钻石40飞机维护手册 DA 40 SERIES AMM 6(21)

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(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 top cowling.  Refer to Section 71-10. 
(3)  Disconnect the airplane battery.  Refer to Section 24-31. 
(4)  Remove the cover from the relay box: S Remove the 2 bolts which attach the relay box cover. S Remove the relay cover. 

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(5)  Disconnect the cables from the starter relay. Original design: S Remove the 2 control cables and the 1 indicator cable. S Remove the 2 power cables. Modified design (M.M 40-057): S Remove the 1 ring terminal with the diode suppression cable and the control cable. S Remove the 1 power cable. S Remove the 1 nut and 1 washer of the bus bar connection.  Make a note of the position of the cables. Refer to Figure 2. Refer to Figure 3. 
(6)  Remove the starter relay. 
Original design: S Remove the 2 bolts and nuts which attach the relay to the bulkhead. S Move the relay clear of the airplane.  Refer to Figure 2. 
Modified design (M.M 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 3. 

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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 (M.M 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 (M.M 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. 
　
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