercooler Mounting
%
% A
Exhaust Mounting
% Firewall Mounting Pad
% Shock Mount D
Fuel Filter Mounting
% Exhaust Mounting
%
C
%
Cabin Heat
% Exchanger Firewall Mounting Pad
Mounting
%
% B
% Shock Mount
%
%
%
% Shock Mount
% Coolant Cooler Mountings
% C
% Shock Mount
Firewall
% D Bolt
Nose Landing Gear
% Mounting Pad Washer
Firewall
% Bolt
% Washer
%Firewall Mounting Pad Washer
% Washer
Nut
% Nut Bushing C Nose Landing
Gear Elastomer
%
Pack
%
Figure 2: Engine Mount Assembly (if MÄM 40-434 is installed)
Doc # 6.02.15 Page 3
Rev. 2 71-20-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 71-20-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Trouble-Shooting
1. General
The table below lists possible defects of the engine mounting. When experiencing the trouble detailed
in the Trouble column read across to the Possible Cause column, then do the repair in the Repair
column.
Trouble Possible Cause Repair
Engine vibration. Cracked engine mount. Examine the engine mount.
Look specially for cracks at the
welded joints.
Defective shock mounts. Refer to the engine
manufacturer.
Doc # 6.02.15 Page 101
Rev. 2 71-20-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 71-20-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Maintenance Practices
1. General
The Maintenance Practices for the engine mount are limited to removal/installation. If the engine mount
is damaged it must be repaired by an authorized repair facility.
2. Remove/Install the Engine Mount (Without Engine Installed)
A. Equipment
Item Quantity Part Number
Engine hoist. 1 Commercial.
Engine sling. 1 Commercial.
Tail trestle. 1 Commercial.
B. Remove the Engine Mount (Without Engine Installed)
Detail Steps/Work Items Key Items/References
(1) Remove the engine. Refer to Section 71-00.
(2) Release all clamps, clips and ties holding the
electrical harness and hoses to the engine mount.
(3) Remove the cabin heat-exchanger and shroud. Refer to Section 21-40.
(4) Remove the engine coolant radiator. Refer to Section 75-00.
(5) Remove the inter-cooler with coolant tank. Refer to Section 81-00.
(6) Remove the 5 bolts and washers which attach the
engine mount to the firewall and remove elastomer
pack of the nose landing gear from its mounting
pad.
(7) Move the engine mount clear of the airplane.
Doc # 6.02.15 Page 201
Rev. 2 71-20-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
C. Install the Engine Mount (Without Engine Installed)
Detail Steps/Work Items Key Items/References
(1) Move the engine mount into position on the
firewall.
(2) Install the 5 bolts which attach the engine mount
to the engine firewall and connect the elastomer
pack of the nose landing gear to the nose
landing gear mounting pad:
S Fasten the bolts through the firewall. The center firewall bolt:
Torque: 60 ± 6 Nm (44.3 ± 4 lbf.ft.).
The remaining four bolts:
Torque: 40 ± 4 Nm (29.5 ± 3 lbf.ft.).
(3) Install the engine coolant radiator.
(4) Install the intercooler with coolant tank.
(5) Install the cabin heat-exchanger and shroud.
(6) Install all the clamps, clips and ties that hold the The clamps, clips and ties that you
electrical harness and hose to the engine mount. removed in Paragraph 2 B, item 2.
Page 202 Doc # 6.02.15
15 Apr 2013 71-20-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Section 71-50
Electrical Cables in the Engine Compartment
1. General
The engine compartment has a main electrical wiring harness. The harness is supplied as part of the
engine installation. The harness incorporates all of the low-power cables for the engine control system.
It is integral part of the engine control system. Refer to Section 76-00 for data about the main electrical
wiring harness.
There is a small number of separate cables for the alternator and starter. See Chapter 24 for data
about the battery and alternator wiring. See Chapter 80 for more data about the starter cables. See
Chapter 92 wiring diagrams for data about the cables in each system.
Doc # 6.02.15 Page 1
Rev. 2 71-50-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 71-50-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Section 71-60
Air Intakes
1. General
An air filter housing, air filter and alternate air valve assembly make up the low pressure engine air
intake system of the DA 40 NG airplane. The air filter box is connected to the air intake duct via by a
flexible hose. The same sort of hose feeds the air from the alternate air valve to the turbo-charger. A
lever below the instrument panel, right-side of the pilot, operates the alternate air valve.
Figure 1 shows the engine air filter and alternate air valve.
Doc # 6.02.15 Page 1
Rev. 2 71-60-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Swivel Fitting
Locking Washer
Inner Control Cable
Nut
Outer Sheath
with Adjuster Nut
Turbo-Charger
Air Intake Hose
Worm-Drive Worm-Drive
Clamp Clamp
Turbo-Charger
Alternate Air Valve
Air Filter
Box Assy
Worm-Drive Clamp
Air Filter
Alternate Air Valve Air Filter Box Body
Quick Release Fasteners
Washer Bolt
Nut Washer
Figure 1: Air Filter and Alternate Air Assembly
Page 2 Doc # 6.02.15
15 Apr 2013 71-60-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Locking Ring
Ring
O-Ring
Alternate Air Valve Body
O-Ring
Flange
Mesh Ring
Bushing
Guide Bolt
Bowden Cable Guide
Screw
Camloc Bolt
& Lock Washer
Suction Nozzle
Locking Ring
Figure 2: Air Valve Assembly
Doc # 6.02.15 Page 3
Rev. 2 71-60-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
2. Description
The air intake has three main parts:
) Alternate air valve assembly.
) Air filter housing.
) Air filter.
A. Alternate Air Assembly
Refer to Figure 1. The alternate air valve is attached to the RH face of the air filter housing. The air
filter attaches to the front of the alternate air valve. The alternate air valve also has an intake direct
from the engine compartment. Rotary motion of the outer ring opens different holes to the engine
compartment which allows unfiltered air to enter the engine induction system.
B. Air Filter Housing
The air filter housing is made of aluminum. A flexible hose connects the housing to the air intake
duct. Bolts attach the air filter housing to the firewall.
C. Air Filter
Refer to Figure 1. The air filter is a K&N RU high-flow air filter. The air filter is connected to the
alternate air valve assembly via a worm-drive clamp.
3. Operation
When the pilot pulls the alternate air valve control lever towards the rear of the airplane the alternate
air valve screen opens and air from the engine compartment (unfiltered air) enters the engine induction
system.
When the pilot moves the alternate air valve control lever forward the alternate air valve moves back
to the normal (OFF) position.
Page 4 Doc # 6.02.15
15 Apr 2013 71-60-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the possible defects of the air intake system. When experiencing trouble detailed
in the Trouble column read across to the Possible Cause column, then do the repair given in the
Repair column.
Trouble Possible Cause Repair
An engine does not develop Air filter blocked/defective on Replace air filter.
full power. the engine.
Doc # 6.02.15 Page 101
Rev. 2 71-60-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 71-60-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices describe how to remove and install the air filter, the alternate air valve
assembly and instruct how to adjust, remove and install the alternate air valve control cable.
2. Remove/Install the Air Filter
A. Remove the Air Filter
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
TURNS IT CAN CAUSE INJURY TO PERSONS.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the engine top cowling. Refer to Section 71-10.
(4) Remove the air intake duct from the air filter box.
(5) Disconnect the alternate air valve Bowden cable.
(6) Open the 3 Camlocs of the alternate air valve.
(7) Pull out the alternate air valve with the attached
filter element.
(8) Open the worm-drive clamp which holds the filter
element. Pull off the filter from the alternate air
valve.
Doc # 6.02.15 Page 201
Rev. 2 71-60-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
B. Install an Air Filter
Detail Steps/Work Items Key Items/References
(1) Place the filter on the alternate air valve. Close
the worm drive clamp which holds the filter
element.
Do not use the worm drive clamp provided with
K&N filter package. Use 9 mm (3/8 in) wide
worm drive clamp instead.
(2) Place the alternate air valve with the attached
filter element into the air filter box.
(3) Close the 3 Camlocs of the alternate air valve.
(4) Connect the alternate air valve Bowden cables.
(5) Install the air intake duct to the air filter box.
(6) Check if position of the alternate air valve is in Refer to Paragraph 5.
accordance to the selector handle position.
(7) Install the engine top cowling. Refer to Section 71-10.
Page 202 Doc # 6.02.15
15 Apr 2013 71-60-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
3. Remove/Install the Alternate Air Valve
A. Remove the Alternate Air Valve
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
TURNS IT CAN CAUSE INJURY TO PERSONS.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the engine top cowling. Refer to Section 71-10.
(4) Remove the air intake duct from the air filter box.
(5) Disconnect the alternate air control cable.
(6) Remove the 3 Camlocs of the alternate air valve.
(7) Disconnect the hose that connects the alternate
air valve to the turbo-charger inlet:
S Open the worm-drive-clamp. At the alternate air valve.
S Pull the hose off the valve.
(8) Move the alternate air valve clear of the airplane.
Doc # 6.02.15 Page 203
Rev. 2 71-60-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
B. Install the Alternate Air Valve
Detail Steps/Work Items Key Items/References
(1) Install the air filter. Refer to Paragraph 2.
(2) Install the alternate air valve to the air filter
housing.
(3) Connect the alternate air valve control cable.
(4) Check if position of the alternate air valve is in Refer to Paragraph 5.
accordance to the selector handle position.
(5) Connect the hose that connects the alternate air
valve to the turbo-charger inlet:
S Connect the hose to the valve. At the alternate air valve.
S Tighten the worm-drive clamp.
(6) Install the air intake duct to the air filter box.
Page 204 Doc # 6.02.15
15 Apr 2013 71-60-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
4. Remove/Install the Alternate Air Control Cable
A. Remove the Alternate Air Control Cable
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
TURNS IT CAN CAUSE INJURY TO PERSONS.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the engine top cowling. Refer to Section 71-10.
(4) Disconnect the control cable from the alternate Refer to Figure 3.
air control operating lever in the cockpit:
S Loosen the screw on the cable swivel fitting
at the operating lever.
S Remove the swivel fitting from the cable. Retain the swivel fitting.
(5) Disconnect the control cable from the alternate
air valve.
Doc # 6.02.15 Page 205
Rev. 2 71-60-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(6) Remove the firewall feed-thru from the engine
side of the firewall:
S Remove the firewall sealant from the
feed-thru.
S Drill out the two rivets which hold the shields
to the firewall.
S Remove the shields.
S Pull the 2 parts of the feed-thru clear of the Keep the 2 parts of the feed-thru.
firewall.
(7) Move the control cable clear of the airplane.
Page 206 Doc # 6.02.15
15 Apr 2013 71-60-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Nipple
Operating Lever
Bush
Cold Air
Spacer
Locking Washer
Angle
Bracket
Swivel Fitting
Locking Washer
Inner Control Cable
Nut
Outer Sheath with Adjuster
Nut
Turbo-Charger
Air Filter
Box Assy
Alternate Air Valve
Figure 3: Alternate Air Valve Operating Cables
Doc # 6.02.15 Page 207
Rev. 2 71-60-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
B. Install an Alternate Air Control Cable
Detail Steps/Work Items Key Items/References
(1) Move the alternate air control cable in position in Through the hole in the firewall and the
the airplane. slot in the floor area near the alternate
air lever.
(2) Connect the alternate air control cable to the
alternate air lever in the cockpit.
(3) Install the feed-thru to the engine side of the
firewall with firewall sealant:
S Put the 2 parts of the feed-thru round the
control cable.
S Push the feed-thru in the firewall.
S Put the 2 shields in position over the Use PR 812 (MIL-S-38249 Type 1)
feed-thru. Apply firewall sealant. firewall sealant.
S Install 2 pop-rivets to attach the shields to
the firewall.
(4) Install the alternate air valve. Refer to Paragraph 3.
(5) Connect the alternate air control cable to the Refer to Paragraph 5.
alternate air valve.
(6) Install the engine cowling. Refer to Section 71-10.
Page 208 Doc # 6.02.15
15 Apr 2013 71-60-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
5. Adjust the Alternate Air Valve Control Cable
A. Adjust the Alternate Air Valve Control Cable
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
TURNS IT CAN CAUSE INJURY TO PERSONS.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) If necessary, disconnect the airplane main Refer to Section 24-31.
battery.
(3) If necessary, remove the engine top cowling. Refer to Section 71-10.
(4) Move the alternate air lever in the cockpit from
OFF to ON:
S Make sure the lever moves freely with no
restrictions.
(5) Set the alternate air lever in the cockpit to OFF Fully forward.
and hold it in position:
S Make sure that the alternate air valve is fully
closed.
Doc # 6.02.15 Page 209
Rev. 2 71-60-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(6) Set the alternate air lever in the cockpit to ON
and hold it in position:
S Make sure that the alternate air control valve
is in the fully open position.
(7) If necessary, adjust the alternate air control At the alternate air lever.
cable to get the correct settings at item 5.
(8) Connect the airplane battery. Refer to Section 24-31.
(9) Install the engine top cowling. Refer to Section 71-10.
Page 210 Doc # 6.02.15
15 Apr 2013 71-60-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Section 71-70
Engine Drains
1. General
The DA 40 NG has a breather for the oil separator. Refer to Chapter 72 for more data about the engine
oil system and refer to Chapter 75 for more data about the engine liquid cooling system.
2. Description
Figures 1 and 2 show the engine drains of the Austro Engine E4-A engine.
The breather hose of the oil separator connects to an outlet at the top of the oil separator. A
% worm-drive-clamp secures the hose at the outlet. The other end of the breather hose connects to a
% drain adapter, which is an additional breather line outlet. From there a second breather hose leads the
% breather air to the drain collector at the bottom of the firewall.
Doc # 6.02.15 Page 1
Rev. 2 71-70-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
%
%
%
%
%
%
%
%
%
%
%
%
Crankcase
% Drain Hose 1
% Worm Drive Clamp
%
%
% Drain Adaptor
Worm
% Drive Crankcase
Clamps Drain Hose 2
%
%
%
%
% Worm
Drive
%
Clamps
%
% Elbow 90°
Tube
% Adapter
% Firewall
%
% Drain Hose
Bolt
%
Washer
% P-Clamp Rivet
Engine
% P-Clamp Mounting
% Frame
Drain Collector
% Cylinder Head Washer
Drain Hose Nut
% Engine Mounting
% Frame
%
Figure 1: Engine Nacelle Drains
Page 2 Doc # 6.02.15
15 Apr 2013 71-70-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
%
%
%
%
%
%
%
%
%
%
%
% Crankcase
Drain Hose 1
%
Worm Drive Clamp
%
%
% Drain Adaptor
Worm
% Drive Crankcase
% Clamps Drain Hose 2
%
%
%
%
Worm
Drive
% Clamp
%
%
%
% Firewall
Drain Hose
%
%
Bolt
% Washer
% P-Clamp Rivet
% Engine
P-Clamp Mounting
%
Frame
% Drain Collector
Cylinder Head Washer
% Drain Hose Nut
Engine Mounting
% Frame
%
%
Figure 2: Engine Nacelle Drains (if MÄM 40-434 is installed)
Doc # 6.02.15 Page 3
Rev. 2 71-70-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 71-70-00 Rev. 2
DA 40 NG AMM Power Plant
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove/install the oil separator breather hose.
2. Remove/Install the Oil Separator Breather Hose
A. Remove the Oil Separator Breather Hose
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
TURNS IT CAN CAUSE INJURY TO PERSONS.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the engine cowling. Refer to Section 71-10.
% (4) Remove the cable ties and P-clamps that secure Refer to Figures 1or 2.
% the breather hoses and the drain adapter.
Doc # 6.02.15 Page 201
Rev. 2 71-70-00 15 Apr 2013
Power Plant DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(5) Remove the breather hose:
S Remove the hose clamp that secures the
breather hose to the outlet at the top of the
oil separator.
S Pull the breather hose from the outlet at the
top of the separator.
% S Remove the hose clamps that attach the
% breather hose to the air filter box and drain
% adapter to the engine mount.
% S Pull the breather hose assy out of the drain
collector at the bottom of the fuselage and
% move the breather hose assy clear of the
fuselage.
B. Install the Oil Separator Breather Hose
Detail Steps/Work Items Key Items/References
(1) Install a new hose clamp onto the breather hose
and connect the hose to the breather outlet and
tighten the hose clamp.
% (2) Install the breather hose assy with the drain Refer to Figure 1 or 2.
% adapter and attach them with P-clamps to the air
% filter box and engine mount.
% (3) Install the P-clamps that attaches the breather
% hose assy.
(4) Install the engine cowling. Refer to Section 71-10.
(5) Connect the airplane main battery. Refer to Section 24-31.
Page 202 Doc # 6.02.15
15 Apr 2013 71-70-00 Rev. 2
DA 40 NG AMM Engine
AIRCRAFT
CHAPTER 72
ENGINE
Doc # 6.02.15 Page 1
Rev. 2 72-TITLE 15 Apr 2013
Engine DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2
15 Apr 2013 72-TITLE Doc # 6.02.15
Rev. 2
DA 40 NG AMM Engine
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 72
ENGINE
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Engine Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Change the Engine Oil and Replace the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . 202
3. Replace the Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Read an Engine Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Doc # 6.02.15 Page 1
Rev. 2 72-CONTENTS 15 Apr 2013
Engine DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 72-CONTENTS Rev. 2
DA 40 NG AMM Engine
AIRCRAFT
CHAPTER 72
ENGINE
1. General
This Section provides background information about the Austro Engine E4-A engine installed on the
DA 40 NG airplane and describes maintenance events of the oil system of the Austro Engine E4-A
engine.
Refer to these Chapters for more data about the engine systems:
) Chapter 73. Engine fuel and control.
) Chapter 75. Liquid cooling system.
) Chapter 76. Engine controls.
) Chapter 77. Engine indicating.
) Chapter 78. Engine exhaust.
) Chapter 79. Oil cooling.
) Chapter 80. Engine starting.
) Chapter 81. Turbo charger.
Note: Only Austro Engine authorized maintenance organizations may carry out
maintenance and inspection work on the Austro Engine E4-A engine. Any engine
malfunction must be reported to Austro Engine.
Doc # 6.02.15 Page 1
Rev. 2 72-00-00 15 Apr 2013
Engine DA 40 NG AMM
AIRCRAFT
Engine Oil Filter Housing
Gearbox Oil Filler Plug
Locking Wire
Washer Engine Oil Drain Plug
Gearbox Oil Drain Plug
Engine Oil Filler
Gearbox Oil Level
Locking Wire Inspection Window
Figure 1: Oil System Maintenance Locations
Page 2 Doc # 6.02.15
15 Apr 2013 72-00-00 Rev. 2
DA 40 NG AMM Engine
AIRCRAFT
2. Description
The Austro Engine E4-A engine is a liquid-cooled, in-line four-stroke four cylinder engine with a double
overhead camshaft (DOHC). The valves are actuated by the cam follower. The direct fuel injection is
realized with a common rail technique and the engine is charged by a turbo charger. All engine
components are controlled by an EECU system. The engine is equipped with an electrical starter, an
alternator, a water pump, an oil pump, a coolant system and an oil cooler. The propeller is powered
by a directly integrated gearbox with an integral torsional vibration damper.
Doc # 6.02.15 Page 3
Rev. 2 72-00-00 15 Apr 2013
Engine DA 40 NG AMM
AIRCRAFT
3. Engine Oil System
The engine has a regular wet sump oil system. The sump has a maximum capacity of 7 liter
(7.4 US qt). Refer to the Airplane Flight Manual Chapter 2 for data about the oil types to be used in the
engine.
The internal oil pump supplies oil to all bearings and other components that require oil. Oil galleries
inside the engine crankcase and cylinder head supply oil to the internal components.
Figure 1 shows the location of the items that you can maintain on the engine oil system of the
AE E4-A engine. The engine has the following maintenance points:
) A oil filter located at the top left side of the engine adjacent to the cylinder head. You must replace
the filter at the times specified in Chapter 05.
) An engine oil drain plug at the rear left of the engine sump.
) An engine oil filler located at the top of the oil sump.
) A gearbox oil filler plug located at the top of the gearbox.
) A gearbox oil level window located at the LH side of the gearbox.
) A gearbox oil drain plug located at the bottom of the gearbox.
) A oil separator is located under the injector cover.
Page 4 Doc # 6.02.15
15 Apr 2013 72-00-00 Rev. 2
DA 40 NG AMM Engine
AIRCRAFT
Trouble-Shooting
1. General
The trouble-shooting given in this Section is limited to those items where maintenance is permitted.
For all other engine troubles, refer to an approved Austro Engine E4-A repair facility or the engine
manufacturer.
Trouble Possible Cause Repair
Engine oil pressure low. Not enough oil in the engine oil Fill the engine with oil.
sump.
Oil pressure regulator valve Refer to the engine
does not operate correctly. manufacturer.
Defective oil pump.
Refer to the engine
manufacturer.
Gearbox oil temperature high. Not enough oil in the gearbox. Find the reason for the loss of
gearbox oil and correct the
problem. Fill the gearbox with
oil. Refer to the AFM for
approved oil types.
Doc # 6.02.15 Page 101
Rev. 2 72-00-00 15 Apr 2013
Engine DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 72-00-00 Rev. 2
DA 40 NG AMM Engine
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices describe how to service the oil system on the E4-A engine. Further
maintenance practices are described in the Austro Engine service documents. Refer to an approved
Austro Engine E4-A maintenance facility or the engine manufacturer for all other engine maintenance.
WARNING: DO NOT GET OIL ON YOU. OIL CAN CAUSE SKIN DISEASE.
CAUTION: ALWAYS PUT A CAP ON OPEN CONNECTIONS. IF YOU DO NOT PUT
A CAP ON OPEN CONNECTIONS, THEN CONTAMINATION CAN GET
INTO THE SYSTEM AND CAUSE DAMAGE.
CAUTION: DO NOT MIX OIL TYPES. IF YOU MIX OIL TYPES THE OIL CAN LOSE
ITS PROPERTIES AND THE ENGINE WILL WEAR MORE QUICKLY.
Note: A sample of the oil and the used oil filter must be stored in a clean container,
labeled, and made available to Austro Engine GmbH on request for the complete
engine life time. The label must show the airplane serial number, registration
number, engine serial number, operation time and date. Quantity of the oil sample
must be 100 ml.
Doc # 6.02.15 Page 201
Rev. 2 72-00-00 15 Apr 2013
Engine DA 40 NG AMM
AIRCRAFT
2. Change the Engine Oil and Replace the Oil Filter
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK
ON THE ENGINE CONTROLS. IF THE PROPELLER TURNS IT CAN
CAUSE INJURY TO PERSONS.
Note: For environment protection, changing the gearbox oil is only allowed on sealed
surfaces. Used gearbox oil has to be disposed according to the applicable
regulations. The environment and ground water must not be contaminated.
% (1) Do an engine ground run until the engine oil has
% operating temperature.
(2) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(3) Disconnect the airplane main battery. Refer to Section 24-34.
(4) Remove the engine cowling. Refer to Section 71-10.
% CAUTION: USE ONLY APPROVED ENGINE OIL. REFER TO CHAPTER 2 OF
% THE AIRPLANE FLIGHT MANUAL FOR APPROVED ENGINE OIL
% SPECIFICATION. IF YOU DO NOT USE APPROVED ENGINE OIL,
THE ENGINE CAN BE DAMAGED.
% (5) Change the engine oil and replace the engine Refer to AE Maintenance Manual,
% oil filter. latest revision.
% (6) Visually check engine oil for coolant. No coolant allowed in oil.
(7) Cut open the used oil filter. Look for particles of If the filter contains particles of metal,
metal. refer to the engine manufacturer.
Page 202 Doc # 6.02.15
15 Apr 2013 72-00-00 Rev. 2
DA 40 NG AMM Engine
AIRCRAFT
Detail Steps/Work Items Key Items/References
(8) Install the engine cowling. Refer to Section 71-10.
(9) Do a ground test of the engine, allow the engine Refer to Section 71-00 and AE
to reach normal operating temperatures. Maintenance Manual, latest revision.
(10) Do a test for oil leaks:
S Remove the engine cowling. Refer to Section 71-10.
S Look for oil leaks, specially in the areas
where you have done work (drain).
S Install the engine cowling. Refer to Section 71-10.
Doc # 6.02.15 Page 203
Rev. 2 72-00-00 15 Apr 2013
Engine DA 40 NG AMM
AIRCRAFT
3. Replace the Gearbox Oil
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK
ON THE ENGINE CONTROLS. IF THE PROPELLER TURNS IT CAN
CAUSE INJURY TO PERSONS.
Note: For environment protection, changing the gearbox oil is only allowed on sealed
surfaces. Used gearbox oil has to be disposed according to the applicable
regulations. The environment and ground water must not be contaminated.
% (1) Do an engine ground run until the engine oil has
% operating temperature.
(2) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
% (3) Disconnect the airplane main battery. Refer to Section 24-34.
(4) Remove the engine cowling. Refer to Section 71-10.
% CAUTION: USE ONLY APPROVED GEARBOX OIL. REFER TO CHAPTER 2 OF
% THE AIRPLANE FLIGHT MANUAL FOR APPROVED GEARBOX OIL
% SPECIFICATION. IF YOU DO NOT USE APPROVED GEARBOX OIL,
% THE ENGINE CAN BE DAMAGED.
%
% (5) Change the gearbox oil. Refer to the AE Maintenance Manual,
latest revision.
(6) Install the engine cowling. Refer to Section 71-10.
(7) Do a ground test of the engine Refer to Section 71-00 and AE
Maintenance Manual, latest revision..
