Diamond DA 40 Series Airplane Maintenance Manual PDF – DA 40 & DA 40 D AMM for Lycoming and TAE 125 Engines

Description

The DA 40 Series Airplane Maintenance Manual is the complete factory-issued AMM for the Diamond DA 40 family, published by Diamond Aircraft Industries GmbH under document number 6.02.01, Revision 5, dated 20 September 2007. Written in AECMA Simplified English to the ATA 100 chapter system, it covers the DA 40 with the Lycoming IO-360-M1A engine and the DA 40 D with the TAE 125 Diesel engine. Every airframe system, structure, and powerplant area is addressed across the manual’s numbered chapters, from airworthiness limitations and scheduled maintenance checks through flight controls, fuel, electrical, landing gear, avionics, composite repair, and the complete electrical wiring diagrams.

What This DA 40 Series AMM Covers

This is the full Diamond DA 40 Series Airplane Maintenance Manual used by maintenance organizations to keep both the Lycoming-powered DA 40 and the diesel DA 40 D airworthy. Where the two engine variants require different procedures, the manual separates them into distinct sections (for example 24-00 Electrical Power – Lycoming Engine and 24-01 Electrical Power – TAE 125 Diesel Engine), so a technician never mixes procedures between the two aircraft. Lycoming-specific chapters cover the IO-360-M1A engine, magneto and LASAR ignition systems, fuel injection, and air cooling. TAE 125-specific chapters cover the FADEC engine control system, liquid cooling, the reduction gearbox, and the turbocharging system.

The DA 40 Series Airplane Maintenance Manual is organized around the ATA 100 chapter and section structure. Each system section typically contains Description and Operation, Trouble-Shooting, and Maintenance Practices with data on servicing, removal and installation, adjustment and tests, checking and testing, cleaning and painting, and repairs. Structural chapters cover the composite airframe in depth, including damage classification, inspection techniques, scarfing and laminate repair, sandwich core repair, and control surface balancing limits.

File Details

• Manual type: Airplane Maintenance Manual (AMM)
• Brand: Diamond Aircraft
• Model: DA 40 Series (DA 40 and DA 40 D)
• Document number: Doc # 6.02.01
• Revision: Rev. 5
• Date: 20 September 2007
• Language: English (AECMA Simplified English)
• Page count: 2035 pages
• File format: PDF

Chapters Covered

• 01 – Introduction
• 02 – Organization and Handling of the Manual
• 03 – General Description of the Airplane
• 04 – Airworthiness Limitations
• 05 – Time Limits and Maintenance Checks
• 06 – Dimensions and Areas
• 07 – Lifting and Shoring / Jacking
• 08 – Weighing and Levelling
• 09 – Towing and Taxiing
• 10 – Parking, Mooring, Storage and Return to Service
• 11 – Placards and Markings
• 12 – Servicing (Replenishing, Scheduled Servicing, Cleaning)
• 20 – Standard Practices – Airframe
• 21 – Air Conditioning (Lycoming and TAE 125)
• 22 – Auto Flight / Autopilot
• 23 – Communications (Speech, Audio Integrating, Static Discharging)
• 24 – Electrical Power (Lycoming and TAE 125, generation, battery, emergency battery, external power, load distribution)
• 25 – Equipment/Furnishings (Flight Compartment, Emergency/ELT)
• 26 – Fire Protection
• 27 – Flight Controls (Ailerons, Rudder, Elevator, Elevator Trim, Stall Warning, Flaps)
• 28 – Fuel System (Lycoming and TAE 125, storage, distribution, quantity indicating)
• 31 – Indicating Systems (Instrument and Control Panels, Independent Instruments, Central Warning)
• 32 – Landing Gear (Main, Nose, Wheels and Brakes)
• 33 – Lights (Flight Compartment, Exterior)
• 34 – Navigation (Flight Environment Data, Attitude and Direction, Gyro-Compass, Landing Aids, Strike Finder, Stormscope, VOR/LOC/GS, ADF, DME, Transponder, GPS)
• 37 – Vacuum System
• 51 – Standard Practices and Structures (Investigation, Repair Processes, Materials, Fasteners, Control Surface Balancing, Electrical Bonding)
• 52 – Doors (Canopy and Passenger Door, Access Panels)
• 53 – Fuselage Structure
• 55 – Stabilizers (Horizontal Stabilizer, Elevator, Lower Fin, Rudder)
• 56 – Windows (Flight Compartment Windows)
• 57 – Wings (Wing Structure, Flaps, Aileron)
• 61 – Propeller (Lycoming MTV-12-B/180-17, TAE 125 MTV-6-A, Propeller Control)
• 71 – Power Plant (Lycoming and TAE 125, Cowlings, Mounting, Electrical Cables, Air Intakes, Engine Drains)
• 72 – Engine (Lycoming, TAE 125)
• 73 – Engine Fuel and Control (Lycoming and TAE 125)
• 74 – Ignition (Lycoming)
• 75 – Cooling (Air Cooling – Lycoming, Liquid Cooling – TAE 125)
• 76 – Engine Controls (Lycoming and TAE 125)
• 77 – Engine Indicating (Lycoming Integrated Engine Display, TAE 125 CED/AED)
• 78 – Exhaust (Lycoming and TAE 125)
• 79 – Oil System (Lycoming and TAE 125)
• 80 – Starting (Lycoming and TAE 125)
• 81 – Turbines (TAE 125 Turbocharging)
• 92 – Wiring Diagrams (Lycoming DA4- drawings and TAE 125 D4D- drawings)

What This Manual Enables You to Do

With the DA 40 Series Airplane Maintenance Manual on hand you can carry out scheduled 50, 100, 200, 1000, and 2000-hour inspections, annual checks, and the 5-hour engine check on a new TAE 125 engine. You can troubleshoot and repair systems across the whole aircraft: flight controls, fuel delivery, electrical generation and distribution, landing gear and brakes, avionics, autopilot, and the engine systems specific to each powerplant. The structural chapters give you the actual lay-up data needed for composite repair of the fuselage shells, center section, wings, stabilizers, flaps, and ailerons, along with the control surface balancing limits required after any repair or repaint.

Because the manual gives the exact torque values, adjustment ranges, service limits, and inspection intervals set by the manufacturer, it removes guesswork from DA 40 maintenance. Compression test values, alternator belt tension, idle speed and mixture adjustment, rudder cable tension, flap actuator extension, wheel bearing end play, control surface deflection limits, and air conditioning heat valve bounce are all given so maintenance is done to the correct specification.

Get Instant Access

IMAGES PREVIEW

The DA 40 Series Airplane Maintenance Manual is delivered as a PDF download immediately after payment. There is no shipping and no waiting. You can open the file on any laptop, tablet, or smartphone, print the pages you need for the hangar, and keep the full 2035-page AMM available for every inspection, repair, or troubleshooting job on your DA 40 or DA 40 D.