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S Remove the 2 bolts and nuts which attach the
relay to the bulkhead.
S Move the relay clear of the airplane.
Modified design (MÄM 40-057):
S Remove the 2 bolts, 3 washers, and 1 ring
terminal which attach the relay to the relay
panel.
S Move the relay clear of the airplane.
Refer to Figure 2.
Refer to Figure 3.
AIRCRAFT
Starting DA 40 Series
AMM
Page 204
20 Sep 2007 80-00-00 Doc # 6.02.01
Rev. 5
Figure 3: Starter Relay Installation, Modified Design (MÄM 40-057)
(without Insulating Boots, etc.)
AIRCRAFT
DA 40 Series
AMM
Starting
Doc # 6.02.01
Rev. 5 80-00-00 Page 205
20 Sep 2007
B. Install The Starter Relay
Detail Steps/Work Items Key Items/References
(1) Install the relay.
Original design:
S Put the relay in position.
S Install the 2 washers and bolts which attach
the relay to the bulkhead.
Modified design (MÄM 40-057):
S Put the relay in position.
S Install the 1 ring terminal, 3 washers, and 2
bolts which attach the relay to the relay panel.
Refer to Figure 2.
Refer to Figure 3.
(2) Reconnect the cables to the starter relay.
Original design:
S Connect the 2 power cables.
S Connect the 2 control cables and the 1
indicator cable.
Modified design (MÄM 40-057):
S Connect the bus bar with 1 washer and 1 nut.
S Connect the 1 power cable.
S Connect the 1 ring terminal with the diode
suppression cable and the control cable.
Refer to Chapter 92 for the wiring
diagrams.
Refer to Figure 2.
Refer to Figure 3.
(3) Install the cover on the relay mounting:
S Put the cover in position over the relay box.
S Install the 2 washers and bolts which attach
the relay box cover.
(4) Connect the airplane battery. Refer to Section 24-31.
(5) Install the engine top cowling. Refer to Section 71-10.
(6) Do an engine run-up. Refer to the DA 40 Airplane Flight
Manual.
AIRCRAFT
Starting DA 40 Series
AMM
Page 206
20 Sep 2007 80-00-00 Doc # 6.02.01
Rev. 5
Bolt Plain Nut, Serrated
Washer, Plain Washer
Power Cable
Starter Motor
Spigot
Figure 4: Remove/Install the Starter
AIRCRAFT
DA 40 Series
AMM
Starting
Doc # 6.02.01
Rev. 5 80-00-00 Page 207
20 Sep 2007
3. Remove/Install the Starter
A. Remove the Starter
Detail Steps/Work Items Key Items/References
WARNING: MAKE THE ENGINE IS SAFE BEFORE YOU DO ANY WORK ON THE
STARTER SYSTEM. IF THE ENGINE IS TURNED, THE PROPELLER
CAN CAUSE INJURY OR DEATH.
(1) Make sure that the engine is safe:
S Set the ignition switch to OFF.
S Set the ALT/BAT switch to OFF.
S Set the throttle to IDLE.
S Set the mixture control to LEAN CUT-OFF.
(2) Remove the engine cowlings. Refer to Section 71-10.
(3) Disconnect the airplane battery. Refer to Section 24-31.
(4) Disconnect the electrical cables from the starter:
S Move the rubber boot clear of the power
cable.
S Remove the nut and washer that attaches the
cable to the connector stud.
S Remove the cables from the starter.
(5) Cut the lock-wire on the bolt which holds the link
for the alternator. Remove the bolt.
(6) Release the three nuts and one bolt which attach
the starter to the engine. Remove the starter from
the airplane.
AIRCRAFT
Starting DA 40 Series
AMM
Page 208
20 Sep 2007 80-00-00 Doc # 6.02.01
Rev. 5
B. Install the Starter
Detail Steps/Work Items Key Items/References
(1) Put the starter into position on the engine.
(2) Install the washers, three nuts and one bolt which
attach the starter to the engine.
Torque: 23 Nm (17 ft.lb).
(3) Move the link for the alternator into position and
install the bolt. Lock the bolt with lock-wire.
Torque: 23 Nm (17 ft.lb).
(4) Connect the electrical cable to the starter:
S Install the power cable on the stud.
S Install the shake-proof washer.
S Install the nut.
S Move the rubber boot into position over the
connector.
Torque: 2.7 Nm (2 ft.lb).
(5) Connect the airplane battery. Refer to Section 24-31.
(6) Install the engine cowlings. Refer to Section 71-10.
(7) Do an engine run-up. Refer to the DA 40 Airplane Flight
Manual.
AIRCRAFT
DA 40 Series
AMM
Starting
Doc # 6.02.01
Rev. 5 80-01-00 Page 1
20 Sep 2007
Section 80-01
Starting - TAE 125 Diesel Engine
1. General
This Section tells you about the system that cranks the TAE 125 Diesel engine for starting.
Refer to Section 24-33 for more data on the electrical supplies to the system Refer to Section 76-01
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