(8) Remove the engine cowling. Refer to Section 71-10.
Page 204 Doc # 6.02.15
15 Apr 2013 72-00-00 Rev. 2
DA 40 NG AMM Engine
AIRCRAFT
Detail Steps/Work Items Key Items/References
(9) Check for leakage, especially at the gearbox oil
drain plug and gearbox oil filler plug.
(10) Install the engine cowling. Refer to Section 71-10.
4. Read an Engine Event Log
CAUTION: ONLY AE-AUTHORIZED PERSONNEL MAY DOWNLOAD DATA FROM
THE ENGINE.
CAUTION: WHEN OPERATING THE AIRPLANE ELECTRICAL SYSTEM WITH
ENGINE MASTER ON AND THE ENGINE IS NOT RUNNING ALWAYS
CONNECT AN EXTERNAL POWER SUPPLY WITH A PRESET
% VOLTAGE OF 29V TO THE AIRPLANE. IF MÄM 40-551 IS INSTALLED,
% USE A PRESET VOLTAGE LOWER THAN 26.0 V. OTHERWISE THE
ALTERNATORS MAY BE DAMAGED.
A. Equipment
Item Quantity Part Number
Laptop computer. 1 Commercial.
"Wizard 300" software, latest approved revision. n/a n/a.
CAN interface. 1 Commercial.
B. Read an Engine Event Log
Refer to AE Maintenance Manual, latest revision.
Doc # 6.02.15 Page 205
Rev. 2 72-00-00 15 Apr 2013
Engine DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 206 Doc # 6.02.15
15 Apr 2013 72-00-00 Rev. 2
DA 40 NG AMM Engine Fuel and Control
AIRCRAFT
CHAPTER 73
ENGINE FUEL AND CONTROL
Doc # 6.02.15 Page 1
Rev. 2 73-TITLE 15 Apr 2013
Engine Fuel and Control DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 73-TITLE Rev. 2
DA 40 NG AMM Engine Fuel and Control
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 73
ENGINE FUEL AND CONTROL
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Doc # 6.02.15 Page 1
Rev. 2 73-CONTENTS 15 Apr 2013
Engine Fuel and Control DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 73-CONTENTS Rev. 2
DA 40 NG AMM Engine Fuel and Control
AIRCRAFT
CHAPTER 73
ENGINE FUEL AND CONTROL
1. General
This Section describes the fuel system of the Austro Engine E4-A engine and provides general data
and trouble shooting information of the system.
Refer also to the engine manufacturer’s Repair Manual for the Austro Engine E4-A engine. You can
replace components in the air intake system and the fuel filter. Refer to the engine manufacturer for
data on the engine fuel system.
Doc # 6.02.15 Page 1
Rev. 2 73-00-00 15 Apr 2013
Engine Fuel and Control DA 40 NG AMM
AIRCRAFT
Intercooler
Turbo-Charger
Manifold Pressure
Sensor Air Filter
Alternate Air Valve
Manifold
Temperature
Sensor
Intake Manifold
Common Rail
Fuel Rail
Pressure Sensor
High Pressure Pump
Rail Pressure
Valve Fuel Metering Unit
Fuel Pressure
Injectors Sensor
Fuel Temperature
Sensor
Inlet
Fuel
Filter Gascolator
Return to Main Tank Fuel Supply from Main Tank
Electrically Driven
Fuel Pumps
Figure 1: Engine Fuel System Schematic
Page 2 Doc # 6.02.15
15 Apr 2013 73-00-00 Rev. 2
DA 40 NG AMM Engine Fuel and Control
AIRCRAFT
2. Description and Operation
Figure 1 shows the schematic diagram for DA 40 NG with the AE E4-A engine. The power generation
system has two main parts:
) Air intake system. This system supplies air from the inlet to the air filter to the engine intake
manifold.
) Engine fuel system. The engine fuel system takes fuel from the airplane fuel system and injects it
into the cylinders.
A. Air Intake System
The air intake system has an air filter which is located at the firewall in the engine compartment.
The filter attaches to the forward face of the alternate air valve. The alternate air valve inlet takes
air direct from the engine compartment. The valve can be selected to provide filtered air or warm,
unfiltered air to the engine. Refer to Section 71-60 for more data on the air filter and alternate air
valve.
The outlet of the alternate air valve connects to the turbo charger. The outlet of the turbo-charger
connects then to an intercooler and the engine intake manifold. Refer to Chapter 81 for more data
on the turbo charger and intercooler.
B. Engine Fuel System
The fuel from the main tank flows through the fuel selector, gascolator (filter size 210 µm) to the
electrically driven low pressure fuel pumps. These fuel pumps supply the high pressure pump with
the required fuel pressure and flow. A fine fuel filter is installed upstream of the high pressure pump
to assure clean fuel supply. Located between the fine fuel filter and the high pressure fuel pump
is a damper to reduce the fuel pressure pulsations if MÄM 40-468 is installed.
The high-pressure pump supplies fuel to a common rail connected to the injectors. A fuel metering
unit at the engine driven high pressure fuel pump which ensures that only the required quantity of
fuel is compressed. The necessary rail pressure, which is measured directly at the rail, is controlled
by the rail pressure valve. Surplus fuel returns to the airplane main fuel system. The fuel returning
from the engine is hot. The hot fuel passes through a fuel cooler located in the fuselage wing
attachment area. From there the fuel returns via a cooling loop through the auxiliary tank to the fuel
main tank.
Doc # 6.02.15 Page 3
Rev. 2 73-00-00 15 Apr 2013
Engine Fuel and Control DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 73-00-00 Rev. 2
DA 40 NG AMM Engine Fuel and Control
AIRCRAFT
Trouble-Shooting
1. General
The table below lists possible defects of the engine fuel and control system. Only data about the air
intake, air filter and fuel filter are provided. For more data on troubleshooting the engine fuel and
control system refer to the engine manufacturer.
If trouble are experienced as detailed in the Trouble column read across to the Possible Cause
column, then do the repair given in the Repair column.
Trouble Possible Cause Repair
Loss of engine power. Blocked air intake. Examine the air intake.
Remove any obstructions.
Refer to Section 71-60.
Dirty/damaged air filter. Replace the air filter. Refer to
Section 71-60.
Dirty/damaged fuel filter. Replace the fuel filter. Look for
contaminated fuel in the
airplane fuel system. Refer to
Section 28-00 and Section
28-20.
Air in fuel distribution system. Bleed the fuel distribution
system. Refer to Section
28-20.
Doc # 6.02.15 Page 101
Rev. 2 73-00-00 15 Apr 2013
Engine Fuel and Control DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 73-00-00 Rev. 2
DA 40 NG AMM Engine Fuel and Control
AIRCRAFT
Maintenance Practices
1. General
Only an approved Austro Engine repair shop can repair the engine fuel system. For more data on the
engine fuel and control system refer to the engine manufacturer.
Refer to Section 28-20 for more data on the fuel distribution system. Refer to Section 71-60 for
maintenance data on the air filter and alternate air valve. Refer to Chapter 81 for maintenance data
on the turbo charger system.
Doc # 6.02.15 Page 201
Rev. 2 73-00-00 15 Apr 2013
Engine Fuel and Control DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 202 Doc # 6.02.15
15 Apr 2013 73-00-00 Rev. 2
DA 40 NG AMM Liquid Cooling System
AIRCRAFT
CHAPTER 75
LIQUID COOLING SYSTEM
Doc # 6.02.15 Page 1
Rev. 2 75-TITLE 15 Apr 2013
Liquid Cooling System DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2
15 Apr 2013 75-TITLE Doc # 6.02.15
Rev. 2
DA 40 NG AMM Liquid Cooling System
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 75
LIQUID COOLING SYSTEM
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Coolant Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Remove/Install the Coolant Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5. Fill and Bleed an Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
6. Drain the Engine Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
7. Coolant System Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Doc # 6.02.15 Page 1
Rev. 2 75-CONTENTS 15 Apr 2013
Liquid Cooling System DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 75-CONTENTS Rev. 2
DA 40 NG AMM Liquid Cooling System
AIRCRAFT
CHAPTER 75
LIQUID COOLING SYSTEM
1. General
This Section describes the liquid cooling system of the DA 40 NG airplane. It provides Maintenance
Practices to remove/install the liquid cooling system components.
Figure 1 shows the liquid cooling system schematic. Figure 2 and 3 show the installation of the liquid
cooling system in the airplane.
Doc # 6.02.15 Page 1
Rev. 2 75-00-00 15 Apr 2013
Liquid Cooling System DA 40 NG AMM
AIRCRAFT
Pressure Relief Valve
Radiator Vent Line
Expansion
Tank
Small Cooling Circuit
Thermostat
Radiator
Temperature Sensor
Heat
Exchanger Engine
Water
Pump
Bypass Cooling Circuit
Large Cooling Circuit
Figure 1: Liquid Cooling System Schematic Diagram
Page 2 Doc # 6.02.15
15 Apr 2013 75-00-00 Rev. 2
DA 40 NG AMM Liquid Cooling System
AIRCRAFT
2. Description
The engine has a water-based liquid cooling system. The liquid coolant is a mixture of water and
antifreeze. Refer to the Airplane Flight Manual for approved coolant types.
The engine has an integral coolant pump. The coolant pump is located at the rear of the engine and
is powered by the v-ribbed belt. An automatic tensioner keeps the belt tension at the correct value.
A temperature sensor at the engine coolant outlet connects to the engine control system. The
integrated cockpit system (ICS) or the main engine display (MED) displays the coolant temperature
(COOLING TEMPERATURE or CT).
The cooling system has three circuits (see Figure 1):
A. Small Cooling Circuit
The circuit is active at cooling temperature below 80 °C (176 °F). Coolant circulates from the
closed thermostatic valve to the water pump and the engine.
B. Bypass Cooling Circuit
The bypass cooling circuit is always active. Coolant circulates from the engine to the heat
exchanger, to the water pump and back to the engine.
C. Long Cooling Circuit
This circuit starts opening at 80 °C (176 °F) and is fully opened at 95 °C (203 °F). Coolant circulates
post the thermostatic valve to the radiator (located below the engine mount) back to the water pump
and the engine.
A coolant expansion tank is located on top of the engine next to thermostatic valve. This is the highest
point in the system. A small diameter hose connects the highest point of the system to the top of the
coolant expansion tank. The tank has an over pressure valve which opens when max. coolant system
pressure is exceeded.
A small diameter hose connects the bottom of the coolant tank to the inlet to the coolant pump.
A coolant level sensor is installed in the coolant tank. It operates the WATER LEVEL caution light in
the ICS or the WATERLEV caution light on the SED.
On top of the coolant expansion tank a pressure relief valve is installed. The pressure relief valve limits
the over and under pressure in the cooling circuit.
Doc # 6.02.15 Page 3
Rev. 2 75-00-00 15 Apr 2013
Liquid Cooling System DA 40 NG AMM
AIRCRAFT
Worm Drive Clamps
Coolant
Hose Tube 2
Worm Drive
Clamp Part of
Worm Drive Clamp
Engine
Worm Drive Clamp Bypass Hose
Hose
Worm Drive Clamp
Worm Drive
Clamps Thermostat Valve
Pressure Relief Valve
Bleed
Point Header Tank
To Coolant Bolt
Bypass Pipe
P-Clamp
Coolant
Tube 1 Bolt
P-Clamp Worm Drive
Worm Drive
Clamps
Clamps
Worm Drive
Clamps
Worm Drive Worm Drive
Clamps Hose
Clamps
A Hose Worm Drive Tube
Clamps
Hose
Engine Mounting
Frame Radiator
A
A
Anti Vibration
Coolant Drain Plug
Mount
A
A
Figure 2: Liquid Cooling System Installation (if MÄM 40-434 is not installed)
Page 4 Doc # 6.02.15
15 Apr 2013 75-00-00 Rev. 2
DA 40 NG AMM Liquid Cooling System
AIRCRAFT
Figure 3: Liquid Cooling System Installation (if MÄM 40-434 is installed)
Doc # 6.02.15 Page 5
Rev. 2 75-00-00 15 Apr 2013
Liquid Cooling System DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 6 Doc # 6.02.15
15 Apr 2013 75-00-00 Rev. 2
DA 40 NG AMM Liquid Cooling System
AIRCRAFT
Trouble-Shooting
1. General
This table describes how to troubleshoot the liquid cooling system. When experiencing trouble detailed
in the Trouble column read across to the Possible Cause column, then perform the repair given in the
Repair column.
This table gives only troubles to the airplane parts of the cooling system.
Trouble Possible Cause Repair
Engine overheats. Flat-belt worn or broken. Refer to the engine
manufacturer.
Coolant level low. Fill the cooling system. Refer
to Section 12-10.
Coolant leak. Look for leaks at all system
joints. Repair or replace
defective components.
Air in cooling system. Bleed the cooling system.
Radiator matrix blocked by Remove foreign objects and
foreign objects. clean radiator matrix.
Thermostat valve defective. Refer to the engine
manufacturer.
Coolant pump defective. Refer to the engine
manufacturer.
Defective cylinder head Refer to the engine
gasket. manufacturer.
Doc # 6.02.15 Page 101
Rev. 2 75-00-00 15 Apr 2013
Liquid Cooling System DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 75-00-00 Rev. 2
DA 40 NG AMM Liquid Cooling System
AIRCRAFT
Maintenance Practices
1. General
This Section describes the Maintenance Practices of the liquid cooling system components.
2. Remove/Install the Coolant Expansion Tank
A. Remove the Coolant Expansion Tank
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
TURNS IT CAN CAUSE INJURY TO PERSONS.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the engine cowling. Refer to Section 71-10.
WARNING: DO NOT REMOVE THE PRESSURE CAP FROM THE COOLANT
TANK IF THE ENGINE IS HOT. THE PRESSURE IN THE SYSTEM
CAN FORCE HOT COOLANT TO COME OUT AND BURN YOU.
(4) Remove the pressure cap from the coolant tank:
S Turn the cap counterclockwise a small
distance to release the pressure.
S When the pressure has fully released, turn
the cap completely counterclockwise.
Doc # 6.02.15 Page 201
Rev. 2 75-00-00 15 Apr 2013
Liquid Cooling System DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(5) Disconnect the hose that connects the Use a suitable container to collect
expansion tank to the supply system: coolant.
S Remove the worm-drive-clamp that secures
the hose.
S Pull the hose from the connector at the
expansion tank.
(6) Disconnect the electrical cables for the coolant At the inline connector, at the sensor.
tank level sensor.
(7) Remove the hose from the coolant tank which
connects to the thermostat vent.
(8) Remove the nuts and bolts which attach the
coolant tank to the intercooler.
(9) Move the expansion tank clear of the engine.
Page 202 Doc # 6.02.15
15 Apr 2013 75-00-00 Rev. 2
DA 40 NG AMM Liquid Cooling System
AIRCRAFT
B. Install a Coolant Expansion Tank
Detail Steps/Work Items Key Items/References
(1) Install the expansion tank to the intercooler.
(2) Connect the electrical cables for the coolant
tank level sensor.
(3) Install the hose that connects the coolant tank to
the thermostat vent.
(4) Connect the hose that connects the expansion
tank to the supply system:
S Push the hose onto the connector at the
expansion tank.
S Install the worm-drive-clamp that secures
the hose connection.
(5) Fill and bleed the liquid coolant system. Refer to Paragraph 5.
(6) Install the engine cowling. Refer to Section 71-10.
Doc # 6.02.15 Page 203
Rev. 2 75-00-00 15 Apr 2013
Liquid Cooling System DA 40 NG AMM
AIRCRAFT
3. Remove/Install the Pressure Relief Valve
A. Remove the Pressure Relief Valve
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
TURNS IT CAN CAUSE INJURY TO PERSONS.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Remove the engine cowling. Refer to Section 71-10.
WARNING: DO NOT REMOVE THE PRESSURE CAP FROM THE COOLANT
TANK IF THE ENGINE IS HOT. THE PRESSURE IN THE SYSTEM
CAN FORCE HOT COOLANT TO COME OUT AND BURN YOU.
(3) Remove the locking wire from the pressure
relief valve.
(4) Remove the pressure relief valve.
B. Install the Pressure Relief Valve
Detail Steps/Work Items Key Items/References
(1) Install the pressure relief valve. Torque 12-15 Nm (8.85-11.06 lbf.ft.).
(2) Install the locking wire.
(3) Install the engine cowling. Refer to Section 71-10.
Page 204 Doc # 6.02.15
15 Apr 2013 75-00-00 Rev. 2
DA 40 NG AMM Liquid Cooling System
AIRCRAFT
4. Remove/Install the Coolant Radiator
A. Remove the Coolant Radiator
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
TURNS IT CAN CAUSE INJURY TO PERSONS.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the engine cowling. Refer to Section 71-10.
WARNING: DO NOT REMOVE THE PRESSURE CAP FROM THE COOLANT
TANK IF THE ENGINE IS HOT. THE PRESSURE IN THE SYSTEM
CAN FORCE HOT COOLANT TO COME OUT AND BURN YOU.
(4) Remove the pressure cap from the coolant tank
to relief any pressure which may be resident in
the system:
S Turn the cap counterclockwise a small
distance to release the pressure.
S When the pressure has fully released, turn
the cap completely counterclockwise.
(5) Drain the coolant system.
Doc # 6.02.15 Page 205
Rev. 2 75-00-00 15 Apr 2013
Liquid Cooling System DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(6) Remove the hoses from the radiator: Note the position and orientation of the
hoses on the radiator!
S Remove the worm-drive-clamps that secure
the hoses.
S Pull the hoses from the connectors on the
radiator.
(7) Remove the radiator:
S Remove the nuts and washers that attach
the radiator to the engine mount.
S Move the radiator clear of the engine
compartment.
B. Install a Coolant Radiator
Detail Steps/Work Items Key Items/References
(1) Install the radiator:
S Move the radiator into position at the bottom
of the engine mount.
S Install the washers and nuts that attach the
radiator to the engine mount.
(2) Install the hoses onto the radiator that you In the position and orientation noted in
removed in Paragraph 4A, item 6: Paragraph 4A, item 6.
S Install the radiator hoses onto the radiator
inlet and outlet.
S Secure the hoses with worm-drive-clamps.
(3) Fill and bleed the liquid coolant system. Refer to Paragraph 5.
(4) Install the engine cowling. Refer to Section 71-10.
Page 206 Doc # 6.02.15
15 Apr 2013 75-00-00 Rev. 2
DA 40 NG AMM Liquid Cooling System
AIRCRAFT
5. Fill and Bleed an Engine Cooling System
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
TURNS IT CAN CAUSE INJURY TO PERSONS.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the engine cowling. Refer to Section 71-10.
WARNING: DO NOT REMOVE THE PRESSURE CAP FROM THE COOLANT
TANK IF THE ENGINE IS HOT. THE PRESSURE IN THE SYSTEM
CAN FORCE HOT COOLANT TO COME OUT AND BURN YOU.
(4) Fill the cooling system: Allow time for the coolant to move
through the system.
S Open the bleed point at the coolant radiator
pipe.
S Add coolant to the coolant tank.
S When coolant comes from the bleed points
without air bubbles, close the bleed point.
S Install the coolant tank cap.
Doc # 6.02.15 Page 207
Rev. 2 75-00-00 15 Apr 2013
Liquid Cooling System DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(5) Do an engine ground run: Refer to the Airplane Flight Manual.
S Let the coolant temperature rise up to the
point where the coolant flows from the
thermostat valve through the main circuit.
S After shut down, check for leaks.
(6) Let the engine cool down.
WARNING: DO NOT REMOVE THE PRESSURE CAP FROM THE COOLANT
TANK IF THE ENGINE IS HOT. THE PRESSURE IN THE SYSTEM
CAN FORCE HOT COOLANT TO COME OUT AND BURN YOU.
(7) Remove the pressure cap from the coolant tank:
S Turn the cap counterclockwise a small
distance to release the pressure.
S When the pressure has fully released, turn
the cap completely counter-clockwise.
(8) Check coolant level. Repeat items 1 to 7 until
the system is completely free of trapped air and
the fluid level is at the coolant tank tab.
(9) Install the coolant tank cap.
(10) Install the engine cowling. Refer to Section 71-10.
Page 208 Doc # 6.02.15
15 Apr 2013 75-00-00 Rev. 2
DA 40 NG AMM Liquid Cooling System
AIRCRAFT
6. Drain the Engine Coolant System
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
TURNS IT CAN CAUSE INJURY TO PERSONS.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the engine cowling. Refer to Section 71-10.
WARNING: DO NOT REMOVE THE PRESSURE CAP FROM THE COOLANT
TANK IF THE ENGINE IS HOT. THE PRESSURE IN THE SYSTEM
CAN FORCE HOT COOLANT TO COME OUT AND BURN YOU.
(4) Remove the pressure cap from the coolant tank
to relief any pressure which may be resident in
the system:
S Turn the cap counterclockwise a small
distance to release the pressure.
S When the pressure has fully released, turn
the cap completely counterclockwise.
Doc # 6.02.15 Page 209
Rev. 2 75-00-00 15 Apr 2013
Liquid Cooling System DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(5) Drain the coolant system:
S Remove the drain plug from the bottom left
side of the coolant radiator.
Page 210 Doc # 6.02.15
15 Apr 2013 75-00-00 Rev. 2
DA 40 NG AMM Liquid Cooling System
AIRCRAFT
7. Coolant System Pressure Test
A. Equipment
Item Quantity Part Number
Pressure test equipment. 1 Commercial.
B. Coolant System Pressure Test
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
TURNS IT CAN CAUSE INJURY TO PERSONS.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the engine cowling. Refer to Section 71-10.
WARNING: DO NOT REMOVE THE PRESSURE CAP FROM THE COOLANT
TANK IF THE ENGINE IS HOT. THE PRESSURE IN THE SYSTEM
CAN FORCE HOT COOLANT TO COME OUT AND BURN YOU.
(4) Remove the filler cap from the coolant tank and
install the pressure test equipment instead.
(5) Remove the over pressure valve. Plug opening
with blind plug.
Doc # 6.02.15 Page 211
Rev. 2 75-00-00 15 Apr 2013
Liquid Cooling System DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
(6) Pressurize the coolant system. Apply 3 bar (43.5 PSI). Hold the
pressure for at least 15 min.
Refer to AE Installation Manual, latest
revision.
(7) Check the coolant system for leaks.
(8) Remove the pressure test equipment from the
coolant tank.
S Open the pressure relief valve of test If existent.
equipment.
S Remove the test equipment carefully to
relieve the remaining pressure.
(9) Remove blind plug. Install the over pressure
valve.
(10) Install the coolant tank cap.
(11) Install the engine cowling. Refer to Section 71-10.
(12) Connect the airplane main battery. Refer to Section 24-31.
Page 212 Doc # 6.02.15
15 Apr 2013 75-00-00 Rev. 2
DA 40 NG AMM Engine Controls
AIRCRAFT
CHAPTER 76
ENGINE CONTROLS
Doc # 6.02.15 Page 1
Rev. 2 76-TITLE 15 Apr 2013
Engine Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2
15 Apr 2013 76-TITLE Doc # 6.02.15
Rev. 2
DA 40 NG AMM Engine Controls
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 76
ENGINE CONTROLS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Power Lever Hall Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Engine Control Unit (EECU) . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Remove/Install the Engine Control System Electrical Harness . . . . . . . . . . . . . 206
Doc # 6.02.15 Page 1
Rev. 2 76-CONTENTS 15 Apr 2013
Engine Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 76-CONTENTS Rev. 2
DA 40 NG AMM Engine Controls
AIRCRAFT
CHAPTER 76
ENGINE CONTROLS
1. General
This Section describes the DA 40 NG engine controls. The engine has one control (power) lever.
Electrical cables connect the power lever to the engine control system.
2. Description and Operation
Figure 1 shows the schematic diagram of the engine control system if the G1000 system is installed.
Figure 2 shows the schematic diagram of the engine control system if the conventional cockpit is
installed.
The system has an electronic engine control system (EECS). The control system has two independent
computers, either of which can provide all control functions for the engine and propeller. The system
has these main parts:
) Two digital engine control units (ECU A and ECU B located in one box in the fuselage
compartment).
) An electrical harness that connects the ECUs to the engine, the power lever, the annunciator
panel, control buttons and some instruments.
) Sensors that measure engine parameters.
) An electrical power lever located in the center console.
) An ECU TEST button for testing the engine control system.
) An ECU VOTER switch for switching between AUTO, ECU A and ECU B in emergency.
