Diamond Aircraft DA 40 NG User manual

AIRCRAFT
DA 40 NG
AIRPLANE MAINTENANCE MANUAL
Copyright © by DIAMOND AIRCRAFT INDUSTRIES, Wiener Neustadt, Austria

AIRCRAFT
Introduction DA 40 NG AMM
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 indata
processing facilities, in whole or part, are reserved.
Diamond Aircraft Industries GmbH
N. A. Otto-Str. 5
A-2700 Wiener Neustadt
Austria
Phone: [phone]
Fax: [phone]
E-mail: [email protected]

AIRCRAFT
DA 40 NG AMM Table of Contents
Doc # 6.02.15
Rev. 3 CONTENTS Page i
01 Sep 2017
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

AIRCRAFT
Table of Contents DA 40 NG AMM
Page ii
01 Sep 2017 CONTENTS Doc # 6.02.15
Rev. 3
21-00 Air Conditioning, Heating and Ventilation
21-50 Cooling
21-51 Cooling (OÄM 40-316/i or later 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

AIRCRAFT
DA 40 NG AMM Table of Contents
Doc # 6.02.15
Rev. 3 CONTENTS Page iii
01 Sep 2017
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

AIRCRAFT
Table of Contents DA 40 NG AMM
Page iv
01 Sep 2017 CONTENTS Doc # 6.02.15
Rev. 3
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
%
80-00 Starting
81-00 Turbo Charger
92-00 Wiring Diagrams

AIRCRAFT
DA 40 NG AMM Record of Revision
Doc # 6.02.15
Rev. 3 ROR Page v
01 Sep 2017
Record of Revision
1. Record of Revision
Use this check list to record and control all of the revisions which you put inthis Airplane Maintenance
Manual(AMM). Put theaffectedpages oftherevisioninto theAMMas soonas youget them.Remove
and destroy the pages which are superseded. Complete the table below when you have put the
revision in the AMM.
Revision
Number Date Issued Inserted On Inserted By
Original 01 Apr 2010
1 15 Jun 2011
%%
2 15 Apr 2013
3%01 Sep 2017%
Revision
Number Date Issued Inserted On Inserted By

AIRCRAFT
Record of Revision DA 40 NG AMM
Page vi
01 Sep 2017 ROR Doc # 6.02.15
Rev. 3
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 &
AMM-TR-MÄM 40-549 Cowling Redesign
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

AIRCRAFT
DA 40 NG AMM Record of Revision
Doc # 6.02.15
Rev. 3 ROR Page vii
01 Sep 2017
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 &
AMM-TR-MÄM 40-506/a Replacement of Charged Air Hoses with Tube
AMM-TR-MÄM 40-505 Firewall Reinforcements on Engine Mount Holes
AMM-TR-MÄM 40-519 &
AMM-TR-MÄM 40-520 Breather Line with Additional Outlet
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 &
AMM-TR-OÄM 40-334/b &
AMM-TR-MÄM 40-631
1280 kg Maximum Landing Mass
and/or Landing Gear with
Large or Small Tires
AMM-TR-MÄM 40-607/a 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

AIRCRAFT
Record of Revision DA 40 NG AMM
Page viii
01 Sep 2017 ROR Doc # 6.02.15
Rev. 3
The following Temporary Revisions are incorporated into the DA 40 NG AMM by Revision 3:%
%
Temporary Revision Number%Description of Temporary Revision%
AMM-TR-MÄM 40-561%New GFC 700 Autopilot Hardware%
AMM-TR-MÄM 40-619%Passenger Door Improvement%
AMM-TR-MÄM 40-635%Adjust Taxi Light Procedure%
AMM-TR-MÄM 40-638%Cold Weather Operation%
AMM-TR-MÄM 40-647%Engine Oil Quick Drain%
AMM-TR-MÄM 40-650%Fuel Filter Element Check Valve%
AMM-TR-MÄM 40-654%Trouble Shooting Fuel System%
AMM-TR-MÄM 40-655/a%Governor Nut Torque%
AMM-TR-MÄM 40-658/a%Coolant Tank Pressure Relief Valve Test%
AMM-TR-MÄM 40-661%Coolant System Pressure Test%
AMM-TR-MÄM 40-678%Removal of Checklist Items%
AMM-TR-MÄM 40-709%Stall Warning System%
AMM-TR-MÄM 40-728%Lubrication Schedule%
AMM-TR-MÄM 40-743%Protective Pads for Charged Air Hoses%
AMM-TR-MÄM 40-763%Coolant Water Tank with Threaded Cap and Larger%
Filler Neck%
AMM-TR-MÄM 40-785%Replacement of Passenger Door Hinges%
AMM-TR-MÄM 40-792%Additional Elevator Mass%
AMM-TR-MÄM 40-806/a%Silicate Cartridge%
AMM-TR-MÄM 40-808%Inspection of NLG Elastomer Pack Center Tube%
AMM-TR-MÄM 40-820%Flexible Charge Air Hose%
AMM-TR-MÄM 40-822%Inspection of MLG Strut%
AMM-TR-MÄM 40-824%New Type 6 Lubricants%
AMM-TR-MÄM 40-840%Main Landing Gear Adaptions%
AMM-TR-MÄM 40-841%Fuel Tank Maintenance%
AMM-TR-MÄM 40-846%Door Handle Improvement%
AMM-TR-MÄM 40-847%Fuel Filter Assembly%
AMM-TR-MÄM 40-853/c & -873%Turbo Charger V-Clamp%
AMM-TR-MÄM 40-860%Vent Line Routing%

