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Rev. 5
11. Engine Break-In
You must do this procedure after a new engine has been installed. Refer to Lycoming Service
Instruction No. 1427, latest issue.
Detail Steps/Work Items Key Items/References
(1) Do a careful pre-flight inspection. Refer to Airplane Flight Manual.
(2) Do a normal take-off.
S Mixture control lever . . . . . . . . . . . . . . RICH
S RPM lever . . . . . . . . . . . . . . . . . . HIGH RPM
S Throttle . . . . . . . . . . . . . . . . . . . . MAX PWR
Reduce to 2400 RPM as soon as
possible.
CAUTION: CLIMB WITH A SMALL CLIMB ANGLE TO AVOID ENGINE OVERHEATING.
(3) Climb to an altitude which is suitable for cruise. Stay below 5000 ft.
CAUTION: AVOID LOW MANIFOLD PRESSURE DURING HIGH ENGINE
SPEEDS (DO NOT OPERATE BELOW 15 INCHES HG). IF YOU
MUST REDUCE ENGINE POWER, FIRST REDUCE THE RPM.
(4) Cruise for 2 hours and 30 minutes.
S Cruise at 75 % power during the first hour.
S Change power setting a few times between
65 % and 75 % during the second hour.
S Cruise with 2400 RPM and full throttle during
the last 30 minutes.
CAUTION: DESCEND AT A MODERATE RATE AND LOW CRUISE POWER
SETTINGS.
(5) Descend and land. Refer to Airplane Flight Manual.
AIRCRAFT
DA 40 Series
AMM
Power Plant
Doc # 6.02.01
Rev. 5 71-01-00 Page 1
20 Sep 2007
Section 71-01
Power Plant - TAE 125 Diesel Engine
1. General
This Chapter tells you about the power plant with the TAE 125-01 Diesel engine installed in the DA 40.
It tells you about the components that make the power plant. It also tells you how to remove/install the
power plant.
For data on the engine test after installation refer to the Operator's Manual for the TAE 125-01 engine.
Refer to the DA 40 Airplane Flight Manual for engine start/stop procedures.
Refer to these Chapters for data about other engine systems:
) Chapter 72 Refer to the TAE 125-01 Operator's Manual for data on the engine.
) Chapter 73 Engine fuel and control. Refer to the TAE 125-01 Operator's Manual for data on
the fuel injection system.
) Chapter 76 Engine controls.
) Chapter 77 Engine indicating.
) Chapter 78 Exhaust system.
) Chapter 79 Oil system components installed in the airframe. Refer to the TAE 125-01
Operator's Manual for data on the engine oil system.
) Chapter 80 Starter system control and installation. Refer to the TAE 125-01 Operator's
Manual for data on the starter.
Note: Equipment which is certified for installation in the DA 40 is listed in Section 6.5 of
the Airplane Flight Manual. Such equipment may be installed in accordance with
the Airplane Maintenance Manual.
Any equipment which is not listed in Section 6.5 of the Airplane Flight Manual is
called "Additional Equipment". The installation of Additional Equipment is a
modification which must be handled in accordance with national regulations or a
Service Bulletin.
AIRCRAFT
Power Plant DA 40 Series
AMM
Page 2
20 Sep 2007 71-01-00 Doc # 6.02.01
Rev. 5
Top Cowling
Bottom Cowling
Air Intakes
Engine Mounting Frame
Electrical
Cables
Figure 1: TAE 125-01 Diesel Engine Power Plant
AIRCRAFT
DA 40 Series
AMM
Power Plant
Doc # 6.02.01
Rev. 5 71-01-00 Page 3
20 Sep 2007
2. Description and Operation
The DA 40 has a TAE 125-01 4-cylinder, in line turbo-charged Diesel engine with double overhead
camshafts. The engine has a reduction gear and a wet sump oil system. The TAE 125-01 is liquid
cooled and has a high-pressure, common-rail fuel injector system. It has an electric starter.
The TAE 125-01 engine has a reduction gear. A hollow gear shaft lets oil flow to the propeller from the
propeller governor. The propeller flange has 6 mounting holes. The propeller turns in a clockwise
direction when viewed from the cockpit.
An electronic system (FADEC) monitors and controls engine and propeller performance.
The power plant has these components installed:
A. Cowling
The power plant has a top and bottom engine cowling. The two halves attach to each other and to
the airframe with camloc quick release fasteners.
The top cowling has an access panel for the oil filler. It has air intakes for the coolant radiator and
the intercooler.
The bottom cowling allows access to the oil level window in the reduction gear. It has air intakes for
the oil radiator, the cabin heat heat-exchanger, and the engine air filter.
B. Engine Mount
The engine mount attaches to the firewall at five locations. Tubular steel makes the mounting frame.
The engine attaches to the engine mount with three shock-mounts. Gel-filled rubber elements make
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