Doc # 6.02.15 Page 1
Rev. 2 76-00-00 15 Apr 2013
Engine Controls DA 40 NG AMM
AIRCRAFT
Annunciation Integrated Cockpit System (Display)
on G1000 PFD
RPM
ECU A FAIL OIL PRESS
ECU B FAIL OIL TEMP
GLOW ON ECU VOTER COOLANT TEMP
FUEL PRESS Switch GEARBOX TEMP
OIL PRESS ECU TEST LOAD
Button FUEL FLOW
Throttle
FUEL QTY From
FUEL LOW Airframe
FUEL TEMP Fuel
System
ALTERNATOR From
Electrical
System
Electronic Engine Control Unit
28 VDC ECU A ECU B
28 VDC
Controlled
Components
Injector 1
Injector 2
Engine Sensors
Injector 3
Injector 4 Crankshaft 1 Coolant Temp
Glow Plugs Crankshaft 2 Oil Pressure
Fuel Pump A
Camshaft 1
Fuel Pump B Oil Temp
Camshaft 2
Boost Pressure Gearbox Temp
Actuator Fuel Rail Pressure
Rail Pressure Intake Air Temp 1 Fuel Temp
Control Valve
Intake Air Temp 2 Fuel Pressure
Governor Actuator
Fuel Metering Unit Boost Pressure 1
Boost Pressure 2
Figure 1: Engine Control System Schematic Diagram if the G1000 System Is Installed
Page 2 Doc # 6.02.15
15 Apr 2013 76-00-00 Rev. 2
DA 40 NG AMM Engine Controls
AIRCRAFT
Annunciation
on White Wire MED
Annunciator Panel
RPM
ENGINE OIL PRESS
ECU A Control Buttons OIL TEMP
ECU B ECU VOTER COOLANT TEMP
GLOW ECU TEST GEARBOX TEMP
LOAD
SED
Engine Throttle
FUEL FLOW
From
Airframe
FUEL QTY
Fuel
FUEL TEMP
System
ALTERNATOR From
Electrical
System
WATER LEV
Electronic Engine Control Unit FUEL PRESS
28 VDC ECU A ECU B
28 VDC
Controlled
Components
Injector 1
Injector 2
Engine Sensors
Injector 3
Injector 4 Crankshaft 1 Coolant Temp
Glow Plugs Crankshaft 2 Oil Pressure
Fuel Pump A
Camshaft 1
Fuel Pump B Oil Temp
Boost Pressure Camshaft 2
Actuator Gearbox Temp
Fuel Rail Pressure
Rail Pressure Intake Air Temp 1 Fuel Temp
Control Valve
Intake Air Temp 2 Fuel Pressure
Governor Actuator
Fuel Metering Unit Boost Pressure 1
Boost Pressure 2
Figure 2: Engine Control System Schematic Diagram if the
Conventional Cockpit (OÄM 40-321) Is Installed
Doc # 6.02.15 Page 3
Rev. 2 76-00-00 15 Apr 2013
Engine Controls DA 40 NG AMM
AIRCRAFT
A. Engine Control Units
The ECU A and ECU B are contained in one box located in the fuselage compartment, below the
pilot seat. A wire harness connects the box to the engine, the power lever and the airplane’s
systems.
During normal operation, the alternator supplies power for the system. If the alternator fails, the
ECU B automatically takes over and the ECU backup battery provides power. Refer to Section
24-00 for more data about the electrical supply for the engine control system.
The integrated cockpit system (ICS, if the G1000 system is installed) has two amber caution lights
for the engine control system (marked ECU A FAIL and ECU B FAIL).
The annunciator panel (if the conventional cockpit is installed) has two amber caution lights for the
engine control system (marked ECU A and ECU B).
The ECU VOTER switch on the left hand side of the instrument panel let you toggle between
ECU A and ECU B. For all normal operation, the VOTER switch is set to AUTO and one automatic
selected ECU controls the engine.
The ECU TEST button on the left hand side of the instrument panel activates the test sequence of
the system. Refer to Section 71-00 for the ECU test procedure.
B. Electrical Harness
The electrical harness is an engine component. The harness connects the power lever and sensors
to the ECU A and ECU B. It also provides connections for the ECU buttons and the airplane’s
systems.
The electrical harness comes through the engine firewall. P-clamps and tie-wraps attach the
electrical harness to the engine.
The repair of the electrical harness is limited to damage that occurs near the ends of the cables,
outside of the isolated section. If a cable fails within the isolated section, then you must replace the
complete harness.
Page 4 Doc # 6.02.15
15 Apr 2013 76-00-00 Rev. 2
DA 40 NG AMM Engine Controls
AIRCRAFT
Power Lever
2 Signal Hall Angle Sensors
Throttle Knob
Push Rod Assy
Cover Plate
Screw
Washer (optional)
Nut (optional)
Thumb Switch (optional)
Connector,
2 Pins (optional)
Engine Control Assembly
Figure 2: Engine Power Levers
Doc # 6.02.15 Page 5
Rev. 2 76-00-00 15 Apr 2013
Engine Controls DA 40 NG AMM
AIRCRAFT
C. Manifold Pressure
Manifold pressure is measured by two sensors for each ECU located at the air intake manifold.
D. Power Lever
Figure 2 shows the installation of the engine power lever. The power lever is located in the center
console.
The power lever has two separate and independent electrical systems. One system provides
signals to the ECU A. The other system provides signals to the ECU B. Either system can control
the engine.
The lever operates electrical sensors (HALL effect) that give signals in proportion to the power lever
position. The signals are used by the engine control system to set the power output. The control
system also sets the propeller governor to give best RPM for the power setting. Refer to Section
61-20 for more data on the propeller control function.
A push rod connects the power lever to the Hall-sensors. The power lever can be calibrated by
adjusting the installation angle of the Hall sensors in the elongated hole and by modification of the
length of the push rod.
Page 6 Doc # 6.02.15
15 Apr 2013 76-00-00 Rev. 2
DA 40 NG AMM Engine Controls
AIRCRAFT
E. Sensors
Both ECUs get data about engine performance from the following sensors mounted on the engine:
Sensor Location
Crankshaft 1. Front, right of the crankcase.
Crankshaft 2. Front, left of the crankcase.
Camshaft 1. Front between camshafts.
Camshaft 2. Aft between camshafts.
Coolant temperature. Beneath the air intake manifold.
Oil temperature. On the top side of the oil sump.
Oil pressure. Behind the oil filter.
Manifold air temperature 1 and 2. On the air intake manifold.
Manifold air pressure 1 and 2. On the air intake manifold.
Fuel rail pressure. At the front of the fuel rail.
Gearbox temperature. At the back side of the gearbox next to the starter.
Fuel inlet pressure. At the inlet of the high pressure pump.
Doc # 6.02.15 Page 7
Rev. 2 76-00-00 15 Apr 2013
Engine Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 8 Doc # 6.02.15
15 Apr 2013 76-00-00 Rev. 2
DA 40 NG AMM Engine Controls
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the possible defects of the engine control system. When experiencing trouble
detailed in the Trouble column read across to the Possible Cause column, then perform the repair
given in the Repair column.
For all other engine control trouble, refer to the engine manufacturer.
Trouble Possible Cause Repair
An ECU caution light comes The related ECU is defective. Read engine event log
ON. (Refer to Section 72-00). Refer
to the engine manufacturer.
The engine does not respond Run diagnostic routine in
correctly to power lever ECU Operator software
movement. (Refer to Section 72-00). Refer
to the engine manufacturer.
Doc # 6.02.15 Page 101
Rev. 2 76-00-00 15 Apr 2013
Engine Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 76-00-00 Rev. 2
DA 40 NG AMM Engine Controls
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices describe how to remove and install the main components of the engine
control system. All other work on the engine control system can only be done by a Austro Engine
approved maintenance shop or the manufacturer.
2. Remove/Install the Power Lever Hall Sensor
A. Remove the Power Lever Hall Sensor
Detail Steps/Work Items Key Items/References
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the handles of cabin heat, parking
brake, defrost, power lever and fuel selector.
(4) Remove the cover plate.
(5) Remove the four bolts which position the throttle
quadrant to the center console.
(6) Remove both center console side access
panels (four screws).
(7) Lower the throttle quadrant until obtaining
access to the Hall sensor installation bolts.
(8) Loosen the allen key screw which connects the
Hall sensor to the throttle quadrant push rod.
(9) Remove the two bolts which attach the Hall
sensor to the throttle quadrant bracket.
(10) Remove the Hall sensor from the throttle
quadrant and disconnect the wire harness from
the Hall sensor.
Doc # 6.02.15 Page 201
Rev. 2 76-00-00 15 Apr 2013
Engine Controls DA 40 NG AMM
AIRCRAFT
B. Install the Power Lever Hall Sensor
Detail Steps/Work Items Key Items/References
(1) Connect the wire harness to the Hall sensor.
Position the Hall sensor on the proper location
of the throttle quadrant bracket.
(2) Install and tighten the two bolts which attach the
Hall sensor to the throttle quadrant.
(3) Tighten the allen key screw which connects the
Hall sensor to the throttle quadrant push rod.
(4) Calibrate the Hall sensor. Contact Austro Engine.
(5) Lift the throttle quadrant into position on the
center console and fix it with the four bolts.
(6) Install both center console side access panels.
(7) Install the cover plate.
(8) Install the handles of the cabin heat, parking
break, defrost, power lever and fuel selector.
(9) Connect the airplane main battery. Refer to Section 24-31.
(10) Conduct an engine test.
Page 202 Doc # 6.02.15
15 Apr 2013 76-00-00 Rev. 2
DA 40 NG AMM Engine Controls
AIRCRAFT
3. Remove/Install the Engine Control Unit (EECU)
A. Remove the Engine EECU
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE. IF THE PROPELLER TURNS IT CAN
CAUSE INJURY TO PERSONS.
(1) Read out and write down the EECU IMA-Codes Refer to the AE Maintenance Manual,
and engine serial number. latest revision.
(2) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(3) Disconnect the airplane main battery. Refer to Section 24-31.
(4) Remove the pilot seat. Refer to Section 25-10.
(5) Disconnect the 3 electrical connectors from the Refer to Figure 3.
EECU.
(6) Remove the EECU from the mounting brackets: Refer to Figure 3.
S Release the 4 bolts and washers that hold
the EECU to the mounting brackets.
Doc # 6.02.15 Page 203
Rev. 2 76-00-00 15 Apr 2013
Engine Controls DA 40 NG AMM
AIRCRAFT
Engine Control Unit
Bolt
Washer
Electrical
Connections
Bolt
Washer
ECU Mounting Bracket
Figure 3: EECU Installation
B. Install the Engine EECU
Page 204 Doc # 6.02.15
15 Apr 2013 76-00-00 Rev. 2
DA 40 NG AMM Engine Controls
AIRCRAFT
CAUTION: YOU MUST CONTACT THE ENGINE MANUFACTURER BEFORE YOU
INSTALL A NEW EECU.
Detail Steps/Work Items Key Items/References
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Install the EECU: Refer to Figure 3.
S Move the EECU into position in the fuselage
compartment.
S Install the 4 washers and bolts that attach
the ECU to the mounting brackets.
(3) Connect the 3 electrical connectors to the Refer to Figure 3.
EECU.
(4) Install the pilot seat. Refer to Section 25-10.
(5) Connect the airplane main battery.
(6) Check that IMA-Codes and engine serial Refer to the AE Maintenance Manual,
number at the new ECU match the ones of the latest revision.
engine.
Doc # 6.02.15 Page 205
Rev. 2 76-00-00 15 Apr 2013
Engine Controls DA 40 NG AMM
AIRCRAFT
4. Remove/Install the Engine Control System Electrical Harness
A. Remove the Engine Control System Electrical Harness
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE. IF THE PROPELLER TURNS IT CAN
CAUSE INJURY TO PERSONS.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the pilot seat. Refer to Section 25-10.
(4) Disconnect the 3 electrical connectors from the Refer to Figure 3.
ECU.
(5) Remove the cockpit access panels.
(6) Disconnect the two cockpit connectors. Behind the instrument panel.
(7) Disconnect the engine wire harness and bonding Refer to AE Maintenance Manual, latest
cables from the electrical sensors. revision.
(8) Remove the cable ties and P-clamps that attach Make a note of the type and location of
the cable harness to the engine and structure. each attachment.
(9) Remove the shields and Teflon lines for the
feed-through at the firewall.
(10) Carefully move the harness forward through the Take care not to damage the
firewall. connectors.
(11) Remove the harness from the fuselage.
Page 206 Doc # 6.02.15
15 Apr 2013 76-00-00 Rev. 2
DA 40 NG AMM Engine Controls
AIRCRAFT
% Figure 4: Engine Sensors - RH Side of Engine
Doc # 6.02.15 Page 207
Rev. 2 76-00-00 15 Apr 2013
Engine Controls DA 40 NG AMM
AIRCRAFT
% Figure 5: Engine Sensors - LH Side of Engine
Page 208 Doc # 6.02.15
15 Apr 2013 76-00-00 Rev. 2
DA 40 NG AMM Engine Controls
AIRCRAFT
B. Install the Engine Control System Electrical Harness
Detail Steps/Work Items Key Items/References
(1) Carefully move the engine wire harness from Take care not to damage the
the firewall aft through the firewall feed-through. connectors. Adjust the harness position
so that all connections can be made
without stress.
(2) Connect the engine wire harness and bonding Refer to AE Maintenance Manual. Latest
cables to the electrical sensors. revision.
(3) Connect the two cockpit connectors. Behind the instrument panel.
(4) Connect the 3 electrical connectors to the Refer to Figure 3. Make sure that the
EECU. bayonet locks are correctly engaged.
(5) Install the cable-ties and clamps that attach the Refer to the notes that you made during
cable harness to the engine and structure. removal for the type and location of
each attachment.
(6) Install the Teflon lines and shields for the Seal with PR 812 or equivalent.
feed-through at the firewall.
(7) Install the engine cowling. Refer to Section 71-10.
(8) Install the pilot seat. Refer to Section 25-10.
(9) Connect the main airplane battery. Refer to Section 24-31.
(10) Do an engine run up. Refer to Section 71-00.
Doc # 6.02.15 Page 209
Rev. 2 76-00-00 15 Apr 2013
Engine Controls DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 210 Doc # 6.02.15
15 Apr 2013 76-00-00 Rev. 2
DA 40 NG AMM Engine Indicating
AIRCRAFT
CHAPTER 77
ENGINE INDICATING
Doc # 6.02.15 Page 1
Rev. 2 77-TITLE 15 Apr 2013
Engine Indicating DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2
15 Apr 2013 77-TITLE Doc # 6.02.15
Rev. 2
DA 40 NG AMM Engine Indicating
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 77
ENGINE INDICATING
Section 77-00
Engine Indication
with G1000 System Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 77-01
Engine Instrumentation
with Conventional Cockpit Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 77-40
Engine Indicating System
with G1000 System Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Replace/Install a Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Doc # 6.02.15 Page 1
Rev. 2 77-CONTENTS 15 Apr 2013
Engine Indicating DA 40 NG AMM
AIRCRAFT
Section 77-41
Engine Integrated Instrument System
with Conventional Cockpit Installed
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Page 2 Doc # 6.02.15
15 Apr 2013 77-CONTENTS Rev. 2
DA 40 NG AMM Engine Indicating
AIRCRAFT
CHAPTER 77
ENGINE INDICATING
Section 77-00
Engine Indication
with G1000 System Installed
1. General
This Section describes the engine indicating system of the DA 40 NG airplane if the G1000 system is
installed. An integrated cockpit system (ICS) with two large display screens located in the instrument
panel show all engine related indications.
The electronic engine control unit (EECU) provides most of the indications for the engine. Figure 1
shows a schematic of the engine control and indication system. Refer to Section 76-00 for data about
the engine control system. The ICS also shows airframe fuel system data. Refer to Section 28-40 for
data about the airframe parts of the system.
2. Description and Operation
The ICS gives all engine indications. The ICS displays are located in the left and right sides of the
instrument panel. Each display has a combination of digital and analog displays.
Either display can show all the engine indications. Refer to Section 77-40 for more data about the
system sensors. Refer to Section 31-40 for more data about the ICS.
Doc # 6.02.15 Page 1
Rev. 2 77-00-00 15 Apr 2013
Engine Indicating DA 40 NG AMM
AIRCRAFT
Annunciation Integrated Cockpit System (Display)
on G1000 PFD
RPM
ECU A FAIL OIL PRESS
ECU B FAIL OIL TEMP
GLOW ON ECU VOTER COOLANT TEMP
FUEL PRESS Switch GEARBOX TEMP
OIL PRESS ECU TEST LOAD
Button FUEL FLOW
Throttle
FUEL QTY From
FUEL LOW Airframe
FUEL TEMP Fuel
System
ALTERNATOR From
Electrical
System
Electronic Engine Control Unit
28 VDC ECU A ECU B
28 VDC
Controlled
Components
Injector 1
Injector 2
Engine Sensors
Injector 3
Injector 4 Crankshaft 1 Coolant Temp
Glow Plugs Crankshaft 2 Oil Pressure
Fuel Pump A
Camshaft 1
Fuel Pump B Oil Temp
Camshaft 2
Boost Pressure Gearbox Temp
Actuator Fuel Rail Pressure
Rail Pressure Intake Air Temp 1 Fuel Temp
Control Valve
Intake Air Temp 2 Fuel Pressure
Governor Actuator
Fuel Metering Unit Boost Pressure 1
Boost Pressure 2
Figure 1: Engine Control and Indication Schematic
Page 2 Doc # 6.02.15
15 Apr 2013 77-00-00 Rev. 2
DA 40 NG AMM Engine Indicating
AIRCRAFT
Section 77-01
Engine Instrumentation
with Conventional Cockpit Installed
1. General
This Section tells you about the engine indicating system for airplanes with the conventional cockpit
installed. Two instruments located in the right side of the instrument panel show all engine related
indications.
The engine control unit (ECU) provides most of the indications for the engine. Refer to Section 76-00
for data about the engine fuel control system. The engine instrumentation also shows airframe fuel
system data. Refer to Section 28-40 for data about the airframe parts of the system.
2. Description and Operation
Two instruments give all of the engine indications. The instruments are located in the right side of the
instrument panel. Each instrument has a combination of digital and analogue displays.
The left instrument is the main engine display (MED). It shows RPM, oil pressure, temperatures and
load.
The right instrument is the secondary engine display (SED). It shows fuel quantity, flow, temperature,
the fuel pressure warning and the coolant level caution. It also shows the electrical system current and
voltage.
Refer to Section 77-41 for data about the system.
Doc # 6.02.15 Page 1
Rev. 2 77-01-00 15 Apr 2013
Engine Indicating DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Doc # 6.02.15
Page 2
15 Apr 2013
77-01-00 Rev. 2
DA 40 NG AMM Engine Indicating
AIRCRAFT
Section 77-40
Engine Indicating System
with G1000 System Installed
1. General
This Section describes the engine indicating system of the DA 40 NG airplane. The integrated cockpit
system (ICS) display screens which are located in the instrument panel give all engine and related
airplane system indications. For normal operations the left display is the primary flight display (PFD)
and the right is the multi-function display (MFD). Both displays are similar, except the autopilot control
buttons.
Refer to Section 31-40 for more data about the ICS.
The engine control unit (ECU) provides most of the indications for the engine. Refer to Section 76-00
for data about the engine control system. The ICS also shows fuel and systems data. Refer to Section
28-40 for data about the airframe parts of the system.
2. Description and Operation
The ICS displays the engine indications on the MFD screen. The MFD gives the following engine
indications:
) Load. Indicates the engine loads from 0 to 100%.
) RPM. Indicates the engine RPM from 0 to 2500 RPM.
) Gearbox temperature in °C.
) Coolant temperature in °C.
) Oil temperature in °C.
) Oil pressure in bar.
Doc # 6.02.15 Page 1
Rev. 2 77-40-00 15 Apr 2013
Engine Indicating DA 40 NG AMM
AIRCRAFT
NAV1 117.90 112.20 MPT KTYS DIS 140% DTK 291% TRX291% 136.975 118.000 VOL PUSH
VOL PUSH
ID
SQ
NAV2 108.00 117.95 136.975 118.000
NAV EMERG
COM
TRAFFIC
0
M
140 2
20 20 6600
PUSH PUSH
1-2 130 1 1-2
10 10 6400 CRS BARO
HDG
60
63 40 100
120 20
110
6200 1 PUSH
PUSH 10 10 CRS CTR
HDG SYNC
100 DOOR OPEN
ALTERNATOR RANGE
291° 6000 2 PITOT OFF
80 R FUEL LOW
TAS 120% 30 29.68 L FUEL LOW
w 33
24
NORTH UP
ALERTS PUSH
GPS ENR PAN
21
DOOR OPEN - Canopy and/or rear
N
door isn't closed and locked.
KCL D MENU
ALTERNATOR - Alternator failed
S
Battery is only elec source.
6 PITOT OFF - Pitot heat is off. FPL PROC
15 E Turn switch on to avoid icing.
12
CLR ENT
OAT 08 XPDR 1200 STBY LD 12:03:25
ALT FMS
INSET PFD CDI OBS XPDR REFS NRST WARNING DFLT MAP
Figure 1: Display Screen - Integrated Cockpit System
Page 2 Doc # 6.02.15
15 Apr 2013 77-40-00 Rev. 2
DA 40 NG AMM Engine Indicating
AIRCRAFT
The MFD also gives these auxiliary displays with the engine displays:
) Voltage.
) Generator output, in AMPS.
The MFD can also display the following fuel system information:
) L and R fuel tank quantity (Refer to Section 28-40).
) L and R fuel tank temperature in °C (Refer to Section 28-40).
) Engine fuel flow in gal/hour (Refer to Section 28-40).
Engine alerts are given on the PFD screen. A flashing warning annunciator appears in the PFD when
an alert is activated. Pressing the WARNING softkey at the bottom of the PFD opens an alert window
on the PFD. The alerts window gives more details of the alert. The ICS alert system gives alerts and
warning captions for engine and airplane systems. Refer to Section 31-40 for more data about the ICS.
Doc # 6.02.15 Page 3
Rev. 2 77-40-00 15 Apr 2013
Engine Indicating DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 77-40-00 Rev. 2
DA 40 NG AMM Engine Indicating
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the possible defects of the engine indication system. For more data on the system
refer to the equipment manufacturer’s manual.
When experiencing trouble detailed in the Trouble column read across to the Possible Cause column,
then perform the repair given in the Repair column.
Trouble Possible Cause Repair
One of the indicators in an Sensor/transducer defective. Do a test for continuity of the
integrated instrument does not cables for the relevant sensor.
indicate correctly.
If the cables are serviceable,
then refer to the engine
manufacturer.
Refer to Section 28-40 for the
fuel quantity indicating system.
Refer to Section 76-00 for the
location of engine sensors.
Doc # 6.02.15 Page 101
Rev. 2 77-40-00 15 Apr 2013
Engine Indicating DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 77-40-00 Rev. 2
DA 40 NG AMM Engine Indicating
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices give instructions how to replace the following sensors:
) Crankshaft (RPM).
) Gearbox oil temperature.
) Liquid coolant temperature.
) Engine oil temperature.
) Engine oil pressure.
Refer to the related Chapter or the Austro Engine Maintenance Manual, latest revision for maintenance
data on the sensors.
Where the engine control system provides data for the engine indicating system, only the engine
manufacturer or an Austro Engine approved maintenance shop can replace sensors.
Doc # 6.02.15 Page 201
Rev. 2 77-40-00 15 Apr 2013
Engine Indicating DA 40 NG AMM
AIRCRAFT
Crankshaft Sensor Crankshaft Sensor
Screw
Screw
Figure 2: Crankshaft (RPM) Sensor Installation
Page 202 Doc # 6.02.15
15 Apr 2013 77-40-00 Rev. 2
DA 40 NG AMM Engine Indicating
AIRCRAFT
2. Replace/Install a Sensor
Figures 2 through 6 show the sensors for the engine indications.
Use the following general procedure for replacing all of the sensors on the engine. If any of the sensors
has a different procedure then the procedure will be described.
A. Replace a Sensor
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
TURNS IT CAN CAUSE INJURY TO PERSONS.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the engine cowling. Refer to Section 71-10.
(4) Locate the sensor that you will replace. Refer to Figures 2 thru 6.
(5) Disconnect the electrical cables of the sensor. At the sensor or in-line connector.
(6) Replace the sensor. Refer to AE Maintenance Manual, latest
revision.
(7) Connect the electrical cables to the sensor. At the sensor or in-line connector.
(8) Install the engine cowling. Refer to Section 71-10.
(9) Connect the airplane main battery. Refer to Section 24-31.
(10) Do a ground test of the engine and monitor the Refer to Section 71-00.
engine indication.
Doc # 6.02.15 Page 203
Rev. 2 77-40-00 15 Apr 2013
Engine Indicating DA 40 NG AMM
AIRCRAFT
Fuel Metering Valve
Figure 3: Fuel Metering Valve Installation
Page 204 Doc # 6.02.15
15 Apr 2013 77-40-00 Rev. 2
DA 40 NG AMM Engine Indicating
AIRCRAFT
Figure 4: Engine Coolant Temperature Sensor Installation
Doc # 6.02.15 Page 205
Rev. 2 77-40-00 15 Apr 2013
Engine Indicating DA 40 NG AMM
AIRCRAFT
Oil Temperature Sensor
Figure 5: Engine Oil Temperature Sensor Installation
Page 206 Doc # 6.02.15
15 Apr 2013 77-40-00 Rev. 2
DA 40 NG AMM Engine Indicating
AIRCRAFT
Oil Filter Housing
Oil Pressure Sensor
Figure 6: Engine Oil Pressure Sensor Installation
Doc # 6.02.15 Page 207
Rev. 2 77-40-00 15 Apr 2013
Engine Indicating DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 208 Doc # 6.02.15
15 Apr 2013 77-40-00 Rev. 2
DA 40 NG AMM Engine Indicating
AIRCRAFT
Section 77-41
Engine Integrated Instrument System
with Conventional Cockpit Installed
1. General
This Section tells you about the engine indicating system for airplanes with the conventional cockpit
installed. Two instruments located in the right side of the instrument panel show all engine related
indications.
The engine control unit (ECU) provides most of the indications for the engine. Refer to Section 76-00
for data about the engine fuel control system. The engine instrumentation also shows airframe fuel
system data. Refer to Section 28-40 for data about the airframe parts of the system.
2. Description and Operation
Two instruments give all of the engine indications. The instruments are located in the right side of the
instrument panel. Each instrument has a combination of digital and analog (LED chain) displays.
The main engine display (MED; Figure 1, top) gives the following indications:
) Propeller RPM. This has a 4-character digital display and a linear analog display from 0 to
2300 RPM.
) Oil Pressure. This is a linear analog display from 0.9 to 6.5 bar.
