Diamond Aircraft DA 40 Series User manual

AIRCRAFT
DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
AIRCRAFT MAINTENANCE MANUAL
TEMPORARY REVISION
AMM-TR-MÄM 40-1037
This temporary revision is approved in conjunction with the Mandatory Design Change Advisory MÄM 40-
1037 and is valid in conjunction with the Airplane Maintenance Manual (AMM) until this temporary revision
has been incorporated into the AMM.
The limitations and information contained herein either supplement, or in the case of conflict, override those
in the AMM.
The technical information contained in this document has been approved.
Doc. No. Section Affected Pages
6.02.01
05-28-50 3 to 8
05-50-00 9 to 14
32-20-00 15 to 18
Doc # 6.02.01
AMM-TR-MÄM 40-1037 COVER Page 1 13 Jul 2020

AIRCRAFT
DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
FILING INSTRUCTIONS
Print this temporary revision single sided on 8.5 x 11 inch yellow paper.
Insert the COVER pages as the first pages of the AMM.
Insert the pages of this temporary revision as indicated in the table below.
Record the incorporation of this temporary revision on the yellow RECORD OF REVISIONS sheet at
the front of the AMM.
Keep this temporary revision until the information has been incorporated into the DA 40 AMM.
Pages of this TR Insert in front of the following pages in the basic AMM
Section Pages
1, 2 Cover page
3 to 8 05-28-50 Corresponding pages in 05-28-50
starting on page 1.
9 to 14 05-50-00 Corresponding pages in 05-50-00
starting on page 1.
15, 16 32-20-00 209
17, 18 32-20-00 Before Section 32-40-00.
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AIRCRAFT
DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
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.
1. Front Fuselage
100 hr items marked X* apply to US registered airplanes only
Inspection Items 100 200 1000 2000 Time Initials
1. Examine the complete surface of the front fuselage.
Look specially for damage (dents, cracks, holes and
delamination).
Examine the paint coat.
X X X X
2. Examine these NACA air inlets for blockage:
One in the left stub wing.
Two in the forward fuselage, LH and RH (optional,
OÄM 40-099).
X X X X
3. Examine the canopy.
Make sure the canopy lock mechanism operates
correctly. (Refer to Section 52-10).
Examine the acrylic glass window for damage. Look
specially for cracks.
Examine the bonding between the window and the
canopy frame. (Refer to Section 56-10).
Examine the emergency windows and their hinges
for damage.
Examine the 'pop out' windows and their hinges for
damage, if installed. Check hinges for improper
friction, correct if necessary.
X* X X X
4. Do a function test of the door unlocked warning light
system. (Refer to Section 52-10).
X X X X
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AIRCRAFT
DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
100 hr items marked X* apply to US registered airplanes only
Inspection Items 100 200 1000 2000 Time Initials
5. Examine the safety hook mechanism. (Refer to Section
52-10).
X X X X
6. Examine the carbon hinges for cracks. (Refer to
Section 52-10).
X X X X
7. Examine the rear passenger door:
Make sure the door lock mechanism operates
correctly. (Refer to Section 52-10).
If MÄM 40-139 is installed: Do a test of the
compression gas spring of the passenger door
handle. (Refer to Section 52-10).
Examine the acrylic glass window for damage. Look
specially for cracks.
Examine the bonding between the window and the
door frame. (Refer to Section 56-10).
X* X X X
8. Examine the rear window on the RH side:
Examine the acrylic glass window for damage. Look
specially for cracks.
Examine the bonding between the window and the
frame. (Refer to Section 56-10).
X* X X X
9. Examine all antennas. Look specially for damage and
incorrect attachment.
X X X X
10. Remove the wheel fairings. Look for cracks on the
fairing mounts. (Refer to Section 32-40).
X X X X
11. Lift the airplane on jacks. (Refer to Section 07-10). X X X X
12. Examine the tires. Look specially for cuts and wear.
Measure the tire pressure. (Refer to Section 12-10).
X X X X
13. Examine the rims of the main and the nose wheels.
Look specially for cracks.
X* X X X
14. Examine the wheel bearings. Look specially for play,
corrosion and irregular operation.
X* X X X
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AIRCRAFT
DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
100 hr items marked X* apply to US registered airplanes only
Inspection Items 100 200 1000 2000 Time Initials
15. Remove the main and nose wheels.
Clean and lubricate the bearings (Refer to
Section 12-20).
X* X X X
16. Examine the brake lining. Look specially for wear.
Minimum thickness according to Cleveland/Parker
Maintenance Manual, latest revision.
X X X X
17. Examine the brake disks. Look specially for wear.
Minimum thickness according to Cleveland/Parker
Maintenance Manual, latest revision.
X* X X X
18. Remove the access panels for the main landing gear
legs. (Refer to Section 52-40).
X X X X
19. Examine the mounting for the landing gear. Look
specially for:
Incorrect attachment.
Loose or missing lock devices.
Examine the spacer between the bracket and the
main landing gear leg.