AIRCRAFT
DA 40 NG AMM Record of Revision
Temporary Revision Number%Description of Temporary Revision%
Doc # 6.02.15
Rev. 3 ROR Page ix 01 Sep 2017
AMM-TR-MÄM 40-865%Conservation of Exterior Parts%
AMM-TR-MÄM 40-868%Garmin Hard- und Software Upgrade I%
AMM-TR-MÄM 40-874%Engine Oils%
AMM-TR-MÄM 40-899%Improved Air Charge Hose%
AMM-TR-OÄM 40-251%Electrical Pedal Adjustment%
AMM-TR-OÄM 40-258%HID-Lights%
AMM-TR-OÄM 40-312%Towing Device%
AMM-TR-OÄM 40-314/g%Additional Alternator%
AMM-TR-OÄM 40-316/b%Recirculating Air - Cabin Cooling (RACC)%
AMM-TR-OÄM 40-348%Fuel Quantity of Filler Placard%
AMM-TR-OÄM 40-349%Provisions for Tablet Mount%
AMM-TR-OÄM 40-354%Seat Belt Holder%
AMM-TR-OÄM 40-358%Headset Hanger%
AMM-TR-OÄM 40-363%Battery Heating System%
AMM-TR-OÄM 40-369%Whelen LED Position / Anti Collision Lights%
AMM-TR-OÄM 40-370%Diesel Operation%
AMM-TR-OÄM 40-375%Front Seats with Adjustable Backrest - Hydrolok%
AMM-TR-OÄM 40-379%Bilstein NLG - Damper%
AMM-TR-OÄM 40-398%Higher Main Landing Gear%
AMM-TR-OÄM 40-399%Foot Step Aft, LH Option%
AMM-TR-OÄM 40-400%Foot Step Aft, RH Option%
AMM-TR-OÄM 40-401%Emergency Egress Hammer%

AIRCRAFT
Record of Revision DA 40 NG AMM
Page x
01 Sep 2017 ROR Doc # 6.02.15
Rev. 3
Intentionally left blank

AIRCRAFT
DA 40 NG AMM List of Effective Pages
Doc # 6.02.15
Rev. 3 LOEP Page 1
01 Sep 2017
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
Section Page Revision Date
TOC i 01 Sep 2017
TOC ii 01 Sep 2017
TOC iii 01 Sep 2017
TOC iv 01 Sep 2017
ROR v 01 Sep 2017
ROR vi 01 Sep 2017
LOEP 1 01 Sep 2017
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AIRCRAFT
List of Effective Pages DA 40 NG AMM
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AIRCRAFT
DA 40 NG AMM List of Effective Pages
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01 Sep 2017
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AIRCRAFT
List of Effective Pages DA 40 NG AMM
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AIRCRAFT
DA 40 NG AMM List of Effective Pages
Doc # 6.02.15
Rev. 3 LOEP Page 5
01 Sep 2017
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List of Effective Pages DA 40 NG AMM
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DA 40 NG AMM List of Effective Pages
Doc # 6.02.15
Rev. 3 LOEP Page 7
01 Sep 2017
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List of Effective Pages DA 40 NG AMM
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01 Sep 2017 LOEP Doc # 6.02.15
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