) Oil Temperature. This is a linear analog display from -30 ºC to 140 ºC.
) Coolant Temperature. This is a linear analog display from -30 ºC to 105 ºC.
) Gearbox Temperature. This is a linear analog display from -30 ºC to 120 ºC.
) Load. This has a 4-character digital display and a linear analog display from 0 % to 100 %.
Doc # 6.02.15 Page 1
Rev. 2 77-41-00 15 Apr 2013
Engine Indicating DA 40 NG AMM
AIRCRAFT
OP
0,9 bar 6,5
OT CT
-30 °C 140
1/min
GT -30 °C 105
%
2300 100
RPM -30 °C 120
LOAD
%
LH RH
FUELPRESS
14 14
FLOW-GAL/hr
FT FT
60 60
10 10
VOLTAGE/V
L R
24,1 32
-25 CURRENT/A -25
°C °C
5 5
70
WATERLEV
0 0
GAL
Figure 1: Engine Instruments
Page 2 Doc # 6.02.15
15 Apr 2013 77-41-00 Rev. 2
DA 40 NG AMM Engine Indicating
AIRCRAFT
The secondary engine display (SED; Figure 1, bottom) gives the following indications:
) Water Level (Coolant). This is a low coolant level caution light (color: amber).
) Fuel Quantity Main. This is a circular analog display from 0 to 14 gal.
) Fuel Quantity Aux. This is a circular analog display from 0 to 14 gal.
) Fuel Temp Main. This is a linear analog display from -25 ºC to 60 ºC.
) Fuel Temp Aux. This is a linear analog display from -25 ºC to 60 ºC.
) Generator. This is a linear analog display from 0 to 70 Ampères.
) Volts. This is a linear analog display from 24.1 to 32 Volt.
) Fuel Flow. This is a 4-character digital display.
) Fuel Pressure. This is a fuel pressure warning light (color: red).
) Both digital and analog displays use groups of light-emitting diodes (LEDs).
A. Digital Displays
The RPM, load and fuel flow displays use the usual 7-segment LEDs.
B. Fuel Quantity Analog Displays
Each fuel quantity analog display has a group of 32 LEDs arranged in an arc. All but one of the
LEDs are green. The LED adjacent to the zero mark is red.
C. Linear Analog Displays
All of the linear analog displays use similar groups of 10 LEDs set in a horizontal or vertical line.
Displays showing pressure, temperature, current and voltage use combinations of red, yellow and
green LEDs. The colors have the usual meanings for instrument markings.
Doc # 6.02.15 Page 3
Rev. 2 77-41-00 15 Apr 2013
Engine Indicating DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 4 Doc # 6.02.15
15 Apr 2013 77-41-00 Rev. 2
DA 40 NG AMM Engine Indicating
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the engine-indication system. For more data on
the system refer to the equipment manufacturer’s manual.
If you have the trouble detailed in the Trouble column read across to the Possible Cause column. Then
do the repair given in the Repair column.
Trouble Possible Cause Repair
No indication on the engine INST 1 circuit-breaker not set. Make sure that the
indicators with the engine circuit-breaker for the engine
operating or with the instruments is set.
ELECTRIC MASTER key
switch set to ON.
One of the indicators in an Sensor/transducer defective. Do a test for continuity of the
integrated instrument does not cables for the relevant sensor.
indicate correctly.
Refer to Section 28-40 for the
fuel quantity indicating system.
Refer to Section 76-00 for the
engine sensors.
One instrument defective. Replace the instrument.
Doc # 6.02.15 Page 101
Rev. 2 77-41-00 15 Apr 2013
Engine Indicating DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 77-41-00 Rev. 2
DA 40 NG AMM Exhaust
AIRCRAFT
CHAPTER 78
EXHAUST
Doc # 6.02.15 Page 1
Rev. 2 78-TITLE 15 Apr 2013
Exhaust DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2
15 Apr 2013 78-TITLE Doc # 6.02.15
Rev. 2
DA 40 NG AMM Exhaust
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 78
EXHAUST
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Engine Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Doc # 6.02.15 Page 1
Rev. 2 78-CONTENTS 15 Apr 2013
Exhaust DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 78-CONTENTS Rev. 2
DA 40 NG AMM Exhaust
AIRCRAFT
CHAPTER 78
EXHAUST
1. General
The DA 40 NG engine has a simple 1-piece exhaust system. The exhaust pipe flange attaches with
four bolts to the turbo-charger outlet and is supported at two locations to the engine mount. The
exhaust exits through the bottom cowling opening the cowling outside.
If OÄM 40-310 or MÄM 40-434 is installed, an exhaust muffler is an integral part of the exhaust pipe.
2. Description
Figure 1 shows the engine exhaust system.
No maintenance can be done on the exhaust system.
Doc # 6.02.15 Page 1
Rev. 2 78-00-00 15 Apr 2013
Exhaust DA 40 NG AMM
AIRCRAFT
Exhaust Gasket
Mounting Flange
Turbocharger
4 x Nuts
Engine Exhaust Manifold
Engine Mounting Frame
Bolt
Anti-Vibration Mount
Washer
Washer
Nut
Exhaust Muffler
(if MÄM 40-434
or OÄM 40-310
is installed)
Nut
Exhaust Pipe Washer
Anti-Vibration Mount
Engine Mounting Frame
Washer
Bolt
Figure 1: Exhaust System Installation
Page 2 Doc # 6.02.15
15 Apr 2013 78-00-00 Rev. 2
DA 40 NG AMM Exhaust
AIRCRAFT
Trouble-Shooting
1. General
The table below lists possible defects of the exhaust system. When experiencing trouble detailed in
the Trouble column read across to the Possible Cause column, then perform the repair given in the
Repair column.
Trouble Possible Cause Repair
More noise than usual. Exhaust pipe cracked. Look for signs of exhaust gas
leaks. Replace cracked pipes.
Exhaust muffler (if installed) Replace cracked muffler.
cracked.
Signs of exhaust gas leaks in Exhaust pipe cracked. Look for signs of exhaust gas
the engine compartment. leaks. Replace cracked pipes.
Exhaust muffler (if installed) Replace cracked muffler.
cracked.
Doc # 6.02.15 Page 101
Rev. 2 78-00-00 15 Apr 2013
Exhaust DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 78-00-00 Rev. 2
DA 40 NG AMM Exhaust
AIRCRAFT
Maintenance Practices
1. General
These Maintenance Practices tell you how to remove and install an engine exhaust pipe and an engine
exhaust pipe with an integrated muffler system (if OÄM 40-310 is installed). Refer to Section 81-00 for
data about the turbo-charger.
2. Remove/Install the Engine Exhaust Pipe
WARNING: MAKE SURE THAT THE EXHAUST SYSTEM IS COOL BEFORE YOU
TOUCH IT. THE EXHAUST SYSTEM CAN BE VERY HOT, THIS CAN
CAUSE INJURY TO PERSONS.
A. Remove the Engine Exhaust Pipe
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
TURNS IT CAN CAUSE INJURY TO PERSONS.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-34.
(3) Remove the engine cowling. Refer to Section 71-10.
(4) Remove the exhaust pipe:
S Remove the 4 nuts that attach the exhaust
pipe to the turbo charger.
S Remove the two elastomeric shock absorber
supports.
Doc # 6.02.15 Page 201
Rev. 2 78-00-00 15 Apr 2013
Exhaust DA 40 NG AMM
AIRCRAFT
B. Install the Engine Exhaust Pipe
Detail Steps/Work Items Key Items/References
(1) Install the exhaust pipe:
S Move the exhaust pipe into position.
S Move the exhaust pipe flange over the studs
on the turbo charger outlet.
S Install the 4 nuts that attach the exhaust
pipe to the turbo charger outlet. Use new nuts.
S Install the two elastomeric shock absorber
supports.
(2) Install the engine cowling. Refer to Section 71-10.
(3) Do an engine ground run-up and then check the Specially around the gasket at the turbo
exhaust pipe for leaks. charger outlet.
Page 202 Doc # 6.02.15
15 Apr 2013 78-00-00 Rev. 2
DA 40 NG AMM Oil Cooling
AIRCRAFT
CHAPTER 79
OIL COOLING
Doc # 6.02.15 Page 1
Rev. 2 79-TITLE 15 Apr 2013
Oil Cooling DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2
15 Apr 2013 79-TITLE Doc # 6.02.15
Rev. 2
DA 40 NG AMM Oil Cooling
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 79
OIL
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Doc # 6.02.15 Page 1
Rev. 2 79-CONTENTS 15 Apr 2013
Oil Cooling DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 79-CONTENTS Rev. 2
DA 40 NG AMM Oil Cooling
AIRCRAFT
CHAPTER 79
OIL
1. General
The engine has a regular wet-sump lubrication system. The bottom part of the engine crankcase
makes up the oil sump. An oil filler tube with a screw cap connects to the crankcase on the left of the
engine.
The oil cooler is an integrated oil water heat exchanger which is located under the oil filter case.
The oil breather system has an oil separator located under the injector cover. A flexible hose at the
rear of the oil separator vents blow-by gases and any remaining oil mist to the outside of the cowling.
A small hose drains accumulated oil underneath the injector cover.
To protect the breather system from blockage due to icing of moist blow by gases an engine integrated
over pressure valve is provided below the injector cover.
Doc # 6.02.15 Page 1
Rev. 2 79-00-00 15 Apr 2013
Oil Cooling DA 40 NG AMM
AIRCRAFT
Breather Line
Turbo
Charger
Oil Separator
E4 Diesel Engine
Oil Filler
Oil/Water Heat Exchanger
Oil Pump
Figure 1: Oil System Schematic
Page 2 Doc # 6.02.15
15 Apr 2013 79-00-00 Rev. 2
DA 40 NG AMM Oil Cooling
AIRCRAFT
Trouble-Shooting
1. General
The table below lists possible defects of the oil system. When experiencing trouble detailed in the
Trouble column read across to the Possible Cause column, then perform the repair given in the Repair
column.
Trouble Possible Cause Repair
The engine oil temperature is Oil cooler blocked internally. Contact engine manufacturer.
too high.
Low oil level. Refill oil. Refer to Section
12-10.
The engine oil pressure is too Defective oil pressure sensor. Refer to AE Maintenance
high. Manual, latest revision.
The engine oil pressure is too Low oil level. Replenish oil system. Refer to
low at normal operating Section 12-10.
temperatures.
Defective oil pressure sensor. Refer to AE Maintenance
Manual, latest revision.
Doc # 6.02.15 Page 101
Rev. 2 79-00-00 15 Apr 2013
Oil Cooling DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 79-00-00 Rev. 2
DA 40 NG AMM Starting
AIRCRAFT
CHAPTER 80
STARTING
Doc # 6.02.15 Page 1
Rev. 2 80-TITLE 15 Apr 2013
Starting DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 80-TITLE Rev. 2
DA 40 NG AMM Starting
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 80
STARTING
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the ELECTRIC MASTER Key Switch . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the ENGINE MASTER Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Remove/Install the Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Doc # 6.02.15 Page 1
Rev. 2 80-CONTENTS 15 Apr 2013
Starting DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 80-CONTENTS Rev. 2
DA 40 NG AMM Starting
AIRCRAFT
CHAPTER 80
STARTING
1. General
This Section tells you about the system that cranks the engine for starting.
Refer to Section 24-30 for more data on the electrical supplies to the system Refer to Section 76-00
for data about the engine control system.
2. Description and Operation
Figure 1 shows the simplified schematic diagram of the starter system. The system operates off a
24 VDC supply.
The engine has a small, high-powered electric starter. The starter motor is located on the left side of
the engine near the front. It has an integral solenoid to connect the starter motor to the relay junction
box bus. Either the airplane battery or the external power system can supply the starter.
The ELECTRIC MASTER key switch (marked OFF ON START) is located on the bottom center of the
instrument panel. Turn the key clockwise against the spring to operate the starter. Release the key
when the engine starts. The spring returns the key to the ON position.
A starter relay located on the instrument panel floor controls the current to the starter solenoid. The
ENGINE MASTER switch located on the center left or center bottom of the instrument panel controls
the ground connection for the starter relay. This switch must be set to ON for the starter system to
operate.
A STARTER or START warning light on the G1000 or annunciator panel comes ON when there is
power to the starter. If this light stays on after the engine has started, set the ELECTRIC MASTER key
switch and the ENGINE MASTER switch to OFF.
If necessary during starting, the engine control unit operates the glow plugs to heat intake air for the
engine.
Doc # 6.02.15 Page 1
Rev. 2 80-00-00 15 Apr 2013
Starting DA 40 NG AMM
AIRCRAFT
INSTRUMENT PANEL ENGINE COMPARTMENT
Starter
FUSELAGE
M
A Starter Battery
I
Relay Main Battery
N Relay
START Engine Electric 24V / 13.6Ah
B
10
Master Master
U OFF
S
ON R
E
5A
L
A
Y
J Starter
U Relay
N
C
T
I
O
N
B
O
X
B EPU
U
S Relay
EPU Plug
LEGEND
MAIN
TIE Circuit-Breaker with Name and Rating
30 (Name as on the Placard)
5A
Fuse with Rating
Figure 1: Starter System Schematic Diagram
Page 2 Doc # 6.02.15
15 Apr 2013 80-00-00 Rev. 2
DA 40 NG AMM Starting
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the starting system. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair given
in the Repair column.
WARNING: DO NOT ALLOW PERSONS TO ENTER THE DANGER AREA OF THE
PROPELLER. THE PROPELLER MAY TURN AND CAUSE INJURY TO
PERSONS.
WARNING: DISCONNECT AND ISOLATE THE STARTER POWER CABLE BEFORE
DOING TESTS IN THIS SECTION. THE ENGINE MAY START AND
CAUSE INJURY TO PERSONS.
Trouble Possible Cause Repair
The starter does not operate The START circuit-breaker is Set the START circuit-breaker.
when the ELECTRIC MASTER not set.
key switch is set to START and
The battery is discharged. Replace/recharge the battery.
the ENGINE MASTER switch
is set to ON. The ELECTRIC MASTER key Replace the ELECTRIC
switch is defective. MASTER key switch.
The ENGINE MASTER switch Replace the ENGINE MASTER
is defective. switch.
The starter relay is defective. Starter relay on starter motor:
Refer to the engine
manufacturer.
Starter relay in relay junction
box: Replace.
Starter defective. Refer to the engine
manufacturer.
Defective cable. Do a test of the electrical
cables. Refer to Chapter 92 for
the wiring diagrams.
Repair/replace the defective
cable. Refer to Section 71-50
for repair limits of the engine
harness.
Doc # 6.02.15 Page 101
Rev. 2 80-00-00 15 Apr 2013
Starting DA 40 NG AMM
AIRCRAFT
Trouble Possible Cause Repair
The starter Power-On light The starter relay is defective. Starter relay on starter motor:
stays on after the key is Refer to the engine
released from the START manufacturer.
position.
Starter relay in relay junction
box: Replace.
The starter solenoid is Refer to the engine
defective. manufacturer.
Difficult cold starting. Glow plugs worn. Replace the glow plugs. Refer
to the engine manufacturer.
Page 102 Doc # 6.02.15
15 Apr 2013 80-00-00 Rev. 2
DA 40 NG AMM Starting
AIRCRAFT
Maintenance Practices
1. General
This Section gives you only Maintenance Practices for the airplane part of the starter system. No
repairs are permitted on the engine. Only a authorized repair shop or the manufacturer can repair the
engine part of the system.
2. Remove/Install the ELECTRIC MASTER Key Switch
A. Remove the ELECTRIC MASTER KEY Switch
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE STARTER SYSTEM. IF THE ENGINE STARTS THE
PROPELLER CAN CAUSE INJURY OR DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to IDLE.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the instrument panel cover. Refer to Section 25-10.
(4) Release the retaining nut from the cockpit side of
the ELECTRIC MASTER key switch.
(5) Move the ELECTRIC MASTER key switch
towards the front of the airplane.
(6) Disconnect the cables from the ELECTRIC Make a note of the position of the
MASTER key switch cables.
(7) Remove the ELECTRIC MASTER key switch
from the airplane.
Doc # 6.02.15 Page 201
Rev. 2 80-00-00 15 Apr 2013
Starting DA 40 NG AMM
AIRCRAFT
B. Install the ELECTRIC MASTER Key Switch
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE STARTER SYSTEM. IF THE ENGINE STARTS THE
PROPELLER CAN CAUSE INJURY OR DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to IDLE.
(2) Put the ELECTRIC MASTER key switch in
position between the instrument panel and the
firewall.
(3) Connect the cables to the ELECTRIC MASTER Refer to the wiring diagrams and the
key switch. notes you made during removal.
(4) Move the ELECTRIC MASTER key switch into
position in the instrument panel.
(5) Install the retaining nut to the cockpit side of the
ELECTRIC MASTER key switch.
(6) Install the instrument panel cover. Refer to Section 25-10.
(7) Connect the airplane main battery. Refer to Section 24-31.
(8) Do an engine ground run-up. Refer to Section 71-00.
Page 202 Doc # 6.02.15
15 Apr 2013 80-00-00 Rev. 2
DA 40 NG AMM Starting
AIRCRAFT
3. Remove/Install the ENGINE MASTER Switch
A. Remove the ENGINE MASTER Switch
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE STARTER SYSTEM. IF THE ENGINE STARTS THE
PROPELLER CAN CAUSE INJURY OR DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to IDLE.
(2) Disconnect the airplane main battery and the Refer to Section 24-31.
ECU backup battery.
(3) Remove the instrument panel cover. Refer to Section 25-10.
(4) Release the retaining nut from the cockpit side of
the ENGINE MASTER switch.
(5) Move the ENGINE MASTER switch towards the
front of the airplane.
(6) Disconnect the cables from the ENGINE Make a note of the position of the
MASTER switch. cables.
(7) Remove the ENGINE MASTER switch from the
airplane.
Doc # 6.02.15 Page 203
Rev. 2 80-00-00 15 Apr 2013
Starting DA 40 NG AMM
AIRCRAFT
B. Install the ENGINE MASTER Switch
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE STARTER SYSTEM. IF THE ENGINE STARTS THE
PROPELLER CAN CAUSE INJURY OR DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to IDLE.
(2) Put the ENGINE MASTER switch in position in
the instrument panel.
(3) Connect the cables to the ENGINE MASTER Refer to the wiring diagrams and the
switch. notes you made during removal.
(4) Move the ENGINE MASTER switch into position
in the instrument panel.
(5) Install the retaining nut to the cockpit side of the
ENGINE MASTER switch.
(6) Install the instrument panel cover. Refer to Section 25-10.
(7) Connect the airplane main battery and the ECU Refer to Section 24-31.
backup battery.
(8) Do an engine ground run-up. Refer to Section 71-00.
Page 204 Doc # 6.02.15
15 Apr 2013 80-00-00 Rev. 2
DA 40 NG AMM Starting
AIRCRAFT
4. Remove/Install the Starter Relay
A. Remove the Starter Relay
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE STARTER SYSTEM. IF THE ENGINE STARTS THE
PROPELLER CAN CAUSE INJURY OR DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to IDLE.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Disconnect the cables from the starter relay. Make a note of the position of the
cables.
(4) Remove the screw, washer and nut that attach
the relay.
(5) Remove the starter relay from the airplane.
Doc # 6.02.15 Page 205
Rev. 2 80-00-00 15 Apr 2013
Starting DA 40 NG AMM
AIRCRAFT
B. Install the Starter Relay
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE STARTER SYSTEM. IF THE ENGINE STARTS THE
PROPELLER CAN CAUSE INJURY OR DEATH.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to IDLE.
(2) Put the starter relay in position in the junction
box.
(3) Install the screw, washer and nut that attach the
relay.
(4) Connect the cables to the starter relay. Refer to the wiring diagrams and the
notes you made during removal.
(5) Connect the airplane main battery. Refer to Section 24-31.
(6) Do an engine ground run-up. Refer to Section 71-00.
Page 206 Doc # 6.02.15
15 Apr 2013 80-00-00 Rev. 2
DA 40 NG AMM Turbo Charger
AIRCRAFT
CHAPTER 81
TURBO CHARGER
Doc # 6.02.15 Page 1
Rev. 2 81-TITLE 15 Apr 2013
Turbo Charger DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 81-TITLE Rev. 2
DA 40 NG AMM Turbo Charger
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 81
TURBO CHARGER
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install an Engine Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Doc # 6.02.15 Page 1
Rev. 2 81-CONTENTS 15 Apr 2013
Turbo Charger DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 81-CONTENTS Rev. 2
DA 40 NG AMM Turbo Charger
AIRCRAFT
CHAPTER 81
TURBO CHARGER
1. General
This Chapter describes the turbo-charger system of the Austro Engine E4-A engine.
2. Description
The air intake system has an air filter located downstream of the NACA inlet and air intake duct. Aft
of the air filter is the alternate air valve which has an alternate air inlet from the engine compartment.
A rotating cage in the alternate air valve can be set to take air into the air intake system through the
filter or it can be set to take unfiltered air directly from the engine compartment. Refer to Section 71-60
for more data about the air filter and the alternate air valve.
The outlet from the alternate air valve connects to the turbo charger inlet. The turbo charger
compresses and therefore heats up the air. The outlet from the turbo charger connects to the
intercooler, which cools down the hot compressed air.
The intercooler is located on the top left rear section of the engine. The outlet of the intercooler
connects to the engine intake manifold. A manifold pressure and air temperature sensor is attached
to the engine intake manifold.
Doc # 6.02.15 Page 1
Rev. 2 81-00-00 15 Apr 2013
Turbo Charger DA 40 NG AMM
AIRCRAFT
%
%
%
%
%
%
%
%
%
Waste Gate
%
Compressor
%
Turbocharger Nacelle Cooling
% Ambient Air, In
Turbine Air, Out
%
% Engine
Intercooler
% Exhaust
Gases Engine Intake
%
Manifold
% Compressed
% Air, Out
%
%
Exhaust Gases
%
from Engine
% Manifold
%
%
%
%
% Air Intake Duct
%
% Cooling Air Intake
%
%
%
%
%
% Figure 1: Engine Turbo Charger Schematic Diagram
Page 2 Doc # 6.02.15
15 Apr 2013 81-00-00 Rev. 2
DA 40 NG AMM Turbo Charger
AIRCRAFT
3. Operation
Figure 1 shows the turbo charger system schematic.
When the engine is running the exhaust gases from the engine flow through a manifold to the turbo
charger turbine. A waste gate in the turbo charger turbine inlet can open to allow some of the exhaust
gases from the engine to bypass the turbine and flow directly in to the engine exhaust pipe. The waste
gate opening is controlled by the engine EECU.
Ambient air flows through the air filter (normal operation) or from the fuselage compartment (alternate
air operation) into the turbo charger compressor. The air gains heat while being compressed in the
turbo charger. The hot compressed air flows through a flexible hose to the intercooler.
The hot compressed air flows through the matrix of the intercooler. Cooling air is guided from the left
side of the cowling duct to the intercooler and flows around the intercooler matrix. This will cool the
compressed air. The cooled compressed air from the intercooler matrix flows through a flexible hose
and a charge air duct to the engine air intake manifold.
Doc # 6.02.15 Page 3
Rev. 2 81-00-00 15 Apr 2013
Turbo Charger DA 40 NG AMM
AIRCRAFT
%
%
%
Engine Air Intake Manifold
% Worm Drive
Clamps
%
% Intercooler
Worm Drive
% Clamps
%
Worm Drive
% Clamps Hose Worm Drive
% Clamps
%
% Hose Hose
%
% Pipe
%
Worm Drive
% Clamps
Worm Drive
% Clamps
%
% Turbocharger Engine Mounting Frame
%
%
V-Clamp Charge Air Tube
%
Turbo Connector
% Assy
%
%
Hose
%
%
%
Worm Drive
% Worm Drive Clamps
% Clamps
%
%
%
%
%
Figure 2: Intercooler Installation
Page 4 Doc # 6.02.15
15 Apr 2013 81-00-00 Rev. 2
DA 40 NG AMM Turbo Charger
AIRCRAFT
%
%
%
% Engine Air Intake Manifold
%
%
A
%
Intercooler
Worm Drive
% Clamps
%
Worm Drive Hose
% Worm Drive
Clamps Clamps
% Worm Drive
% Clamps
%
Hose Hose
A
%
%
% Pipe
%
Worm Drive
% Clamps
Worm Drive
%
Clamps Engine Mounting Frame
%
% Turbocharger
%
%
Charge Air
Tube
% V-Clamp
%
A
Turbo Connector Protective Pads
% Assy
% Worm Drive Clamps
%
% A
A Hose
%
%
%
% Worm Drive
Worm Drive Clamps
% Clamps
%
%
% Figure 3: Intercooler Installation (if MÄM 40-630 and MÄM 40-639 are installed)
Doc # 6.02.15 Page 5
Rev. 2 81-00-00 15 Apr 2013
Turbo Charger DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 6 Doc # 6.02.15
15 Apr 2013 81-00-00 Rev. 2
DA 40 NG AMM Turbo Charger
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the possible defects of the turbo charger system. When experiencing the trouble
detailed in the Trouble column read across to the Possible Cause column, then perform the repair
given in the Repair column.
Trouble Possible Cause Repair
The engine intake manifold Waste gate valve defective. Refer to the engine
pressure is too low/ too high. manufacturer.
Inlet air temperature too high. Intercooler matrix Clear intercooler matrix of
blocked/damaged. obstructions. Replace
intercooler if necessary.