X X X X
20. Examine the main landing gear. Look specially for
cracks and deformation.
X X X X
21. Do a test for toe-in and camber. (Refer to Section
32-10).
X X
22. Examine the wing main bolts. Look specially for
incorrect locking.
X* X X X
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DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
100 hr items marked X* apply to US registered airplanes only
Inspection Items 100 200 1000 2000 Time Initials
23. Examine these components on LH and RH sides for
dis-bonding, delamination and damage:
The center section top and bottom shells.
The outer faces of the front and rear main
bulkheads. Look specially in the area of the bushes
for the main pins.
The front, middle and rear outer ribs.
The main landing gear rib.
The front and rear closing ribs.
The rear web.
X
24. Examine the inner faces of the front and rear main
bulkheads with the wings removed. Look specially in
the area of the bushes for the main bolts. (See also
Paragraph 6).
X
25. Install the access panels for the main landing gear legs.
(Refer to Section 52-40).
X* X X X
26. Remove the access panel for the nose landing gear
leg. (Refer to Section 52-40). Inspect the nose landing
gear leg for cracks, corrosion, paint condition, and
deformation.
X X X X
27. Examine the nose-wheel assembly. Look specially for
incorrect attachment, cracks and deformation.
X X X X
28. Examine the nose-gear journal-bearings in the bottom
of the fuselage. Look specially for play.
X* X X X
29. Examine the journals in the elastomeric spring. Look
specially for play.
X X X X
30. Examine the spherical bearing at the top of the
elastomeric spring. Look specially for play.
X X X X
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DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
100 hr items marked X* apply to US registered airplanes only
Inspection Items 100 200 1000 2000 Time Initials
31. Examine the elastomeric spring. Look specially for:
Looseness. Tighten if necessary. (Refer to Section
32-20).
Damage. Replace elastomer donuts if necessary.
(Refer to Section 32-20).
X X X X
32. Examine the elastomer pack center tube:
Remove the elastomer pack (refer to Section 32-20)
Remove the elastomer elements (refer to Section
32-20).
Remove the elastomer pack center tube:
If the center tube shows signs of deformation:
Replace the center tube (refer to Section 32-20).
If the center tube shows signs of wear:
Replace the center tube if a radial wear limit
(depth measured) of 0.8 mm is exceeded.
Remove the elastomer elements in the event that
they are worn or cracks are found. (Refer to Section
32-20).
Adjustment and installation of the elastomer pack
(refer to Section 32-20).
X
33. Remove the NLG fork (Refer to Chapter 32-20). Inspect
the fork for cracks, corrosion and deformation. Look
specially on the legs and filleted areas.
X X X X
34. Inspect the nose landing gear fork collar bushings. X X X X
35. Inspect the NLG leg for cracks, corrosion and damage.
Use a flashlight and a 10X magnifier. Pay special
attention to the pivot axle (especially the radius at the
top), filleted areas, and the threads at the bottom of the
fork pivot axle. If cracks are suspected, perform NDT.
X X X X
36. Inspect the stop plate for cracks and damage. X X X X
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AIRCRAFT
DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
100 hr items marked X* apply to US registered airplanes only
Inspection Items 100 200 1000 2000 Time Initials
37. Install the nose wheel fork. Do a test for play and caster
friction (refer to Section 32-20).
The friction force should be 30 - 50 N (6.75 - 11.25
lb) at the axle.
X X X X
38. Install the main and nose wheels. X X X X
39. Install the wheel fairings. X X X X
40. Examine the gascolator:
Remove and clean the fuel filter bowl.
Clean inspect the filter.
Install the filter bowl. (Refer to Section 28-20 for the
Lycoming version or Section 28-21 for the TAE
version).
Do a check for fuel leakage.
X X X X
41. Examine the fuel pump electrical cables. Look specially
for rub marks.
X* X X X
42. Examine the top hat profile. Look specially for dis-
bonding, delamination and damage.
X X
43. Install the access panel for the nose landing gear leg.
(Refer to Section 52-40).
X* X X X
44. If canopy jettison system (OÄM 40-232) is installed:
Perform release test of canopy jettison system. (Refer
to Section 52-10).
X X 2 yrs.
45. If canopy jettison system (OÄM 40-232) is installed:
100h maintenance check of canopy jettison system.
(Refer to Section 52-10).
X X X X
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AIRCRAFT
DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
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 nose
landing gear.
Refer to Section 52-40.
2. Examine the landing gear fittings. Look specially
for cracks.
Use a mirror and a flashlight.
3. Examine the fuselage structure where the landing
gear attaches. Look specially for:
Delamination of the GFRP structure.
Damage to the mounting brackets.
Refer to Section 32-10.
4. Examine the landing gear struts. Look specially
for:
Bending.
Cracks.
Refer to Section 32-10.
If the bending looks excessive contact the
aircraft manufacturer for direction.
5. Do a test of the wheel tracking. Refer to Section 32-10.
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AIRCRAFT
DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
Detail Steps/Work Items Key Items
6. Examine the tires. Look specially for cuts in the
side walls.
