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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.
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Wings DA 40 Series
AMM
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AIRCRAFT
DA 40 Series
AMM
Wings
Doc # 6.02.01
Rev. 5 57-50-00 Page 201
20 Sep 2007
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 ALT/BAT switch to ON.
S Set the flap selector to LDG.
S When the flaps stop moving.
S Set the ALT/BAT 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:
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.
Hold the flap.
(4) Remove the 6 hinge pins from the flap hinges
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.
Support the flap assembly!
(5) Carefully move the flap aft, and clear of the
airplane.
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Wings DA 40 Series
AMM
Page 202
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Rev. 5
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
horn:
S Push the hinge pins into position from the
inboard side.
S Align the holes in the hinges with the holes in
the hinge pins and install the roll pins.
Make sure that there is a gap of 0.5 -
2.5 mm (0.002 - 0.010 in) between the
faces of the hinge at the horn and a gap
of 1 - 3 mm (0.004 - 0.012 in) between
the faces at the other hinges.
(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.
AIRCRAFT
DA 40 Series
AMM
Wings
Doc # 6.02.01
Rev. 5 57-50-00 Page 203
20 Sep 2007
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.
AIRCRAFT
Wings DA 40 Series
AMM
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Rev. 5
2
6
3
7
4
8
5
9 10 11 12 13 14
2
3
4
5
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15
Item No. Layers Reference No. Type Remarks
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