Doc # 6.02.15 Page 101
Rev. 2 81-00-00 15 Apr 2013
Turbo Charger DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 102 Doc # 6.02.15
15 Apr 2013 81-00-00 Rev. 2
DA 40 NG AMM Turbo Charger
AIRCRAFT
Maintenance Practices
1. General
This Section tells you how to remove/install the intercooler.
CAUTION: YOU CANNOT DO MAINTENANCE ON THE INTERCOOLER.
CAUTION: DO NOT TRY TO ADJUST THE WASTE GATE CONTROL PUSH ROD.
ANY ADJUSTMENT WILL AFFECT THE CHARACTERISTICS OF THE
ELECTRONIC CONTROL SYSTEM.
Refer to Section 71-60 for maintenance data on the air filter and the alternate air valve.
2. Remove/Install an Engine Intercooler
A. Remove an Engine Intercooler
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
TURNS IT CAN CAUSE INJURY TO PERSONS.
(1) Make sure that the engine is safe:
S Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Disconnect the airplane main battery. Refer to Section 24-31.
(3) Remove the engine cowling. Refer to Section 71-10.
Doc # 6.02.15 Page 201
Rev. 2 81-00-00 15 Apr 2013
Turbo Charger DA 40 NG AMM
AIRCRAFT
Detail Steps/Work Items Key Items/References
% (4) Disconnect the flexible hoses and aluminium Refer to Figure 2.
% tubes that connect the intercooler to the turbo
charger and engine air intake manifold:
S Remove the worm-drive-clamps. At the intercooler.
S Pull the hoses off the intercooler connectors
and the turbo charger inlet.
(5) Remove the intercooler:
S Remove the nuts and washers that attach
the intercooler to the engine mount and that
attach the coolant tank to the intercooler.
S Move the intercooler clear of the engine. Take care not to damage the intercooler
matrix!
Page 202 Doc # 6.02.15
15 Apr 2013 81-00-00 Rev. 2
DA 40 NG AMM Turbo Charger
AIRCRAFT
B. Install an Engine Intercooler
Detail Steps/Work Items Key Items/References
CAUTION: MAKE SURE THAT TURBO CHARGER INLET HOSES ARE ROUTED
WITHOUT KINKS AND CONTRADICTIONS. INCORRECT ROUTED
HOSES MAY RESULT IN DAMAGE TO THE TURBO CHARGER.
(1) Install the intercooler to the engine mount:
S Install the nuts and washers that attach the
intercooler to the engine mount.
% (2) Connect the flexible hoses and aluminum tubes
% that connect the intercooler to the turbo charger
and engine air intake manifold:
S Move the worm-drive-clamps into position Do not tighten the worm-drive-clamps!
on the flexible hoses.
S Push the flexible hoses onto the intercooler
connectors.
% S The aluminum charge air tube must have at Refer to Figure 4 or 5.
% least 5 mm (12 mm, if MÄM 40-630 is
%
% installed) clearance to the fire wall and
%
% positive clearance (5 mm, if MÄM 40-630 is
%
% installed) to the RSGU clamp at the coolant
%
% aluminum tube aft of the engine.
%
% S If MÄM 40-639 is installed, place the Refer to Figure 3.
% protective pad underneath the housings of
%
% the worm-drive-clamps.
%
% S Move the worm-drive-clamps into the correct Refer to Chapter 20 for correct
% position and tighten the worm-drive-clamps. installation and tightening torque of
% worm-drive-clamps.
S Install the coolant tank to the intercooler.
(3) Install the engine cowling. Refer to Section 71-10.
(4) Connect the airplane main battery. Refer to Section 24-31.
(5) Do an engine ground run-up and do a test for Refer to Section 71-00.
the correct operation of the engine intercooler.
Doc # 6.02.15 Page 203
Rev. 2 81-00-00 15 Apr 2013
Turbo Charger DA 40 NG AMM
AIRCRAFT
%
%
%
%
%
%
%
%
%
%
% Firewall
%
Min. 5 mm
% Rubber Pad
%
%
%
Charge Air Tube
%
%
%
%
% Positive Clearance
%
%
%
%
%
Coolant Tube RSGU Clamp
%
%
%
%
%
%
%
%
%
%
% Figure 4: Engine Intercooler Tubes - Clearances
Page 204 Doc # 6.02.15
15 Apr 2013 81-00-00 Rev. 2
DA 40 NG AMM Turbo Charger
AIRCRAFT
%
%
%
%
%
%
%
%
%
Firewall
%
Min. 12 mm
%
%
%
%
% Charge Air Tube
%
%
%
%
Min. 5mm Clearance
%
%
%
%
%
% Coolant Tube RSGU Clamp
%
%
Detail B1-1
% N.T.S.
% Installation Schematic
%
%
%
%
%
%
%
% Figure 5: Engine Intercooler Tubes - Clearances (if MÄM 40-630 is installed)
Doc # 6.02.15 Page 205
Rev. 2 81-00-00 15 Apr 2013
Turbo Charger DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 206 Doc # 6.02.15
15 Apr 2013 81-00-00 Rev. 2
DA 40 NG AMM Wiring Diagrams
AIRCRAFT
CHAPTER 92
WIRING DIAGRAMS
Doc # 6.02.15 Page 1
Rev. 2 92-TITLE 15 Apr 2013
Wiring Diagrams DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 92-TITLE Rev. 2
DA 40 NG AMM Wiring Diagrams
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 92
WIRING DIAGRAMS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Doc # 6.02.15 Page 1
Rev. 2 92-CONTENTS 15 Apr 2013
Wiring Diagrams DA 40 NG AMM
AIRCRAFT
Intentionally left blank
Page 2 Doc # 6.02.15
15 Apr 2013 92-CONTENTS Rev. 2
DA 40 NG AMM Wiring Diagrams
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.
Title Drawing No. Rev. No. of
No. Sheets
Schematic, Equipment Cooling D44-9221-20-01 - 1
Schematic, Equipment Cooling D44-9221-20-02 A 1
% Schematic, RACC Wiring D44-9221-50-01 B 1
Schematic, GFC700 Wiring D44-9222-10-01 - 1
Schematic, KAP 140 - G1000 Wiring D44-9222-10-02 - 1
Schematic, PM 1000 Intercom Wiring D44-9223-50-01 A 1
Schematic, Electrical System D44-9224-30-01 C 1
% Schematic, Electrical System D44-9224-30-01_01 - 1
Schematic, Electrical System D44-9224-30-01x01 - 1
% Schematic, Electrical System D44-9224-30-02 B 1
% Schematic, Second Alternator D44-9224-30-05 B 1
Schematic, Emergency Power Package Wiring D44-9225-60-01 - 1
Schematic, ELT ME406, Wiring D44-9225-60-02 - 1
Schematic, ME406, Wiring D44-9225-60-03 - 1
Schematic, Flaps Wiring D44-9227-50-01 - 1
Schematic, Flaps Wiring D44-9227-50-01x01 - 1
Schematic, Flaps Wiring D44-9227-50-02 - 1
% Schematic, Fuel Transfer Wiring D44-9228-20-01 A 1
Schematic, Fuel Transfer Wiring D44-9228-20-01x01 - 1
Schematic, Fuel Transfer Wiring D44-9228-20-02 - 1
Schematic, Pitot Heat Wiring D44-9230-30-01 - 1
Schematic, Pitot Heat Wiring D44-9230-30-01x01 - 1
Schematic, Pitot Heat Wiring D44-9230-30-02 - 1
Schematic, Hourmeter Wiring D44-9231-20-01 - 1
Doc # 6.02.15 Page 1
Rev. 2 92-00-00 15 Apr 2013
Wiring Diagrams DA 40 NG AMM
AIRCRAFT
Title Drawing No. Rev. No. of
No. Sheets
Schematic, Hourmeter Wiring D44-9231-20-02 - 1
Schematic, OAT D44-9231-20-03 A 1
% Schematic, FDR Wiring D44-9231-30-01 A 1
Schematic, Caution & Warning Wiring D44-9231-50-01 A 1
% Schematic, G1000 Wiring D44-9231-60-01 C 6
Schematic, G1000 Wiring D44-9231-60-01x01 - 6
Schematic, Flood Light Wiring D44-9233-10-01 - 1
Schematic, Instrument Lights & Placards D44-9233-10-02 - 1
Schematic, Instrument Flood Light Wiring D44-9233-10-03 - 1
Schematic, Instrument Panel Light Wiring D44-9233-10-05 - 1
Schematic, Map/Reading Light Wiring D44-9233-20-01 - 1
Schematic, Map/Reading Light Wiring, RACC D44-9233-20-01x01 - 1
Schematic, Exterior Lights Wiring D44-9233-40-01 - 1
Schematic, Exterior Lights Wiring D44-9233-40-01x01 - 1
% Schematic, Exterior Lights Wiring D44-9233-40-01x02 - 1
Schematic, Artificial Horizon Wiring D44-9234-10-01 - 1
Schematic, Directional Gyro D44-9234-10-02 - 1
Schematic, Turn & Bank D44-9234-10-03 - 1
Schematic, Artificial Horizon D44-9234-10-04 - 1
Schematic, ADF Wiring D44-9234-50-01 - 1
Schematic, GTX328 D44-9234-50-02 - 1
Schematic, GPSMAP Wiring D44-9234-50-08 - 1
% Schematic, EECU Wiring D44-9274-10-00 C 2
Schematic, EECU Wiring D44-9274-10-01 A 2
Schematic, EECU Wiring D44-9274-10-00x01 - 2
Schematic, Engine Indicating D44-9277-40-01 - 1
Page 2 Doc # 6.02.15
15 Apr 2013 92-00-00 Rev. 2
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
VÄM40-004
- 01 ALL 27.01.10 SEE TB
FIRST RELEASE
F F
REF D44-9231-60-01 21005A22
M AV / CDU J2102
A FAN AVIONICS COOLING FAN
J2403 P2403
E I E
N 3 21002A22 29 21002B22 1
B 2
U
21003A22N 30 21003B22N 3
S
GS-IP-5
REF D44-9231-60-01 21008A22
D D
J2100
MFD COOLING FAN
21000A22 1
REF D44-9231-60-01 21006A22 2
21001A22N 3
GS-IP-1 J2101
PFD COOLING FAN
C 21001B22N 3 C
REF D44-9231-60-01 21007A22 2
21000B22 1
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN K owarsch 27.01.10 TITLE
A3
N ON E CHECKED: K owarsch
Schematic, Equipme nt
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Cooling
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 2 1 -2 0 -0 1 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9221-20-01.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
OÄM 40-321
- 01 ALL 26.01.11 SEE TB
FIRST RELEASE
F OÄM 40-321 F
A 01 ALL 27.02.11 SEE TB
Wire 31200A22 changed to 31202A22
E E
MAIN BUS
AVIONICS COOLING FAN
FAN/OAT J2100 P2100
31202A22 REF D44-9231-20-03
3A 21000A22 1 RED +
21001A22N 2 BLACK -
D D
GS-IP-11
C C
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DP-S-17-00001 - DEPARTMENT SIGN DATE PROJECT DA 40 N G
FIRST ANGLE PROJECTION FORMAT
CLASSIFICATION: - DRAWN Schättler 27.02.11 TITLE
A3
N ON E CHECKED: K owarsch
Schematic
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Equipme nt Cooling
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 2 1 -2 0 -0 2 A
ANGLE u1° MICRO-
RAD u0,5 METER D44-9221-20-02a.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
VÄM 40-004
"-" 01 ALL 27.01.10 SEE TB
FIRST RELEASE
F F
No. 1 GIA 63W FUSELAGE INSTRUMENT PANEL FUSELAGE
INTEGRATED AVIONICS 1P604 P2208 GO AROUND P2406 GSA 81
P2406 2J801 PITCH TRIM SERVO
DISCRETE IN* 4 12 22074A22 2 22074B24 42 22205A22N
22205B22N 1 22205C24N 22000A20 36 22302B20 N AIRCRAFT POWER 1
GS IP-9
22305A20N 23 22305B20N V POWER GROUND
1P603
22309A24BL T RS 485 1 B
SERVO RS 485 B 7 22207A24BL GS IP-7 22309A24WH J RS 485 1 A
SERVO RS 485 A 5 22207A24WH S
S
22308A24BL E RS 485 2 B
E SERVO RS 485 B 6 22108A24BL 22308A24WH S RS 485 2 A E
SERVO RS 485 A 4 22108A24WH S
S F SERVO PROGRAM 3
P2205
UP 22 AWG U PROGRAM GROUND
22026A22 1 22071A20 P SERVO ENABLE
22027A22 2
1P605 MANUAL DOWN
22028A22
ELECTRIC
DISCRETE IN* 3A 39 22033A22 TRIM SWITCH
P2406 ARM
DISCRETE IN* 4A 40 22034A22 3
GSA 81
22030A22N 27 22030B22N 4 3J801 ROLL SERVO
S
S
P2406
1P604 GS IP-8
22025A22 6 22000A20 38 22200B20 N AIRCRAFT POWER 1
CWS
DISCRETE IN* 5 13 22025A22 22204A20N 43 22204B20N V POWER GROUND
22029A22N 28 22029B22N 5
GS IP-9
GS IP-8 40 22016D20 7 22207A24BL T RS 485 1 B
DISCRETE IN* 9 19 22035A22 22207A24WH J RS 485 1 A
P2209 DISC
AFCS DISCONNECT IN 11 22036A22 S
1.
D DISCRETE IN* 6 14 22041A22 22037A22 1 22037B22 9 D
DISCRETE IN 16 15 27010A20 22038A22 22206A24BL E RS 485 2 B
DISCRETE IN 17 16 27011A20 22072A20 8 22206A24WH S RS 485 2 A
3.
REF S
D44-9227-50-01 G SERVO PROGRAM 2
P2207
22 AWG U PROGRAM GROUND
No. 2 GIA 63W
22072A20 2 2. 22071B20 P SERVO ENABLE
INTEGRATED AVIONICS 2P604
22038A22 3
DISCRETE IN* 6 14 22042A22
AFCS DISCONNECT IN 11 22036A22
DISCRETE IN* 9 19 22035A22 22306A22N 22 22306B22N 4
22071A20 1
GS IP-7 GSA 81
2P605 1J801 PITCH SERVO
P2406
DISCRETE IN* 4A 40 22034A22 22000A20 37 22100B20 N AIRCRAFT POWER 1
DISCRETE IN* 3A 39 22033A22 22102A20N 18 22102B20N V POWER GROUND
P2209 3.
2. 22108A24BL T RS 485 1 B
22073A20 22071A20 GS IP-6
2 22073B20 22108A24WH J RS 485 1 A
C 2.
C
2P603 S
22016C20 22016C20
SERVO RS 485 B 6 22109A24BL 22109A24BL E RS 485 2 B
SERVO RS 485 A 4 22109A24WH 22109A24WH S RS 485 2 A
S S
H SERVO PROGRAM 1
SERVO RS 485 B 7 22206A24BL 22 AWG U PROGRAM GROUND
SERVO RS 485 A 5 22206A24WH 22071C20 P SERVO ENABLE
S
AUTO
PILOT
22016C20
AVIONIC BUS 5 22000A20
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
NOTES: CLASSIFICATION: - DRAWN K owarsch 27.01.10 TITLE
A3
1. TERMINATED AT GIA CONNECTORS. N ON E CHECKED: K owarsch
Schematic,
2. TERMINATED AT CONNECTOR J2207. UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A GFC700 Wiring
DIMENSIONS ARE IN MM
3. LOCATED IN FUSELAGE. 3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 2 2 -1 0 -0 1 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9222-10-01.dft APPROVED: TL CODE SCALE SH
710197 1:1 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
INSTRUMENT PANEL ENGINE COMPARTMENT
F F
AVIONIC A J2410
RELAY REF
V 31002A22 2 31002B22
AV. BUS 87A I D44-9231-60-01
24108A10 80103A20 3 80103B20
30 O
25 24107A10 N
87 CURRENT
I SENSOR
C
86 85 24007A4 ALT START
24106A22N 24105A22 B
TO AVIONIC U
S CPC 2
GS-IP-11 SWITCH REF
D44-9231-60-01 4
5A
24010C22 H
TB3 O
T J2424 ALT. REG.
24011A22N + 24200A22 4 5A FUSELAGE
E 24020B22 2 24020A22 2 FIELD E
- 24201A22N B
OFF ENGINE REF D44-9274-10-00 24019B20 24019A20 3
GS-IP-15 U 3 ENABLE
ELECTRIC MASTER AUX.
POWER GS-IP-10 S REF D44-9231-60-01 31004B22 4 31004A22 4 LAMP
MASTER ON
80102A22 80102B22 PLUG 24018B20N 1 24018A20N 1 GROUND
PWR RELAY
24007A4 100A J2421 1.0 k / 1W
M PWR E 24201A22
24201B22 2
A 87 30
C
24201C22
I 60 24015A10 24008A10 U
5A
N BATTERY RELAY
B
5A
20A
B START 85 86 U
U 24311A22 REF S 24000A2
S STARTER D44-9274-10-00 J2420 MAIN
10
RELAY J2421 BATTERY
MAIN TIE 87A 2
D 24010A22 B1 D
24010C22 1 24010B22 1
30 24V / 13.6Ah
30 80100A20 80101C22 3
87
31022A22 5A GS-RP
ESS TIE
80A
RELAY 86 85
REF
24012A22
ESS TIE 3 D44-9231-60-01 B 24008A4N
A
24340A14
9 STARTER RELAY
E 30 24007A10 T
S T GS-IP
10 AWG
S 1
80104A2
E 7 B 24000A4 100A
N 24006A10 24200A10 50A U
4
T 3 2 5A S J2421
I OFF
80101B22 3 80101A22 80102A22N
A C 1 A B 2
L 24310A22 24315A22
ON
C GS-RP C
4 TB1
B 24313A22
U 1 74000A10 50A
S REF
E D44-9274-10-00
ESSENTIAL 2
C
24340B14
BUS TO AVIONIC U
MASTER EPU RELAY
OFF RELAY EECU BACKUP RELAY REF
CONTROL B 10A 24021A20
24105A22 87A D44-9274-10-00
ON REF
2 24104A22 D44-9274-10-00 B 30
24308A14 24318B14 1 24318A14 32A
AVIONIC U 87 10 AWG
S B2 EPU PLUG
MASTER 12V J2421
J2411
85 86 EECU 7.2Ah 24401A22 4 24401B22
5A
24328A22 24304A22N BACKUP
REF BATTERY 24403A6
GS-IP-15 B3
D44-9274-10-00 12V
GS-RP 24405A6N
B 7.2Ah B
GS-RP
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRIC Airc raft Diamond Aircraft Industries A-2700 Wiener Neustadt
Indust ries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT DA 40 N G
FIRST ANGLE PROJECTION FORMAT
CLASSIFICATION: - DRAWN K owarsch 24.02.10 TITLE
A2
N ON E CHECKED: K owarsch
A
Schem atic, A
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Electrical System
REVISION DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
REV SH ZONE DESCRIPTION DATE APPROVAL DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
FIRST RELEASE 2 DECIMAL u0,25
B 01 ALL 14.01.10 SEE TB
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAIA D44-9224-30-01 "C"
VÄM 40-004, connected voltage suppressor
C 01 ALL 24.02.10 SEE TB ANGLE u1° MICRO-
to the ECU Bus, added enable wire at ECU D44-9224-30-01b.dft
RAD u0,5 METER APPROVED: TL CODE 710197 SCALE SH 01 OF 01
Backup Relay NTS
8 7 6 5 4 3 2 1 Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
Confidential 8 7 6 5 4 3 2 1
INSTRUMENT PANEL ENGINE COMPARTMENT
F F
AVIONIC A J2410
RELAY REF
V 31002A22 2 31002B22
AV. BUS 87A I D44-9231-60-01
24108A10 80103A20 3 80103B20
30 O
25 24107A10 N
87 CURRENT
I SENSOR
C
86 85 24007A4 ALT START
24106A22N 24105A22 B
TO AVIONIC U CPC 2
SWITCH S 4
GS-IP-11 REF
D44-9231-60-01
5A
24010C22 FUSELAGE ALT. REG.
J2424 JA
TB3 H
O 24017B20 2 24017A20 7 EXCITATION
24011A22N + 24200A22 4 5A
E T REF D44-9274-10-00 24019B20 3 24019A20 6 SUPPLY E
- 24201A22N
OFF ENGINE REF D44-9231-60-01 31004B22 4 31004A22 12 LAMP
GS-IP-15 B
ELECTRIC MASTER AUX. 24018B20N 24018A20N
GS-IP-10 U 1 4 GROUND
MASTER ON POWER
80102A22 80102B22 PLUG S 5 24022A22
JB
24022B22 5 USENSE
PWR RELAY
PWR 24007A4 100A
M E
A C 24201A22
87 30
I 60 24015A10 24008A10 U J2421
N BATTERY RELAY
24201C22
5A
24201B22 2
B
5A
20A
B START 85 86 U
U 24311A22 REF S 24000A2
S STARTER D44-9274-10-00 J2420 MAIN
10
RELAY J2421 BATTERY
MAIN TIE 87A 2
D 24010A22 B1 D
24010C22 1 24010B22 1
30 24V / 13.6Ah
30 80100A20 80101C22 3
87
31022A22 5A GS-RP
ESS TIE
80A
RELAY 86 85
REF
24012A22
ESS TIE 3 D44-9231-60-01 B 24008A4N
A
24340A14
9 STARTER RELAY
E 30 24007A10 T
S T GS-IP
10 AWG
S 1
80104A2
E 7 B 24000A4 100A
N 24006A10 24200A10 50A U
4
T 3 2 5A S J2421
I OFF
80101B22 3 80101A22 80102A22N
A C 1 A B 2
L 24310A22 24315A22
ON
C GS-RP C
4 TB1
B 24313A22
U 1 74000A10 50A
S REF
E D44-9274-10-00
ESSENTIAL 2
C
24340B14
BUS TO AVIONIC U
MASTER EPU RELAY
OFF RELAY EECU BACKUP RELAY REF
CONTROL B 10A 24021A20
24105A22 87A D44-9274-10-00
ON REF
2 24104A22 D44-9274-10-00 B 30
24308A14 24318B14 1 24318A14 32A
AVIONIC U 87 10 AWG
S B2 EPU PLUG
MASTER 12V J2421
J2411
85 86 EECU 7.2Ah 24401A22 4 24401B22
5A
24328A22 24304A22N BACKUP
REF BATTERY 24403A6
GS-IP-15 B3
D44-9274-10-00 12V
GS-RP 24405A6N
B 7.2Ah B
GS-RP
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRIC Airc raft Diamond Aircraft Industries A-2700 Wiener Neustadt
Indust ries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT DA 40 N G
FIRST ANGLE PROJECTION FORMAT
CLASSIFICATION: - DRAWN Schät tler 20.10.11 TITLE
A2
N ON E CHECKED: K owarsch
A
Schem atic, A
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Electrical System
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
REVISION 2 DECIMAL u0,25
1DECIMAL u0,5 FINISH
REV SH ZONE DESCRIPTION DATE APPROVAL DECIMAL u1 IN FILENAME SYSTEM: N/A DAIA D44-9224-30-01_01 "-"
ANGLE u1° MICRO-
MÄM 40-551 RAD u0,5 D44-9224-30-01_01.dft
"-" 01 ALL 20.10.11 SEE TB METER APPROVED: TL CODE 710197 SCALE SH 01 OF 01
FIRST RELEASE NTS
8 7 6 5 4 3 2 1 Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
Confidential 8 7 6 5 4 3 2 1
ENGINE COMPARTMENT
ALT ALT. REGULATOR
100 / 3W J2432
AUX
F 24357A20 3 BROWN AUX F
F2 F1
+ 24358A20 2 BLUE FIELD
24359A20N 8 BLACK GROUND
6 YELLOW VOLTAGE SENSE
24353C20 1 RED ALT CONTROL
24354C20 7 ORANGE ALT PROTECTION
24600A4
24601A22 4 GRAY ALT OUT
24360A20N
E E
100A
3 2 4 1
FUSELAGE J2433 INSTRUMENT PANEL
24600B4
2nd ALT
MASTER
OFF
24600B4
24353B20
24354B20
RELAY PANEL
ON
ALT.