Refer to Section 32-40.
7. Examine the wheel rims. Look specially for
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:
Deformation of the upper cross bar of the
engine mount.
Nose wheel strut axle area.
Remove the fork assembly. (Refer to Section
32-20.) Use a flashlight and a 10X magnifier.
Pay special attention to the pivot axle
(especially the radius at the top, filleted areas,
and the threads at the bottom of the fork pivot
axle). If cracks are suspected, perform NDT.
Install the fork assembly. Refer to Section 32-
20.
CAUTION: IF YOU THINK THE AIRPLANE HAS DAMAGE TO AN AREA THAT
TRANSMITS A LOAD, YOU MUST ASK THE AIRPLANE
MANUFACTURER FOR ADVICE.
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AIRCRAFT
DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
Details Steps/Work Items Key Items
10. Examine the elastomer pack center tube:
Remove the elastomer pack.
Remove the elastomer elements.
Examine the elastomer pack center tube:
If the center tube shows signs of
deformation: Replace the center tube (refer
to Section 32-20).
If the center tube shows signs of wear:
Replace the center tube if a radial wear limit
(depth measured) of 0.8 mm is exceeded.
Remove the elastomer elements in the event
that they are worn or cracks are found.
Adjustment and installation of the elastomer
pack.
Refer to Section 32-20.
11. Examine the top hat profile 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.
13. Examine the control surfaces. Look specially for:
Correct attachment of the hinges.
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.
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DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
Detail Steps/Work Items Key Items
18. Examine the engine mount points on the firewall.
19. Examine the propeller. Look specially to see if the
propeller has touched the ground.
If the adjustable front seats (OÄM 40-252 or OÄM 40-375) are installed:
WARNING: DO NOT LOOSEN THE LEVER FOR THE ADJUSTABLE BACKREST
OF THE FRONT SEATS UNINTENTIONALLY. THE SPRING LOADED
BACKREST MAY SNAP FORWARD AND CAUSE INJURY.
20 If the adjustable front seats (OÄM 40-252 or OÄM
40-375) are installed:
Do a test of the backrest adjustment
mechanism on both front seats (refer to
Section 25-10).
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DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
Figure 1: Hard Landing Check Areas - Nose Landing Gear and Firewall
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DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
Figure 2: Hard Landing Check Areas - Main Landing Gear
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AIRCRAFT
DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
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
the nose wheel clear of the ground.
Use a strap around the fuselage.
(2) Put a padded trestle under the front fuselage just
aft of the nose wheel mounting.
(3) Remove the nose wheel fairing.
(4) Adjust the nose wheel fork pivot nut. The nose-wheel must just castor when a
force of 30-50 N (6.75 - 11.25 lb) is
applied along the direction of the nose
wheel axle. Refer to Figure 5.
(5) Apply corrosion protection to the stud, hexagon
nut, small waster, two disk springs, large washer,
and the stop plate.
Use CA 1000 corrosion inhibitive joining
compound.
Do not get CA 1000 on the tire or the
fiberglass.
(6) Install the nose-wheel fairing.
(7) Remove the trestle from the front fuselage.
(8) Lower the nose-wheel to the floor. Remove the weights from the rear
fuselage.
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DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
Pivot Nut
Apply a Force of
30 - 50 N (6.75 - 11.25 lb.)
in both Directions along
the Line of the Axle
6. Nose Wheel Balancing
Always have the nose-wheel balanced before installation.
Figure 4: Adjust the Nose Wheel Steering Friction
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DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
7. Remove/Install the NLG Fork Assembly
A. Equipment
Refer to Chapter 07-10-00 for the equipment required for jacking the aircraft.
B. Remove the NLG Fork Assembly
Detail Steps/Work Items Key Items/References
(1) Jack the Aircraft. Refer to Chapter 07-10-00.
(2) Remove the fairing, if installed.
(3) Remove the hexagon nut, small washer, two disc
springs, large washer, and stop plate.
Refer to Figure 4.
(4) Remove the fork assembly from the pivot.
C. Install the NLG Fork Assembly
Detail Steps/Work Items Key Items/References
(1) Clean the NLG strut and fork bushing of any dirt or
residue.
(2) Install the fork assembly on the NLG strut axle as
follows:
Install the fork assembly to the NLG strut.
Install the stop plate, large washer, two disk
springs, small washer, and hexagon nut.
Tighten the nut to achieve break out force
required.
Refer to Figure 4.
Ensure the disk springs are installed with
the open side facing up.
The nose-wheel must just castor when a
force of 30-50 N (6.75 - 11.25 lb) is
applied along the direction of the nose
wheel axle. Refer to Paragraph 7.
(3) Adjust the nose wheel steering friction. Refer to Paragraph 7.
(4) Install the fairing, if removed.
(5) Remove aircraft from the jacks. Refer to Chapter 07-10-00.
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DA 40 Series AMM Temporary Revision
NLG Inspection & Maintenance
Figure 5: NLG Fork Assembly
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