EXCITATION RELAY CONTROL RELAY J2435
D 5A 24353A20 3 D
87A 87A
30 30
24355A14 24356A14 10A 24352A20 5A 24354A20 4 ELECTRIC
P2434
87 87 MASTER
OFF
2 1 J2409
86 85 86 85 ON
24351C22 24351B22 2 24351A22 24350B22 15 24350A22 24011A22N
MAIN RELAY REF D44-9224-30-02
32A
5A 24603A22
12V ALT. FAIL RELAY
1.3Ah 87A
24602A22
C 30 C
12V
87
1.3Ah
85 86
24601C22 1 24601B22
2nd EPU
RELAY REF D44-9224-30-01
TO ADDITIONAL
ELECTRICAL LOADS
24360A14N
24413A6 EPU RELAY
J2435
24411B22 9 24411A22
EPU PLUG J2421
B 24401B22 4 24401A22 B
24403A6
24405A6N GS-RP
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRIC Airc raft Diamond Aircraft Industries A-2700 Wiener Neustadt
Indust ries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT DA 40 N G
FIRST ANGLE PROJECTION FORMAT
CLASSIFICATION: - DRAWN 10.04.12 TITLE
A2
N ON E CHECKED:
A
Schem atic, A
REVISION UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Second Alternator
REV SH ZONE DESCRIPTION DATE APPROVAL DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
OÄM 40-314 DIMENSION TOLERANCES
- 01 ALL 19.08.10 SEE TB SOFTWARE:
FIRST RELEASE SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
2 DECIMAL u0,25
OÄM 40-314/a 1DECIMAL u0,5 FINISH
A 01 D-5 11.10.10 SEE TB SYSTEM: N/A D44-9224-30-05 "B"
DIODE AT ALT. CONTROL RELAY ADDED DECIMAL u1 IN FILENAME DAIA
OÄM 40-314/j ANGLE u1° MICRO-
B 01 C-8 10.04.12 SEE TB RAD u0,5 METER D44-9224-30-05b.dft APPROVED: TL
WIRE NUMBER ADDED. CODE 710197 SCALE NTS SH 01 OF 01
8 7 6 5 4 3 2 1 Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
VÄM 40-004
- 01 ALL 27.01.10 SEE TB
FIRST RELEASE
F F
E E
EMERGENCY BATTERY
30 VDC / 2600 mAh
EMERGENCY POWER SWITCH
B4
J2430 P2430
1 ON REF
24303B20 33204B22
D44-9233-10-01
2 24302B20N REF OFF
33204A22
D44-9233-10-01
REF
34903B22 D44-9234-10-01
REF
D 34903A22 D
D44-9234-10-01
GS IP-15
C C
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN K owarsch 27.01.10 TITLE
A3
N ON E CHECKED: K owarsch
Schematic, Emergency
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Power Pack a ge Wiring
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 2 5 -6 0 -0 1 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9225-60-01.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
VÄM 40-004
"-" 01 ALL 27.01.10 SEE TB
FIRST RELEASE
F F
REMOTE
ELT UNIT HOT BUS SWITCH
E J2562 P2500 J2561 E
G-SWITCH LOOP 5 1A 25601A22 1 22 AWG 3 +28 VDC
G-SWITCH LOOP 12
RESET 2 13 25603A22 25603A22 2 RESET 2
RESET 1 6 25604A22 25604A22 5 RESET 1
EXTERNAL ON 14 25605A22 25605A22 7 EXTERNAL ON
LIGHT 2 25606A22 25606A22 8 LIGHT
GROUND 7 25607A22N 25607A22N 6 GROUND
25608A22N P2500
25602A22N 2 22 AWG 9 GROUND
D LOCAL D
GS-IP 18
HORN POWER 8 25609A22 / red +
BUZZER
25608A22N / black -
LOCAL
C C
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN K owarsch 27.01.10 TITLE
A3
N ON E CHECKED: K owarsch
Schematic, ELT ME406,
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Wiring
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 2 5 -6 0 -0 2 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9225-60-02.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
OÄM 40-321
"-" 01 ALL 26.01.11 SEE TB
FIRST RELEASE
F F
REMOTE
ELT UNIT HOT BUS SWITCH
E J2562 P2500 J2561 E
G-SWITCH LOOP 5 1A 25601A22 1 22 AWG 3 +28 VDC
G-SWITCH LOOP 12
RESET 2 13 25603A22 25603A22 2 RESET 2
RESET 1 6 25604A22 25604A22 5 RESET 1
EXTERNAL ON 14 25605A22 25605A22 7 EXTERNAL ON
LIGHT 2 25606A22 25606A22 8 LIGHT
GROUND 7 25607A22N 25607A22N 6 GROUND
25608A22N P2500
25602A22N 2 22 AWG 9 GROUND
D LOCAL D
GS-IP 4
HORN POWER 8 25609A22 / red +
BUZZER
25608A22N / black -
LOCAL
C C
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN Schättler 26.01.11 TITLE
A3
N ON E CHECKED: K owarsch
Schematic, ELT ME406,
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Wiring
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 2 5 -6 0 -0 3 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9225-60-03.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
VÄM 40-004
"-" 01 ALL 28.01.10 SEE TB
FIRST RELEASE
F F
FUSELAGE
FLAP POSITION
SWITCH ASSEMBLY
FLAP-SWITCH S1 S5 S2 S4 S3
INSTRUMENT PANEL PC-BOARD
E E
E
FLAPS
S J2409 P2409 J2412 P2412 J2700 P2700 J2703 P2703
S
E 5A 27008A20 27000A22 10 27000B22 3 27000C22 2 x2a_2 x3_2 2
N 27001A22 1 27001B22 4 27001C22 3 x2a_3 x3_3 3
T 27002B22 5
27002A22 2 27002C22 4 x2a_4 x3_4 4
I
A 27003A22 3 27003B22 6 27003C22 5 x2a_5 x3_5 5
L 27004A22 4 27004B22 7 27004C22 6 x2a_6 x3_6 6
27005A22 5 27005B22 8 27005C22 7 x2a_7 x3_1 1
B
U 27007A20 7 27007B20 2 27007C20 1 x2a_1
S 27006A20N 6 27006B20N 1 27006C20N 8 x2a_8
D D
J2702 P2702
GS-IP-10 2.7 /50W
x4_2 2 RED
2 M
x4_1 1 BLK
REF. 33026A22 1
D44-9233-10-02
J2704 P2704 FLAP MOTOR
1 27010A20 REF.
2 27011A20 D44-9222-10-01
J2705 P2705
C C
1
LDG 2
T/O
UP 3 LDG
4
5 UP
6
B T/O B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN K owarsch 28.01.10 TITLE
A3
UP T/O LDG N ON E CHECKED: K owarsch
Schematic, Fla ps Wiring
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 2 7 -5 0 -0 1 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9227-50-01.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
VÄM 40-004
"-" 01 ALL 28.01.10 SEE TB
FIRST RELEASE
F F
E INSTRUMENT PANEL E
30003A22 FUSELAGE L/H WING
REF. D44-9231-60-01
30004A22
3A
3A
PITOT PITOT
HEAT
Pitot Static
OFF
Probe
10 30000A14
ON
t°2
D 87A D
J2402 P2402 J2400 P2400 J3002 P3002 HEATER
ESS 30
BUS 30001A14 30001A14 19 30001B14 29 30001C14 1 1
87
2
1 2 30002A14N 21 30002B14N 34 30002C14N 2
t°1
0.01 86
3W 85
GS-IP-16
31015A22BL
REF D44-9231-60-01
31015A22WH
C C
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN K owarsch 28.01.10 TITLE
A3
N ON E CHECKED: K owarsch
Schematic,
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Pitot Heat Wiring
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 0 -3 0 -0 1 -
ANGLE u1° MICRO-
RAD u0,5 METER D44-9230-30-01.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
VÄM 40-004
- 01 ALL 28.01.10 SEE TB
FIRST RELEASE
F F
E E
INSTRUMENT PANEL FUSELAGE
J2409 P2409
ENGINE 1A 31100A22 31100A22 8 31100C22
HOUR
MASTER OFF 31101A22 9 31101C22 METER
D D
REF D44-9274-10-00 REF D44-9274-10-00
ON
GS-IP-12
C C
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN K owarsch 28.01.10 TITLE
A3
N ON E CHECKED: K owarsch
Schematic,
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Hourmeter Wiring
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 1 -2 0 -0 1 -
ANGLE u1° MICRO-
RAD u0,5 METER D44-9231-20-01.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
OÄM 40-321
- 01 ALL 26.01.11 SEE TB
FIRST RELEASE
F F
E E
INSTRUMENT PANEL FUSELAGE
J2409 P2409
ENGINE 1A 31100A22 31100A22 8 31100C22
HOUR
MASTER OFF 31101A22 9 31101C22 METER
D D
REF D44-9274-10-01 REF D44-9274-10-01
ON
GS-IP-10
C C
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN Schättler 26.01.11 TITLE
A3
N ON E CHECKED: K owarsch
Schematic,
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Hourmeter Wiring
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 1 -2 0 -0 2 -
ANGLE u1° MICRO-
RAD u0,5 METER D44-9231-20-02.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
OÄM 40-321
- 01 ALL 21.10.10 SEE TB
FIRST RELEASE
F OÄM 40-321 F
A 01 ALL 24.01.11 SEE TB
Wire 31200A22 changed to 31202A22
MAIN BUS
E E
CLOCK/OAT
FAN/OAT J3121
21000A22 REF D44-9221-20-02
3A 31202A22 31202A22 2 28 VDC POWER IN
31201A22N 31201A22N 1 POWER GROUND
REF D44-9233-10-05 33030A22 8 INTERNAL LIGHTING
D GS-IP-2
D
J3122 P3122 P2404 J2404
1 31203B24OR 37
31203C24WH 2 31203B24WH 34 31203A24WH 7 TEMP SENS HI
O.A.T.
31203C24BL 3 31203B24BL 35 31203A24BL 6 TEMP SENS LO
PROBE
4 36
C C
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DP-S-17-00001 - DEPARTMENT SIGN DATE PROJECT DA 40 N G
FIRST ANGLE PROJECTION FORMAT
CLASSIFICATION: - DRAWN Schättler 24.01.11 TITLE
A3
N ON E CHECKED: K owarsch
Schematic,
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A OAT
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 1 -2 0 -0 3 A
ANGLE u1° MICRO-
RAD u0,5 METER D44-9231-20-03a.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
IDC ANNUN. REV SH ZONE DESCRIPTION DATE APPROVAL
P3100
OÄM 40-321
31025A22 ESS. BUS - 01 ALL 26.01.11 SEE TB
POWER 15 3 FIRST RELEASE
F POWER 14 OÄM 40-321 F
A 01 ALL 15.03.11 SEE TB
Title updated
GROUND 18
GROUND 17 31008A22N
STARTER MOTOR 11 31002A22 GS-IP-1
REF D44-9224-30-02
STARTER CONTACTOR 10 31022A22 REF D44-9224-30-02
PITOT CURRENT SENSE 8 31015A22 REF D44-9230-30-02
ALTERNATOR FAIL 31004B22 REF D44-9224-30-02
2
FUEL TRANSFER PUMP 13 31003A22 REF D44-9228-20-02
DIMMING 22 33051A22 REF D44-9233-10-05
E E
AUDIO 20 31020B24WH
REF D44-9223-50-01
AUDIO LO 19 31020B24BL
DOOR WARNING
J2402 FWD AFT
DOOR UNLOCKED 1 31023A22 15 31023B22 1
31024A22N 14 31024B22N 2
J2400 J3101 LEFT FUEL LO
GS-IP-18
L FUEL TANK LOW QTY 4 31018A22 27 31018B22 9 31018C22 1
31019A22N 28 31019B22N 10 31019C22N 2
D GS-IP-19 D
CPC 1
ACKNOWLEDGE OUT 23 31028A22 10 29
MED 1
ENGINE 12 31026A22 14 16 1
10
SED
14
REF D44-9274-10-01
GLOW 24 31005A22
P3111 J3111
C 1 31030A22 C
P3110 J3110
2 31001B22 CPC 2
ECU A 6 31001A22 1
3 31021B22 22 1
ECU B 7 31021A22 2
4 31031A22N
GS-IP-6
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
FLAG NOTES DP-S-17-00001 - DEPARTMENT SIGN DATE PROJECT DA 40 N G
FIRST ANGLE PROJECTION FORMAT
CLASSIFICATION: - DRAWN Schättler 15.03.11 TITLE
1 INDICATE THE AUSTRO ENGINE HARNESS
A3
N ON E CHECKED: K owarsch
Schematic,
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Caut ion & Warning
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A Wiring
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 1 -5 0 -0 1 A
ANGLE u1° MICRO-
RAD u0,5 METER D44-9231-50-01a.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
VÄM 40-004
A ALL ALL see ÄM 06.04.09 SEE TB
F 01 OÄM 40-311 F
B 06 ALL Note 3 and jumper added. 08.04.10 SEE TB
03 OÄM 40-340, Avidyne 9900BX TAS
C 06 ALL and its connection added 16.01.12 SEE TB
NOTES:
1. SYMBOL DESIGNATIONS
TWISTED SHIELDED SINGLE CONDUCTOR
SHIELD TERMINATED TO GROUND TWISTED SHIELDED 4 CONDUCTOR
SHIELD TERMINATED TO GROUND
TWISTED SHIELDED SINGLE CONDUCTOR
SHIELD FLOATS
E E
TWISTED SHIELDED PAIR
SHIELD TERMINATED TO GROUND TWISTED SHIELDED 4 CONDUCTOR
SHIELD FLOATS
TWISTED SHIELDED PAIR
SHIELD FLOATS
AIRCRAFT GROUND
TWISTED SHIELDED 3 CONDUCTOR GARMIN (SHIELD BLOCK) GROUND
S
SHIELD TERMINATED TO GROUND REFER TO DOC. 190-00313-09
WIRE SPLICE CONNECTION
D TWISTED SHIELDED 3 CONDUCTOR
D
SHIELD FLOATS COAXIAL CABLE
N/C = NO CONNECTION
2. USE DOUBLE-SHIELDED WIRING: BOTH SHIELDS SHOULD BE GROUNDED ON THE RECEIVING SIDE;
ON THE TRANSMITTING SIDE, ONLY THE OUTER SHIELD SHOULD BE GROUNDED, WHILE THE INNER
SHIELD SHOULD FLOAT.
C C
3. OPTIONAL JUMPER FOR TOP MOUNTED ANTENNA INSTALLATION.
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN Schättler 16.01.12 TITLE
A3
N ON E CHECKED: K owarsch
Schematic,
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A G1000 Wiring
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 1 -6 0 -0 1 "C"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9231-60-01c.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 06
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
GMA1347 P3471
F AUDIO PANEL F
REF SHEET 3
NO. 2 GIA63W
2
J2414 P2414 2P604 INTEGRATED AVIONICS
23029A22BL 55 23029B22BL 3 VOICE ALERT 500 AUDIO LO (GND)
UNSWITCHED AUDIO IN 3 HI 38 23029A22WH 56 23029B22WH 2 VOICE ALERT 500 AUDIO HI
57
S
S 54 S
NO. 1 GIA63W
2
J2413 P2413 1P604 INTEGRATED AVIONICS
23030A22BL 21 23030B22BL 3 VOICE ALERT 500 AUDIO LO (GND)
UNSWITCHED AUDIO IN 2 HI 20 23030A22WH 22 23030B22WH 2 VOICE ALERT 500 AUDIO HI
23
S AUDIO
S 24 S
23010A22 5A
23018A22 23017A22 AVIONIC
BUS
100 10W 1P601
E +28 V ANR TIP POWER E
ON SIDE COM MIC AUDIO OUT HI 26 23202B24WH 6 23202A24WH 7 COM MIC AUDIO IN HI
ON SIDE COM MIC 27 23202B24BL 7 23202A24BL 4 COM MIC KEY
8
S
ON SIDE COM AUDIO IN HI 7 23203B24WH 44 23203A24WH 9 COM AUDIO OUT HI
ON SIDE COM AUDIO LO 8 23203B24BL 45 23203A24BL 10 COM AUDIO OUT LO
46 8 COM MIC AUDIO IN LO
S COM 1
ESS
23200A20 26 23200B20 17 AIRCRAFT POWER 1
P3472 BUS 5A
19 AIRCRAFT POWER 1
23201A20N 27 23201B20N 30 POWER GROUND
POWER 53 31 POWER GROUND
GS IP-4
ON SIDE COM MIC DIGI AUDIO OUT 8 23210B24WH 52 23210A24WH 14 COM MIC DIGITAL AUDIO IN
ON SIDE COM DIGI AUDIO IN 9 23210B24BL 53 23210A24BL 13 COM DIGITAL AUDIO OUT
54
S S
GPS/NAV 1 0.499 20W 1P605
ESS 34000A22 37 34000B22
5A 34000E22 29 AIRCRAFT POWER 1
BUS
34001A22N 38 34001B22N 76 POWER GROUND
D GS IP-3 3.2
D
GS AVB 53V 1P602
ON SIDE NAV DIGI AUDIO IN 28 34002B24WH 15 34002A24WH 59 VOR/LOC DIGI AUDIO OUT
AIRCRAFT GROUND 71 34002B24BL 16 34002A24BL 61 SIGNAL GROUND
17
S S
POWER GROUND 14 23011A22N
1P603
GS IP-8
RS 232 OUT 1 6 23012B24WH 18 23012A24WH 59 MAIN RS 232 IN 7
RS 232 IN 1 7 23012B24BL 19 23012A24BL 62 MAIN RS 232 OUT 7
S 20 S
J3481 P3481 P3482 J3482
MKR ANTENNA HI 78 MARKER
34890A400 34890B400
ANTENNA
MKR ANTENNA LO 59
P2407 J2407 J2404 P2404
P2301 J2301
SPKR AUDIO OUT HI 42 23008A24WH 42 23008B24WH 20 23008C24WH 1
SPEAKER
SPKR AUDIO OUT LO 41 23008A24BL 43 23008B24BL 21 23008C24BL 2
44 22
C S C
2P601 NO. 2 GIA63W
J2414 P2414 INTEGRATED AVIONICS
CROSS SIDE COM MIC DIGI AUD OUT 47 23302B24WH 6 23302A24WH 14 COM MIC DIGITAL AUDIO IN
CROSS SIDE COM DIGI AUDIO IN 48 23302B24BL 7 23302A24BL 13 COM DIGITAL AUDIO OUT
COM 2 8
S S
AVIONIC 15 17 AIRCRAFT POWER 1
5A 23300A20 23300B20
BUS
19 AIRCRAFT POWER 1
23301A20N 16 23301B20N 30 POWER GROUND
31 POWER GROUND
GS IP-6
2P602
CROSS SIDE NAV DIGI AUDIO IN 68 34102B24WH 9 59 VOR/LOC DIGI AUDIO OUT
34102A24WH
AIRCRAFT GROUND 69 34102B24BL 10 34102A24BL 61 SIGNAL GROUND
11
S S
2P603
RS 232 OUT 2 38 23013B24WH 17 59 MAIN RS 232 IN 7
23013A24WH
B RS 232 IN 2 39 23013B24BL 18 62 MAIN RS 232 OUT 7 B
23013A24BL
19
S S
GPS/NAV 2 0.499 20W 2P605
AVIONIC 23 29 AIRCRAFT POWER 1
5A 34100A22 34100B22 34100E22
BUS
34101A22N 24 34101B22N 76 POWER GROUND
GS IP-10 3.2
P2407 J2407
GS AVB 53V
28V LIGHTING HI 52 33004B22 41 REF D44-9233-10-02
A Diamond PROJECT DA 40 N G TITLE DWG.ORIG. DWG.NO. REV A
Aircraft
Industries GmbH
Schematic, DAI A D44-9 2 3 1 -6 0 -0 1 "C"
N. A. Otto-Straße 5
Diamond Aircraft Industries A-2700 Wiener Neustadt G1000 Wiring CODE 710197 SCALE NTS SH 02 OF 06
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
F F
34412A22 REF SHEET 6/6
+28 V ANR
23026A24OR PILOT
HAND
GMA1347 P3471 23026A24WH
MIC
AUDIO PANEL 23026A24BL J2405 P2405
S
PILOT
PILOT MIC AUDIO IN HI 28 23000A24WH 1 23000B24WH
MIC
PILOT MIC AUDIO IN LO 30 23000A24BL 2 23000B24BL
23000A24OR 3 23000B24OR
S
4
PILOT PTT
PILOT MICKEY IN 29 23014A24WH 55 23014B24WH 1
23014A24BL 56 23014B24BL 2
S S 57
PILOT PHONE AUDIO LT HI OUT 9 23001A24WH 5 23001B24WH
PILOT PHONE AUDIO RT HI OUT 10 23001A24OR 49 23001B24OR PILOT
E PILOT PHONE AUDIO LO OUT 11 23001A24BL
PHONE
E
6 23001B24BL
S 7
PASS 1 MIC AUDIO IN HI 46 23004A24WH 15 23004B24WH
PASS #1
PASS 1 MIC AUDIO IN LO 47 23004A24BL 16 23004B24BL MIC
S 17
PASS 2 MIC AUDIO IN HI 65 23006A24WH 21 23006B24WH
PASS #2
PASS 2 MIC AUDIO IN LO 66 23006A24BL 22 23006B24BL MIC
S 23
PASS PHONE L OUT HI 67 23005A24WH 18 23005B24WH
23005A24OR 50 PASS #1
PASS PHONE R OUT HI 68 23005B24OR
PHONE
PASS PHONE AUDIO LO OUT 48 23005A24BL 19 23005B24BL
S 20
23007A24WH 24 23007B24WH
PASS #2
23007A24OR 51 23007B24OR PHONE
23007A24BL 25 23007B24BL
+28V ANR S 33
D COPILOT MIC AUDIO IN HI 49 23002A24WH 13 23002B24WH
D
CO-PILOT
COPILOT MIC AUDIO IN LO 51 23002A24BL 12 23002B24BL MIC
23002A24OR 11 23002B24OR
S 14
34413A22 REF SHEET 6/6 CO-PILOT PTT
COPILOT MICKEY IN 50 23015A24WH 53 23015B24WH 1
23015A24BL 54 23015B24BL 2
S S 48
COPILOT PHONE AUDIO LT OUT HI 69 23003A24WH 8 23003B24WH
COPILOT PHONE AUDIO RT OUT HI 70 23003A24OR 40 23003B24OR CO-PILOT
23003B24BL PHONE
COPILOT PHONE AUDIO OUT LO 71 23003A24BL 9
S 10
MUSIC IN 2 LEFT 56 23025A24WH 27 23025B24WH
MUSIC IN 2 RIGHT 57 23025A24OR 26 23025B24OR
MUSIC IN 2 LO 76 23025A24BL 28 23025B24BL
S 29
BECKER
RA 3502 ADF
C J2403 P2403 P2 (OPTIONAL INSTALLATION) C
ADF AUDIO IN HI 35 34206A24WH 15 34206B24WH 2 AUDIO OUT HI
ADF AUDIO IN LO 36 34206A24BL 16 34206B24BL 3 AUDIO OUT LO
S 17
HONEYWELL
KN 63 DME
P631 (OPTIONAL INSTALLATION)
DME AUDIO IN HI 15 34300A24WH 37 34300B24WH C AUDIO HI
DME AUDIO IN LO 16 34300A24BL 38 34300B24BL N AUDIO LO
S 39
AVIDYNE
9900BX
J2413 P2413 J3446 P3446 TAS
P1 (OPTIONAL INSTALLATION)
UNSWITCHED AUDIO IN 1 HI 19 34430A22WH 14 34430B22WH 1 34430C22WH 3 AUDIO
UNSWITCHED AUDIO IN LO 39 34430A22BL 13 34430B22BL 2 34430C22BL 4 AUDIO GROUND
S 12 3
B B
REF SHEET 2
A Diamond PROJECT DA 40 N G TITLE DWG.ORIG. DWG.NO. REV A
Aircraft
Industries GmbH
Schematic, DAI A D44-9 2 3 1 -6 0 -0 1 "C"
N. A. Otto-Straße 5
Diamond Aircraft Industries A-2700 Wiener Neustadt G1000 Wiring CODE 710197 SCALE NTS SH 03 OF 06
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
F GEA71 P701 J2410 P2410 F
ENGINE/AIRFRAME STARTER MOTOR
ANALOG IN 1 HI 22 31002A22 2 31002B22 28V
STARTER RELAY
J2407 P2407 J2413 P2413 1P603 NO. 1 GIA63W
INTEGRATED AVIONICS
RS 485 1 A 5 77010A24WH 20 77010B24WH 28 77010C24WH 23 GEA RS 485 1 A
RS 485 1 B 6 77010A24BL 21 77010B24BL 29 77010C24BL 24 GEA RS 485 1 B
S 22 30 S
J2414 P2414 2P603 NO. 2 GIA63W
INTEGRATED AVIONICS
RS 485 2 A 7 77011A24WH 23 77011B24WH 12 77011C24WH 23 GEA RS 485 1 A
RS 485 2 B 8 77011A24BL 24 77011B24BL 13 77011C24BL 24 GEA RS 485 1 B
S 25 14 S
PITOT SWITCH PITOT
PITOT HEAT AMPS SENSOR
ESS
ANALOG IN 7 HI 48 31015A22WH 10A BUS
0.01 OHM
ANALOG IN 7 LO 49 31015A22BL HEATER REF D44-9230-30-01
S
ANALOG IN 7 HI 64 30004A22 3A
E ANALOG IN 8 HI 66 30003A22 3A E
ANALOG IN 4 HI 44 ENG INST
ESS
POWER 35 77015A22 5A BUS
POWER GROUND 20 77016A22N
ANALOG IN 4 LO 45 GS-IP-14
J3111 DOORS CLOSED
31023B22 1
31024B22N 2
P702 J2402 P2402 FWD AFT
DISCRETE IN 19 A 42 31023A22 15 J2400 P2400 J3101 FUEL LEVEL LEFT LOW
SIGNAL GROUND 37 31024A22N 14
DISCRETE IN 1A 60 31018A22 27 31018B22 9 31018C22 1
SIGNAL GROUND 31 31019A22N 28 31019B22N 10 31019C22N 2
J2402 P2402 J2400 P2400
25 25
ANALOG IN 1 A HI 52 31300A22WH 23 31300B22WH 23 31300C22WH 1 LH FUEL
ANALOG IN 1 A LO 53 31300A22BL 24 31300B22BL 24 31300C22BL 2 TEMP SENSOR
SIGNAL GROUND 38 S
D J2404 P2404 J2401 P2401 D
29 13
ANALOG IN 2 A HI 54 31200A22WH 30 31200B22WH 11 31200C22WH 1 RH FUEL
ANALOG IN 2 A LO 55 31200A22BL 31 31200B22BL 12 31200C22BL 2 TEMP SENSOR
SIGNAL GROUND 39 S
ALT WARNING
J2424 P2424
OK REF D44-9224-30-01
DISCRETE IN 3 A 62 31004B22 4 31004A22
FAIL ENGINE WATER
J2410 P2410 OK
DISCRETE IN 17 A 40 77403B22 1 77403A22
4.7 k
LOW
+10V TRANSDUCER POWER 14
J2402 P2402 J2400 P2400 J2801 FUEL LEVEL LEFT
TRANSDUCER LO (GND) 11 28001A22BL 11 28001B22BL 6 28001C22BL 3 BK GROUND
+12V TRANSDUCER POWER 16 28001A22OR 16 28001B22OR 7 28001C22OR 2 RD EXCITATION
DIGITAL IN 1A 74 28001A22WH 10 28001B22WH 5 28001C22WH 1 WHT OUT HI
S 17 8
J2404 P2404 J2401 P2401 J2802 FUEL LEVEL RIGHT
28002A22BL 11 28002B22BL 26 28002C22BL 3 BK GROUND
C 28002A22OR 16 28002B22OR 27 28002C22OR 2 RD EXCITATION C
DIGITAL IN 3A 76 28002A22WH 10 28002B22WH 25 28002C22WH 1 WHT OUT HI
S START SWITCH 17 28
28V
DISCRETE IN 13 A 27 31022A22 FUEL XFER MOTOR
28V
DISCRETE IN 7 A 66 31003A22
GLOW LAMP
28V REF D44-9274-10-00
ANALOG/CURR MON IN 3A HI 48 31005A22
ANALOG/CURR MON IN 3A LO 49 74005A22N
GS-IP-14
P701
ANALOG IN 5 HI 46 31299A22WH 3A BUS VOLTS
HI ESSENTIAL BUS
ANALOG IN 5 LO 47 31299A22BL LO
S
B J7700 ALT AMPS SENSOR B
+10V TRANSDUCER POWER 14 24331A22OR 24331A22OR 1 RED V+
ANALOG IN 3 HI 42 24331A22WH 24331A22WH 2 WHT OUT HI
ANALOG IN 3 LO 43 24331A22BL 24331A22BL 3 BLK OUT LO
TRANSDUCER LO (GND) 11 S
A Diamond PROJECT DA 40 N G TITLE DWG.ORIG. DWG.NO. REV A
Aircraft
Industries GmbH
Schematic, DAI A D44-9 2 3 1 -6 0 -0 1 "C"
N. A. Otto-Straße 5
Diamond Aircraft Industries A-2700 Wiener Neustadt G1000 Wiring CODE 710197 SCALE NTS SH 04 OF 06
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
GRS77 P771 CONFIG MODULE
F AHRS 012-00605-00 F
CONFIG MODULE GROUND 1 BLK
1 GND
CONFIG MODULE POWER 17 RED
4 VCC
CONFIG MODULE DATA 16 YEL
3 DATA SAFE 128
CONFIG MODULE CLOCK 31 WHT 2 CLK PFD FAN 1P10001 NO. 1 GDU1040 PFD
FAN FAIL 2 14 FAN MONITOR VALID
P2403 J2403 21007A22 21007A22
AHRS
0.499 / 20W ESS
18 27 BUS GMA1347 P3472
34902E22 34902B22 34902A22 5A AUDIO PANEL
22 34903A22N 28 34903B22N REVERSIONARY MODE 1 36 58 REVERSIONARY MODE SEL 1
AIRCRAFT POWER 1
GS IP-5 REV MOD COMMON 1 37 31101A24WH 31101A24WH 38 AIRCRAFT GROUND
POWER GROUND 3.2
S 31101A24BL 31101A24BL S
GS AVB P2407 J2407 J2404 P2404 J2401 P2401
J441 P441 GMU44
53V MAGNETOMETER NO. 1 GIA63 W 1P603 P2413 J2413
RS 485 IN A 25 34701E24WH 7 1 34701C24WH 14 34701B24WH 31 4 RS 485 OUT A INTEGRATED AVIONICS
34701D24WH
RS 485 IN B 39 34701E24BL 8 34701D24BL 2 34701C24BL 15 34701B24BL 32 2 RS 485 OUT B ETHERNET IN B 77 31100A24WH 2 31100B24WH 3 ETHERNET OUT 1 B
34701A24WH
9 RS 485 OUT B ETHERNET IN A 76 31100A24OR 1 31100B24OR 2 ETHERNET OUT 1 A
S 3 13 36 34701A24BL 1
ETHERNET OUT B 3 31100A24GR 4 31100B24GR 5 ETHERNET IN 1 B
RS 232 OUT 2 10 34700E24WH 11 34700D24WH 4 34700C24WH 8 34700B24WH 29 8 RS 232 IN
ETHERNET OUT A 2 31100A24BL 3 31100B24BL 4 ETHERNET IN 1 A
MAGNETOMETER POWER OUT 9 34700E24OR 13 34700D24OR 6 34700C24OR 12 34700B24OR 34 9 +12VDC POWER
MAGNETOMETER GROUND 40 34700A24WH S 5 S
34700E24BL 12 34700D24BL 5 34700C24BL 9 34700B24BL 30 6 POWER GROUND
34700A24OR
S 14 7 18 35 34700A24BL 3 ESS PFD
0,5 / 25W
BUS
E 5A 31105A22 31105B22 35 AIRCRAFT POWER 1 E
31106A22N 27 POWER GROUND
59 LIGHTING BUS HI
33000B22
GS IP-9 CONFIG MODULE BLK 1
NO. 1 GIA63W 012-00605-00 CONFIG MODULE GROUND
1P603 J2407 P2407 GND 1 RED
ARINC 429 OUT 1 A 14 INTEGRATED AVIONICS REF D44-9233-10-02 23 CONFIG MODULE POWER
39 VCC 4 YEL
ARINC 429 OUT 1 B 29 14 MAIN ARINC 429 IN 6 A 22 CONFIG MODULE DATA
34904A24WH DATA 3 WHT
15 MAIN ARINC 429 IN 6 B 43 CONFIG MODULE CLOCK
34904A24BL CLK 2
RS 232 OUT 1 26 S
GDC74 P741
SIGNAL GROUND 41 56 MAIN RS 232 IN 6 AIR DATA
16 ARINC 429 IN 2 A
34905A24WH 57 SIGNAL GROUND ARINC 429 OUT 3 A 32
34905A24BL 31103A24WH 31103A24WH 17 ARINC 429 IN 2 B
RS 232 IN 1 11 58 MAIN RS 232 OUT 6 ARINC 429 OUT 3 B 33
34905A24OR 31103A24BL 31103A24BL
S S S
ARINC 429 OUT 2 A 13 34906A24WH ARINC 429 OUT 3 A 47 31102A24BL
31151A24WH 6 ETHERNET OUT 2 A
ARINC 429 OUT 2 B 28 34906A24BL ARINC 429 OUT 3 B 48 31102A24GR
31151A24BL 7 ETHERNET OUT 2 B
S S 31102A24OR 8 ETHERNET IN 2 A
RS 232 OUT 4 21 31102A24WH 9 ETHERNET IN 2 B
SIGNAL GROUND 35 34907A24OR
GRS77 P771 P2403 J2403 S
RS 232 IN 4 6 34907A24BL AHRS
34907A24WH ARINC 429 OUT 3 A 12 55 18 ARINC 429 IN 1 A
S P2403 J2403 31104A24WH 31104B24WH
ARINC 429 OUT 3 B 27 56 19 ARINC 429 IN 1 B
31104A24BL 31104B24BL
ARINC 429 IN 1 A 15 4
34908A24WH S 57 S
ARINC 429 IN 1 B 30 5
D 34908A24BL D
S 6
41 MAIN RS 232 IN 1 P2414 J2414
2P10001 NO. 2 GDU1044 MFD
42 SIGNAL GROUND
43 MAIN RS 232 OUT 1 ARINC 429 OUT 3 A 33 31152A24WH 20 31152B24WH 18 ARINC 429 IN 1 A
ARINC 429 OUT 3 B 19 31152A24BL 21 31152B24BL 19 ARINC 429 IN 1 B
GDC74 P741
S 22 S
AIR DATA
ARINC 429 OUT 1 B 42 34908B24BL 31102A24WH 7 ETHERNET OUT 2 B
ARINC 429 OUT 1 A 41 34908B24WH 31102A24OR 6 ETHERNET OUT 2 A
J2413 P2413 31102A24GR 9 ETHERNET IN 2 B
S
31102A24BL 8 ETHERNET IN 2 A
ARINC 429 OUT 1 A 26 34909B24WH 31 34909A24WH 12 MAIN ARINC 429 IN 5 A
ARINC 429 OUT 1 B 27 34909B24BL 32 34909A24BL 13 MAIN ARINC 429 IN 5 B S
33 31151A24WH 16 ARINC 429 IN 2 A
S
GMA1347 31151A24BL 17 ARINC 429 IN 2 B
P3472
P2407 J2407 J2404 P2404 AUDIO PANEL
J3122 P3122 GTP 59 S
OAT PROBE REVERSIONARY MODE 2 56 31153A24WH 31153A24WH 58 REVERSIONARY MODE SEL 1
TEMP PROBE POWER OUT 2 34 2 POWER
26 31203C24WH 31203B24WH 31203A24WH REV MOD COMMON 2 57 31153A24BL 31153A24BL 38 AIRCRAFT GROUND
TEMP PROBE IN HI 3 31203D24WH
27 31203C24BL 35 31203B24BL 3 31203A24BL SENSE
TEMP PROBE IN LO 4 31203D24BL S J2407 P2407 33002B22 S
28 31203C24OR 37 31203B24OR 1 31203A24OR LOW
31203D24OR 40 59 LIGHTING BUS HI
S 29 36 4 REF D44-9233-10-02
2P603 NO. 2 GIA63W 57 CDU ID PROG 3
INTEGRATED AVIONICS NO. 2 GIA63 W 2P603 P2414 J2414
ADC 14 MAIN ARINC 429 IN 6 A INTEGRATED AVIONICS
0,5 25W 15 2 31150A24WH 31150B24WH
ESS MAIN ARINC 429 IN 6 B ETHERNET OUT A 2 4 ETHERNET IN 1 A
C AIRCRAFT POWER 1 55 34900B22 34900A22 5A 3 31150A24OR 31150B24OR C
BUS ETHERNET OUT B 1 5 ETHERNET IN 1 B
POWER GROUND 17 GS IP-5 76 31150A24GR 31150B24GR
34901A22N ETHERNET IN A 4 2 ETHERNET OUT 1 A
77 31150A24BL 31150B24BL
56 MAIN RS 232 IN 6 ETHERNET IN B 3 3 ETHERNET OUT 1 B
57 SIGNAL GROUND S 5 S
J2403 P2403 58 MAIN RS 232 OUT 6
31156A22N 27 POWER GROUND
ARINC 429 OUT 2 A 29 34910B24WH 34910A24WH
18 12 MAIN ARINC 429 IN 5 A MFD GS IP-4
ARINC 429 OUT 2 B 30 34910B24BL 34910A24BL 0,5 25W
19 13 MAIN ARINC 429 IN 5 B MAIN
BUS 5A 31155A22 31155B22 35 AIRCRAFT POWER 1
S 20
RS 232 OUT 1 11
AIRCRAFT GROUND 12 34911B24OR 23 34911A24OR
RS 232 IN 1 10 34911B24BL 22 34911A24BL
34911B24WH 21 34911A24WH
S 24
CONFIG MODULE
BLK 012-00605-00 SAFE 128
CONFIG MODULE GROUND 1 1 GND
21 MFD FAN
40 YEL
RED FAN FAIL 2 21006A22 21006A22 14 FAN MONITOR VALID
CONFIG MODULE POWER 4 VCC
60 WHT
CONFIG MODULE DATA 3 DATA
CONFIG MODULE CLOCK 2 CLK
B B
A Diamond PROJECT DA 40 N G TITLE DWG.ORIG. DWG.NO. REV A
Aircraft
Industries GmbH
Schematic, DAI A D44-9 2 3 1 -6 0 -0 1 "C"
N. A. Otto-Straße 5
Diamond Aircraft Industries A-2700 Wiener Neustadt G1000 Wiring CODE 710197 SCALE NTS SH 05 OF 06
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
F F
GTX33
NO. 1 GIA63W MODE S XPDR
INTEGRATED AVIONICS 34590A142 OPTIONAL
1P612 P3302
XPDR ANTENNA
NO. 2 GIA63W COM ANTENNA 23290A400 COUPLER
INTEGRATED AVIONICS
1P611
2P606
GPS ANTENNA 34690B142
34410A142
OPTIONAL
1P603 REF 9900BX TAS
BECKER 34502A24WH P3301
AC 3504-(1) 34502A24BL
MAIN RS 232 IN 5 53
34502A24OR 34502A24WH 23 RS 232 OUT 1
RMI CONVERTER
REF D60-9234-50-01 MAIN RS 232 OUT 5 55 34502A24BL 22 RS 232 IN 1
P1
SIGNAL GROUND 54 34502A24OR 51 SIGNAL GROUND
ADF X / COS 10 34202A22 17 ADF COS
S P2414 J2414 S
ADF Y / COS 11 34203A22 16 ADF SIN
ADF Z (GROUND) 12 41
OPTIONAL CAN BUS 1 HI 20 77401A22WH 77401B22WH
REF D44-9274-10-00
S CAN BUS 1 LO 22 77401A22BL 42 77401B22BL
HONEYWELL S 43
KN 63 P2403 J2403 DME
E P631 DME P631 AVIONICS E
MAIN KING SERIAL DME DATA 59 6 DATA BUS A/C POWER 2 34302B22 40 34302A22 BUS 77402A22WH
34306A24 3A
A/C POWER 3 77402A22BL
MAIN KING SERIAL DME CLK 60 34307A24 F CLOCK BUS A/C GROUND 1 34303B22N 25 34303A22N S
A/C GROUND A
MAIN KING SERIAL DME REQ 62 34305A24 D DME REQUEST GS IP-2
S REF GTX 33 XPDR 12 GROUND
1P604
34304A22 K SUPPRESSION
DISCRETE IN* 12 24 21005A22 REF D44-9221-20-01
P632
11 DME ON 1P613
ANTENNA 34390A142
NAV ANTENNA 34090A400
REF KN 63 DME 34304A22 31 SUPPRESSION
1P614
OPTIONAL S
G/S ANTENNA 34091A400
BECKER 34424A22
RA 3502-(01) REF 9900BX TAS
2P603
P2 ADF RECEIVER NO. 2 GIA63W 2P614 S
REF D60-9234-50-01 INTEGRATED AVIONICS
RS 485/422 OUT A 36 34200A24WH 13 RX-A 34191A400
RS 485/422 OUT B 37 34200A24BL 14 RX-B G/S ANTENNA
2P613
D S D
27 GROUND 34190A400
NAV ANTENNA
RS 485/422 IN A 27 34201A24WH 12 TX-A 2P603 XPDR
ESS J2413 P2413
RS 485/422 IN B 28 34201A24BL 31 TX-B CAN BUS 1 TERMINATION 34 BUS
S CAN BUS 1 LO 22 77402A22BL 34500A22 34 34500B22 21 AIRCRAFT POWER 1
5A
CAN BUS 1 HI 20 77402A22WH 34501A22N 35 34501B22N 27 POWER GROUND
OPTIONAL
S
AVIDYNE GS IP-2
P3446 J3446 P2403 J2403 TAS
P1 9900BX P1 2P604
AVIONICS
22 AWG 22 RS-232 RX 3 TAS +28 VDC POWER 1 34420C22 6 34420B22 2 34420A22 3A BUS
N/C 20 RS-232 TX 3 +28 VDC POWER 2 ANNUNCIATE OUT* 14 37 34428A22 REF 9900BX TAS
21 RS-232 GROUND 3POWER GROUND 14 34421C22N 7 34421B22N 10 34421A22N DISCRETE IN* 12 24 21008A22 REF D44-9221-20-01
GS IP-1 GIA SYS ID PROGRAM 1 22
POWER GROUND 15
P3446 N/C 25 RS-232 RX 4 POWER SWITCH 16
J3446
N/C 23 RS-232 TX 4
SIGNAL GROUND 42 34422A24OR 11 34422B24OR 24 RS-232 GROUND 4 J1 2P603
P3446 J3446 34503A24WH
MAIN ARINC 429 IN 4 A 10 34422A24WH 9 34422B24WH 8 429 TX+ NO RYAN DISPLAY 15 MAIN RS 232 IN 5 53 34503A24WH 25 RS 232 OUT 2
MAIN ARINC 429 IN 4 B 11 10 9 429 TX- 34428B22 14 34428A22 REF. GIA 63W (2P604) MAIN RS 232 OUT 5 55 34503A24BL 34503A24BL 24 RS 232 IN 2
34422A24BL 34422B24BL WEIGHT ON WHEELS 14
S 12 SIGNAL GROUND 54 34503A24OR 34503A24OR 58 SIGNAL GROUND
S S
34423A24OR 17 34423B24OR
C 10 429 RX 1+ TOP ANTENNA 2P612
C
MAIN ARINC 429 OUT 1 A 71 34423A24WH 15 34423B24WH
MAIN ARINC 429 OUT 1 B 70 34423A24BL 16 34423B24BL 11 429 RX 1- COM ANTENNA
S 18 J1 34411B142 ATT. 1dB 34411A142
2P611 23390A400
34424A22 4 34424B22 7 SUPPRESSION 34413B142 ATT. 1dB BOTTOM ANTENNA GPS ANTENNA
J3 34413A142
2P604 REF GTX 33 XPDR 5 2.2k , OPTIONAL
0.25W 34691B142 GOODRICH WX-500
J2 34412B142 ATT. 1dB 34412A142 J2403 P2403
ANNUNCIATE* 15 38 34425A22 8 34425B22 5 REMOTE MUTE Wx 500
34414B142 AVIONICS 3A 31
J4 ATT. 1dB 34414A142 AIRCRAFT POWER STORMSCOPE
22 AWG 19 RS-232 RX 2 34400B20WH 32 34400A20WH 1 J1
J2 J3441
BUS
34400B20BL 34400A20BL 5 AIRCRAFT GROUND
N/C17 RS-232 TX 2 COUPLER 34410A142 REF GTX 33 XPDR (COUPLER) 34402A20N 33
X LOOP 3 ORANGE C
NO. 1 GIA63 18 RS-232 GROUND 2
34426A22
INTEGRATED AVIONICS 1P604 GS IP-3 +12V 16 RED D
2P603 J3 SENSE 17 BROWN B
ANNUNCIATE* 15 38 MAIN RS 232 IN 3 47 34404A24WH 20 RS 232 TX ANT REF 2 BLACK J
MAIN RS 232 OUT 3 49 34404A24BL 8 RS 232 RX -12V 15 YELLOW F
SIGNAL GROUND 48 34404A24OR 3 TOP ANT. Y LOOP 4 GREEN G
ANT TEST 14 BLUE H
S
ANT COM 1 DRAIN A
3 J2
CR 900
J2403 P2403 6 CONFIG GROUND
B 34412A22 5 RS 232 GROUND B
REF SHEET 3 34411B22 34 34411A22 22 INHIBIT
34413A22
A Diamond PROJECT DA 40 N G TITLE DWG.ORIG. DWG.NO. REV A
Aircraft
Industries GmbH
Schematic, DAI A D44-9 2 3 1 -6 0 -0 1 "C"
N. A. Otto-Straße 5
Diamond Aircraft Industries A-2700 Wiener Neustadt G1000 Wiring CODE 710197 SCALE NTS SH 06 OF 06
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
VÄM 40-004
"-" 01 ALL 28.01.10 SEE TB
FIRST RELEASE
F F
ESS BUS
REF.
D44-9225-60-01
FLOOD
ON
FLOOD 33204B22
E OFF DIMMING E
3A 33204A22
CONTROL
2.5k
J3305 P3305
33207A22 1 RED SWITCHED D.C. IN
33208A22N 2 BLK GROUND
EMERGENCY POWER GS-IP-16
SWITCH
33211A22 5 YL ADJ
33212A22 6 YL ADJ
33210A22 4 WH LAMP
D D
33209A22 3 WH LAMP
J3307
1 2
P3307
C C
ELECTROLUMINESCENCE
LAMP
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN K owarsch 28.01.10 TITLE
A3
N ON E CHECKED: K owarsch
Schematic,
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Flood Light Wiring
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 3 -1 0 -0 1 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9233-10-01.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
VÄM 40-004
"-" 01 ALL 28.01.10 SEE TB
FIRST RELEASE
F F
TERMINAL BLOCK J3337
COMPASS
33001A22 1
33003A22N 2
33050A22 1
GS-IP-17
V IN J2407 P2407
V OUT 2 33000A22 39 REF D44-9231-60-01
E REGULATOR 33002A22 40 REF D44-9231-60-01
E
LM 138K 300
3 33004A22 41 REF D44-9231-60-01
INSTRUMENT V ADJ 4
MAIN BUS OFF
33051A22 5
ON 33026A22 REF D44-9227-50-01
33049A22
INST LT. 5k
D D
3A 33048A22
33020A22N
DIMMING
STANDBY CIRCUIT SWITCH LH
CONTROL INSTRUMENTS BREAKER
GS-IP-17 5k
J3306 P3306 J3333 J3330 J3336
2 1 1 2 2 1
33047A22 1 RED SWITCHED D.C. IN
33042A22N 2 BLK GROUND
GS-IP-17 33058A22 33055A22
33059A22 33054A22
33021A22 5 YL ADJ
C C
33022A22 6 YL ADJ
SWITCH SWITCH TOP SWITCH RH
4 WH LAMP BOTTOM
33057A22
33044A22
33043A22
33056A22 3 WH LAMP J3334 J3331 J3332
1 2 2 1 1 2
33056A22 33046A22 33052A22
33057A22 33045A22 33053A22
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN K owarsch 28.01.10 TITLE
A3
N ON E CHECKED: K owarsch
Schematic, Instrument
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Lights & Plac ards
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 3 -1 0 -0 2 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9233-10-02.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
OÄM 40-321
- 01 ALL 21.10.10 SEE TB
FIRST RELEASE
F F
ESS BUS
FLOOD FLOOD
3A 33204A22
E
DIMMING E
CONTROL
5k J3305 P3305
33207A22 1 RED SWITCHED D.C. IN
33208A22N 2 BLK GROUND
GS-IP-6
33211A22 5 YL ADJ
33212A22 6 YL ADJ
D 33210A22 4 WH LAMP D
33209A22 3 WH LAMP
J3307
1 2
P3307 L1
C C
ELECTROLUMINESCENCE
LAMP
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DP-S-17-00001 - DEPARTMENT SIGN DATE PROJECT DA 40 N G
FIRST ANGLE PROJECTION FORMAT
CLASSIFICATION: - DRAWN Schättler 21.10.10 TITLE
A3
N ON E CHECKED: K owarsch
Schematic, Instrument
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Flood Light Wiring
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 3 -1 0 -0 3 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9233-10-03.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
OÄM 40-321
- 01 ALL 26.01.11 SEE TB
FIRST RELEASE
F F
DIMMING MODULE
J3100 J3309 J3309
IDC 22 33051A22 33051A22 2
J3308
1 33038A22 33038A22 13
COMPASS
2 33039A22N 1 33032A22
GS-IP-2 ALT 33032A22 12
E 1 J2407 E
2 33035A22N INST 4
GS-IP-15
33048A22
21 33014A22 6
J3300 5
AVIONICS EQUIPMENT
MAIN BUS 9 33013A22 7
J3304 5A 6
1 33031A22 33031A22 11
T&B
2 33036A22N
33026A22 1
GS-IP-17
J3490 24 J3330
D 33027A22 33027A22 18 15 33015A22 1
D44-9234-10-04 HOR MED
A 34904A22N 33042A22N 2
REF. 33025A22 17
GS-IP-13
33024A22 16
GS-IP-4
D 33028A22 23 D
J3302 J3303
J3331
1 33025A22 1 33024A22 33040A22 19
ALT 33045A22 1
ASI SED
2 33034A22N 2 2 33033A22N 33030A22 10
33046A22N 2
GS-IP-16
GS-IP-3
33049A22 20
GS-IP-3
33021A22 8
J2701
33022A22 14
9 33026A22
D44-9227-50-02 FLAP
7
REF.
J3301
33020A22N
1 33028A22
C VSI GS-IP-12
C
2 33037A22N
GS-IP-10 INSTRUMENT
33022A22
J3491 33021A22
D 33040A22 R5
D44-9234-10-02
DG
REF. B 33041A22N
GS-IP-10
33049A22
5K
J3121
CLOCK 8 33030A22
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DP-S-17-00001 - DEPARTMENT SIGN DATE PROJECT DA 40 N G
FIRST ANGLE PROJECTION FORMAT
CLASSIFICATION: - DRAWN Schättler 26.01.11 TITLE
A3
N ON E CHECKED: K owarsch
Schematic, Instrument
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Panel Light Wiring
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 3 -1 0 -0 5 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9233-10-05.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
VÄM 40-004
"-" 01 ALL 28.01.10 SEE TB
FIRST RELEASE
F F
E E
INSTRUMENT PANEL RIGHT FUSELAGE
MAIN BUS
TAXI / MAP J2404 P2404
PILOT MAP LIGHT
33115A20 REF D44-9233-40-01 J3320 P3320
33200A22 23 33200B22 1
5A
33201A22N 24 33201B22N 2
GS-IP-12 CO-PILOT MAP LIGHT
J3321 P3321
D 33202A22 25 33202B22 1 D
33203A22N 26 33203B22N 2
PASSENGER READING LIGHT
GS-IP-13
C C
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN K owarsch 28.01.10 TITLE
A3
N ON E CHECKED: K owarsch
Schematic, Map/Reading
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Light Wiring
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 3 -2 0 -0 1 -
ANGLE u1° MICRO-
RAD u0,5 METER D44-9233-20-01.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
OÄM 40-316
"-" 01 ALL 03.09.10 SEE TB
FIRST RELEASE
F F
E E
INSTRUMENT PANEL RIGHT FUSELAGE
MAIN BUS
TAXI / MAP J2404 P2404
PILOT MAP LIGHT
33115A20 REF D44-9233-40-01 J3320 P3320
33200A22 23 33200B22 1
5A
33201A22N 24 33201B22N 2
GS-IP-12 PASSENGER READING LIGHT
J3321 P3321
D 33202A22 25 33202B22 1 D
33203A22N 26 33203B22N 2
GS-IP-13
C C
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN K owarsch 03.09.10 TITLE
A3
N ON E CHECKED: K owarsch
Schematic, Map/Reading
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Light Wiring, RACC
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 3 -2 0 -0 1 x 0 1 -
ANGLE u1° MICRO-
RAD u0,5 METER D44-9233-20-01x01.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
VÄM 40-004
- 01 ALL 28.01.10 SEE TB
FIRST RELEASE
F F
L/H WING LEFT FUSELAGE INSTRUMENT PANEL RIGHT FUSELAGE
NAV LIGHT ASSY 33113A20 5 STROBE
P3312
P2400 J2400 P2402 J2402 STROBE J2404 P2404
STROBE LIGHT
RED 1 1 33104C20WH 1 33104B20WH 33104B20WH 1 33104A20WH 33109A20WH 1 33109B20WH
POWER
BLACK 2 2 33104C20BL 2 33104B20BL 33104B20BL 2 33104A20BL 33109A20BL 2 33109B20BL
SUPPLY
WHITE 3 3 33104C20OR 3 33104B20OR 33104B20OR 3 3 33109B20OR
GS-IP-19
E 4 4 4
E
GS-IP-19
NAV LIGHT
P3313 J3313 33117A20
RED bl
rd 1 33100C20 28 33100B20
bl 33100B20 6 33100A20 33114A20 5 POSITION
WHITE 2 33101C20N 33 33101B20N
bk POSITION
33101B20N 7 33101A20N 33102B20
33102A20 6
33102A20 33103A20N 7 33103B20N
GS-IP-17
GS-IP-16
P3316 J3316 33115A20 5 TAXI
TAXI
TAXI 1 33107C20 21 33107B20 33107B20 36 33107A20
2 33108C20N 22 33108B20N 33108B20N 35 33108A20N 33108A20N
D LANDING GS-IP-11 D
1 33105C20 17 33105B20 33105B20 30 33105A20
2 33106C20N 16 33106B20N 33106B20N 29 33106A20N 33116A20 5 LANDING
LANDING
P3317 J3317
33106A20N
GS-IP-11
R/H WING
NAV LIGHT ASSY
NAV LIGHT P2401 J2401
J3315
WHITE bl
2 33103C20N 7 33103B20N
bk
bl
1 33102C20 6 33102B20
GREEN rd
C C
STROBE LIGHT P3314
WHITE 3 3 33109C20OR 3 33109B20OR
POWER
BLACK 2 2 33109C20BL 2 33109B20BL
SUPPLY
RED 1 1 33109C20WH 1 33109B20WH
4
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT DA 40 N G
FIRST ANGLE PROJECTION FORMAT
CLASSIFICATION: - DRAWN K owarsch 28.01.10 TITLE
A3
N ON E CHECKED: K owarsch
Schematic, Exterior Lights
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A
DIMENSIONS ARE IN MM
Wiring
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 3 -4 0 -0 1 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9233-40-01.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
OÄM 40-341
- 01 ALL 04.10.11 SEE TB
FIRST RELEASE
F F
L/H WING LEFT FUSELAGE INSTRUMENT PANEL RIGHT FUSELAGE
NAV LIGHT ASSY 33113A20 5 STROBE
P3312 P2400 J2400 P2402 J2402 STROBE J2404 P2404
STROBE LIGHT
RED 1 1 33104C20WH 1 33104B20WH 1 33104A20WH 33109A20WH 1 33109B20WH
POWER
BLACK 2 2 33104C20BL 2 33104B20BL 2 33104A20BL 33109A20BL 2 33109B20BL
SUPPLY
E WHITE 3 3 33104C20OR 3 33104B20OR 3 3 33109B20OR
E
GS-IP-19
4 4 4
GS-IP-19
NAV LIGHT
33117A20
P3313
J3313
RED
WHITE 1 33100C20 28 33100B20 6 33100A20 33114A20 5 POSITION
POSITION
BLACK 2 33101C20N 33 33101B20N 7 33101A20N 33102B20
33102A20 6
WHITE
33102A20 33103A20N 7 33103B20N
GS-IP-17 GS-IP-16
P3316 J3316 33115A20 5 TAXI
TAXI
1 33107C20 21 33107B20 36 33107A20
TAXI
2 33108C20N 22 33108B20N 35 33108A20N 33108A20N
D D
1 33105C20 17 33105B20 30 33105A20 GS-IP-11
LANDING
2 33106C20N 16 33106B20N 29 33106A20N 33116A20 5 LANDING
LANDING
P3317 J3317
33106A20N
GS-IP-11
R/H WING
NAV LIGHT ASSY
NAV LIGHT
P2401 J2401
P3315 J3315
GREEN
BLACK 2 33103C20N 7 33103B20N
WHITE 1 33102C20 6 33102B20
WHITE
C C
STROBE LIGHT P3314
WHITE 3 3 33109C20OR 3 33109B20OR
POWER
BLACK 2 2 33109C20BL 2 33109B20BL
SUPPLY
RED 1 1 33109C20WH 1 33109B20WH
4
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DP-S-17-00001 - DEPARTMENT SIGN DATE PROJECT DA 40 N G
FIRST ANGLE PROJECTION FORMAT
CLASSIFICATION: - DRAWN K owarsch 04.10.11 TITLE
A3
N ON E CHECKED: K owarsch
Schematic, Exterior Lights
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A
DIMENSIONS ARE IN MM
Wiring
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 3 -4 0 -0 1 x 0 2 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9233-40-01x02.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
VÄM 40-004
"-" 01 ALL 27.01.10 SEE TB
FIRST RELEASE
F F
E E
REF.
D44-9225-60-01
ESS BUS EMERGENCY SWITCH
J3490
ON
HORIZON 34903B22 C BACKUP
D
D OFF ARTIFICIAL D
3A 34903A22 34904A22N A
GS-IP-6 B HORIZON
C C
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN K owarsch 27.01.10 TITLE
A3
N ON E CHECKED: K owarsch
Schematic, Art ificial
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Horizon Wiring
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 4 -1 0 -0 1 -
ANGLE u1° MICRO-
RAD u0,5 METER D44-9234-10-01.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
OÄM 40-321
"-" 01 ALL 15.11.10 SEE TB
FIRST RELEASE
F F
E E
MAIN
BUS
D44-9233-10-05
REF. J3491
D DG D
33040A22 D
34900A22 34900A22 C DIRECTIONAL
3A
34901A22N A GYRO
33041A22N B
GS-IP-14
GS-IP-10
C C
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN Schättler 15.11.10 TITLE
A3
N ON E CHECKED: K owarsch
Schematic,
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Direct ional Gyro
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 4 -1 0 -0 2 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9234-10-02.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
OÄM 40-321
"-" 01 ALL 15.11.10 SEE TB
FIRST RELEASE
F F
E E
MAIN
BUS
J3492
T&B
D D
3A 34906A22 34906A22 A T&B
34905A22N B GYRO
GS-IP-15 C
C C
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN Schättler 15.11.10 TITLE
A3
N ON E CHECKED: K owarsch
Schematic, Turn & Bank
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 4 -1 0 -0 3 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9234-10-03.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
OÄM 40-321
"-" 01 ALL 22.11.10 SEE TB
FIRST RELEASE
F F
E E
ESS BUS
HORIZON
J3490
3A 34903A22 34903A22 C
D REF. D44-9233-10-05 33027A22 D ARTIFICIAL D
34904A22N A
B
HORIZON
GS-IP-13
C C
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN Schättler 22.11.10 TITLE
A3
N ON E CHECKED: K owarsch
Schematic,
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Art ificial Horizon
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 4 -1 0 -0 4 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9234-10-04.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
FIRST RELEASE
"d1" 01 ALL 06.06.08 SEE TB
F OÄM 40-313 F
- 01 ALL 06.04.10 SEE TB
updated TB format
BECKER
RA 3502-(01)
ADF RECEIVER P2 P2403 J2403 ADF
AVIONICS
SUPP. VOLT. +28VDC 18 34204B22 35 2A BUS
34204A22
SUPP. VOLT. +28VDC 36 34205B22N 26
34205A22N
GROUND 4
GS IP-2
AUDIO OUT HI 2 34206B24WH
AUDIO OUT LO 3 34206B24BL
RX-A 13 34200A24WH
RX-B 14 34200A24BL REF D44-9231-60-01
TX-A 12 34201A24WH
TX-B 31 34201A24BL BECKER
E AN 3500 E
GROUND 27 P1 ADF ANTENNA
ON 11 G OP. VOLT. +18VDC
OP. VOLT. +18VDC 1 34207A22 34207A22 H OP. VOLT. +18VDC
GROUND 23 34208A22 34208A22 K GROUND
+ADF 16 34209A22 34209A22 C +ADF
+18V 20 34210A22
C-CONTROL 34 34211A22
SUPP. VOLT. +28VDC SWITCHED 37 34212A22
/AUDIO NAV 32 34213A24WH A 50 HZ
34215A24WH
AUDIO NAV 33 34213A24BL B 100 HZ
34215A24BL
J MOD GROUND
GROUND 29 34214A22N
J9
ANTENNA 34290A142 34290A142 E RF HI
F RF GND
D D
BECKER
AC 3504-(1)
RMI CONVERTER P1
SUPP. VOLT. +28VDC 11 34204C22
SUPP. VOLT. +28VDC 24
GROUND 21 34214A22N
AUDIO NAV 3 34213A24BL
/AUDIO NAV 4 34213A24WH
SUPP. VOLT. +28VDC SWITCHED 12 34212A22
C-CONTROL 10 34211A22
+18V 6 34210A22
+ADF 5 34209B22
C /50 HZ 8 34215A24WH C
34215A24BL
100 HZ 9
GROUND 20
ADF SIN 16 34203A22
ADF COS 17 34202A22 REF D44-9231-60-01
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 40 N G
CLASSIFICATION: - DRAWN K owarsch 06.04.10 TITLE
A3
N ON E CHECKED: K owarsch
Schematic, ADF Wiring
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 4 -5 0 -0 1 -
ANGLE u1° MICRO-
RAD u0,5 METER D44-9234-50-01.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
OÄM 40-321
- 01 ALL 10.01.11 SEE TB
FIRST RELEASE
F F
ENCODER
GTX 328 SAE5-35
P3281 J3454A
RS 232 IN 2 24 34517A24 34517A24 2 RS 232 OUT 2
6 SHIELD DRAIN
PM 1000
J1
AUDIO OUT HI 15 34540A24WH 17 A/C RADIO AUDIO HI
E J3454B E
AUDIO OUT LO 16 4 A/C RADIO AUDIO LO
34514A22 8 +28VDC A/C POWER
6 STROBE
34515A22N 15 A/C GROUND
P2407 J2407
AV MASTER ON SEL 1 34515A22N 33 34515B22N
34514A22 31 34514B22 XPDR
A/C POWER 1 21
GS-IP-5
A/C POWER 1 42 34513A18 34513A18 30 34513B18 5A AV BUS
D A/C GROUND 27 34500A18N 34500A18N 32 34500B18N D
GS-IP-3
A/C GROUND 43
33014B22 6 REF.
28VDC LIGHTING 14 33014B22
D44-9233-10-05
P3282 J3452 P3452 P3453
XPDR ANT. XPDR
34590A142 34590B142 ANTENNA
C C
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DP-S-17-00001 - DEPARTMENT SIGN DATE PROJECT DA 40 N G
FIRST ANGLE PROJECTION FORMAT
CLASSIFICATION: - DRAWN Schättler 10.01.11 TITLE
A3
N ON E CHECKED: K owarsch
Schematic, GT X328
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 4 -5 0 -0 2 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9234-50-02.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
OÄM 40-321
- 01 ALL 09.03.11 SEE TB
FIRST RELEASE
F F
E E
AVIONIC
BUS
GPS
P2407
5A 34622A22 14 34622B22 GARMIN
D 34621A22N 13 34621B22N D
GPSMAP 696
GS-IP
C C
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DP-S-17-00001 - DEPARTMENT SIGN DATE PROJECT DA 40 N G
FIRST ANGLE PROJECTION FORMAT
CLASSIFICATION: - DRAWN Schättler 09.03.11 TITLE
A3
N ON E CHECKED: K owarsch
Schematic,
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A GPSMAP Wiring
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 3 4 -5 0 -0 8 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9234-50-08.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
OÄM 40-321
- ALL ALL 21.10.10 SEE TB
FIRST RELEASE
OÄM 40-321
A ALL ALL GS-IP-20, GS-IP-21 and Wire 24020B20, 17.01.11 SEE TB
31030A22 added.
F F
FUSELAGE INSTRUMENT PANEL ENGINE HARNESS
J7701
CPC 1
1 77405B22OR 1 77405A22OR 1 A Sensor 1 Supply
POWER 4 77405B22WH 4 77405A22WH 5 A Sensor 1 Signal
LEVER 2 77405B22BL 2 77405A22BL 6 A Sensor 1 GND
SENSOR 6 77410B22OR 6 77410A22OR 2 A Sensor 2 Supply
ECU A 3 77410B22WH 3 77410A22WH 4 A Sensor 2 Signal
5 77410B22BL 5 77410A22BL 3 A Sensor 2 GND
GS-IP-21
GS-IP-20
E E
32001A22 30 A/C on Ground(WOW)
ENGINE 20 A/C on Ground(WOW)
32002A22N
COMPARTMENT
GS-IP-7 22 AWG
9
8
VOTER 7
EECU 12
TEST 11
24321A22WH 13 Selftest Signal
10
24321A22BL 14 Selftest GND
D 74016A22N 32 GPC Caution Lamp D
4.7k
GS-IP-18
ENGINE MASTER
OFF
ON
5A 24302A20 24302A20 24303A22 11 Engine Master
E 24304A22 12 Engine Master
E EECU 31
74015A22 Glow Enable
C A
24362A20 17 ECU A Power Supply
U
24350A10 20 24300A14 24363A20 18 ECU A Power Supply
B 24364A20 19 ECU A Power Supply
U 24310A20N 24310A20N 21 GND
S 24311A20N 24311A20N 22 GND
C 24312A20N 24312A20N 23 GND C
GS-IP-12 24313A20N 24313A20N 24 GND
GS-IP-14
TB1 74011A16 25 GPC Power Supply
REF D44-9224-30-02 74000A10 1 74012A16 26 GPC Power Supply
74013A16 27 GPC Power Supply
4.7k 2 74014A16 28 GPC Power Supply
74017A22N
REF D44-9231-50-01 31005A22 29 Advisory Lamp
GS-IP-18
REF 77401A22BL 7 Display CAN Low
D44-9277-40-01 77401A22WH 8 Display CAN High
B DIAGNOSTIC B
2 77404A22BL
7 77404A22WH
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRIC Airc raft Diamond Aircraft Industries A-2700 Wiener Neustadt
Indust ries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT DA 40 N G
FIRST ANGLE PROJECTION FORMAT
CLASSIFICATION: - DRAWN Schät tler 17.01.11 TITLE
A2
N ON E CHECKED: K owarsch
A
Schem atic, A
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A EECU Wiring
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
2 DECIMAL u0,25
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAIA D44-9274-10-01 A
ANGLE u1° MICRO-
RAD u0,5 METER D44-9274-10-01a.dft APPROVED: TL CODE 710197 SCALE NTS SH 01 OF 02
8 7 6 5 4 3 2 1 Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
Confidential 8 7 6 5 4 3 2 1
F F
FUSELAGE INSTRUMENT PANEL ENGINE HARNESS
FUEL J7701
PUMP B CPC 2
J2811 1 77406B22OR 8 77406A22OR 7 B Sensor 1 Supply
28019B20N 2 28019C20N POWER 4 77406B22WH 12 77406A22WH 11 B Sensor 1 Signal
LEVER 2 77406B22BL 9 77406A22BL 12 B Sensor 1 GND
28013B20 1 28013C20 SENSOR 6 77407B22OR 14 77407A22OR 8 B Sensor 2 Supply
ECU B 3 77407B22WH 10 77407A22WH 10 B Sensor 2 Signal
FUEL
PUMP A 5 77407B22BL 13 77407A22BL 9 B Sensor 2 GND
E J2810 22 AWG E
28018B20N 2 28018C20N 3
2 GS-IP-21
28012B20 1 28012C20 GS-IP-20
1
24325A22 15 Voter ECU A
6
5 16
24324A22 Voter ECU B
24322A22 13 Voter Control OUT
FUEL PUMP A 4
24323A22 14 Voter Control IN
RELAY FUEL
ENGINE MASTER VOTER
87A PUMP A SCHOTTKY
J2409 RECTIFIER OFF
30 31030A22 REF D44-9231-50-01
29 28012A20 28010A20 7.5 E
87
E 10A 24320A20 24320B20 24019B20 REF D44-9224-30-02
30 28018A20N C ON
85 86 U REF D44-9224-30-02 24021A20 1A REF D44-9231-20-02
D D
GS-IP-20 B
U
S REF D44-9224-30-02
24328A22
FUEL PUMP B E 5A 24307A20 24307A20 24308A22 17 Engine Master
RELAY FUEL E
24309A22 18 Engine Master
87A PUMP B C
EECU
30
U B
31 28013A20 28011A20 7.5 24367A20 23 ECU B Power Supply
87
B 20 24305A14 24368A20 24 ECU B Power Supply
32 28019A20N 24369A20 25 ECU B Power Supply
85 86 B
24314A20N 24314A20N 27 ECU B GND
U
24315A20N 24315A20N 28 ECU B GND
GS-IP-21 S
C 24316A20N 24316A20N 29 ECU B GND C
GS-IP-15 24317A20N 24317A20N 30 ECU B GND
GS-IP-17
28015A22 28015A22 3 Fuel Pump B
28014A22 28014A22 2 Fuel Pump A
OFF
ON
28017A22 28010A22N
FUEL PUMPS
B 28016A22 B
GS-IP-16
A A
Diamond PROJECT DA 40 N G TITLE DWG.ORIG. DWG.NO. REV
Airc raft
Indust ries GmbH
Schem atic, DAIA D44-9274-10-01 A
N. A. Otto-Straße 5
Diamond Aircraft Industries A-2700 Wiener Neustadt EECU Wiring CODE 710197 SCALE NTS SH 02 OF 02
8 7 6 5 4 3 2 1 Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
Confidential 8 7 6 5 4 3 2 1
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
AE OÄM 40-321
- 01 ALL 26.01.11 SEE TB
MED FIRST RELEASE
F MED INST. 1 F
5
VBATT +24V 15 31111A20
CAN HIGH 7 77401A22WH
REF D44-9274-10-01 IDC
CAN LOW 6 77401A22BL
CONFIRM/TEST SWITCH 10 31028A22 P3100
MASTER CAUTION OUT 14 31026A22
GROUND 1 31112A20N 31028A22 23 ACKNOWLEDGE OUT
GS-IP-05 31026A22 12 ENGINE
E E
AE
SED
31026B22
31028B22
31111B20
31112B20N
77401B22BL
77401B22WH
SED
GROUND 1
MASTER CAUTION OUT 14
CONFIRM/TEST SWITCH 10
CAN LOW 6
CAN HIGH 7
J2402 P2402 J2400 P2400
VBATT +24V 15
25 25
D D
FUEL TEMP LH 9 31300A22WH 23 31300B22WH 23 31300C22WH 1 FUEL TEMP
31300A22BL 24 31300B22BL 24 31300C22BL 2 SENSOR LH
17 8 J2801
SUPPLY FQ LH 13 28001A22OR 16 28001B22OR 7 28001C22OR 2 ORANGE
FUEL QTY
28001A22BL 11 28001B22BL 6 28001C22BL 3 BLUE SENSOR LH
FUEL QTY LH 28001A22WH 10 28001B22WH 5 28001C22WH WHITE
3 1
J2404 P2404 J2401 P2401
29 13
FUEL TEMP RH
8 31200A22WH 30 31200B22WH 11 31200C22WH 1 FUEL TEMP
31200A22BL 31 31200B22BL 12 31200C22BL 2 SENSOR RH
J2802
17 28
C SUPPLY FQ RH 12 28002A22OR 16 28002B22OR 27 28002C22OR 2 ORANGE
C
FUEL QTY
28002A22BL 11 28002B22BL 26 28002C22BL 3 BLUE SENSOR RH
FUEL QTY RH 2 28002A22WH 10 28002B22WH 25 28002C22WH 1 WHITE
J2410 P2410 J7700 P7700
SUPPLY CURRENT SENSE 11 6
24331A22OR 24331B22OR 1 RED
CURRENT
CURRENT SENSE 5 24331A22WH 7 24331B22WH 2 YELLOW SENSOR
24331A22BL 8 24331B22BL 3 BLUE
9
LOW COOLANT 4 77403B22 1 77403A22
COOLANT LEVEL SWITCH
B B
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
DP-S-17-00001 - DEPARTMENT SIGN DATE PROJECT DA 40 N G
FIRST ANGLE PROJECTION FORMAT
CLASSIFICATION: - DRAWN Schättler 26.01.11 TITLE
A3
N ON E CHECKED: K owarsch
Schematic,
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Engine Indic ating
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
A 2 DECIMAL u0,25 A
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D44-9 2 7 7 -4 0 -0 1 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D44-9277-40-01.dft APPROVED: TL CODE SCALE SH
710197 NTS 01OF 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
You might also like
- KA B200 - B200GT - 250 PL21 Pilot Training Manual100% (7)KA B200 - B200GT - 250 PL21 Pilot Training Manual490 pages
- Gulfstream G500/G550 Maintenance Training Manual: Flightsafety100% (11)Gulfstream G500/G550 Maintenance Training Manual: Flightsafety859 pages
- Pro Line Fusion For King Air Operator Guide - 5230820001 2100% (10)Pro Line Fusion For King Air Operator Guide - 5230820001 2350 pages
- Beech 1900 Airliner Maintenance Training Manual V.I PDF100% (5)Beech 1900 Airliner Maintenance Training Manual V.I PDF505 pages
- KING-AIR-350-Ch 16 - Avionics - CH 1 - Aircraft General100% (8)KING-AIR-350-Ch 16 - Avionics - CH 1 - Aircraft General49 pages
- Gulfstream g150 Pilot Training Manual Volume 2 Aircraft Syst PDF100% (3)Gulfstream g150 Pilot Training Manual Volume 2 Aircraft Syst PDF474 pages
- Preflight Inspection Hawker 800XP AircraftNo ratings yetPreflight Inspection Hawker 800XP Aircraft9 pages
- 190 01499 02 GTX3x5 - Installation - Manual PDFNo ratings yet190 01499 02 GTX3x5 - Installation - Manual PDF67 pages
- Newbie's Guide To DA40 NG: Malmin Ilmailukerho RyNo ratings yetNewbie's Guide To DA40 NG: Malmin Ilmailukerho Ry15 pages
- EASA TCDS R.008 - Eurocopter - AS350 EC130 06 25052012100% (1)EASA TCDS R.008 - Eurocopter - AS350 EC130 06 2505201242 pages
- Bonanza G36 Specification and Description E-4063 Thru E-4080100% (1)Bonanza G36 Specification and Description E-4063 Thru E-408020 pages
- Garmin Bell 407gx W Sys SW 1237 03 Cockpit Reference Guide 720924100% (2)Garmin Bell 407gx W Sys SW 1237 03 Cockpit Reference Guide 720924158 pages
- Oral and Practical Review: Reflections on the Part 147 CourseFrom EverandOral and Practical Review: Reflections on the Part 147 CourseNo ratings yet
- Air Crash Investigations - Aloha Airlines Flight 243 - Explosive Decompression in FlightFrom EverandAir Crash Investigations - Aloha Airlines Flight 243 - Explosive Decompression in Flight1.5/5 (2)
- Missed Approach to Death: A Missed Approach Aborted, and Where It LeadsFrom EverandMissed Approach to Death: A Missed Approach Aborted, and Where It LeadsNo ratings yet
- Xxi 3 Learjet H51 LJ45 Om DDG R8 11oct2008100% (1)Xxi 3 Learjet H51 LJ45 Om DDG R8 11oct2008275 pages
- GSE & Tools: Optimising Your MaintenanceNo ratings yetGSE & Tools: Optimising Your Maintenance32 pages
- Airbus PMS 01-02-02 - Cadmium Plating of Steels100% (1)Airbus PMS 01-02-02 - Cadmium Plating of Steels31 pages
- Staff Studies SC & SC Phase - I SQN LDR Iqbal NadeemNo ratings yetStaff Studies SC & SC Phase - I SQN LDR Iqbal Nadeem20 pages
- Gilberto Mendoza - Final Thesis - 071716 PDFNo ratings yetGilberto Mendoza - Final Thesis - 071716 PDF114 pages
- BOEING 737-700 - SKYbrary Aviation SafetyNo ratings yetBOEING 737-700 - SKYbrary Aviation Safety3 pages
- Aircraft Design Project - 280 Seat Transport75% (4)Aircraft Design Project - 280 Seat Transport108 pages
