DA 40 Series

Time Limits and

AMM
AIRCRAFT Maintenance Checks

Section 05-28-50
Maintenance Checklist Airframe

Note: The items of the Major Structural Inspection (MSI) are included in the maintenance
checklist of the airframe and identified by the term ‘MSI’ in the ‘Time’ column.

1. Front Fuselage

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

1. Examine the complete surface of the front fuselage. X X X X
Look specially for damage (dents, cracks, holes and
delamination).

Examine the paint coat.

2. Examine these NACA air inlets for blockage: X X X X

S One in the left stub wing.

S Two in the forward fuselage, LH and RH (optional,

OÄM 40-099).

% 3. Examine the canopy. X* X X X

S Make sure the canopy lock mechanism operates

correctly. (Refer to Section 52-10).

S Examine the acrylic glass window for damage.

Look specially for cracks.

S Examine the bonding between the window and

the canopy frame. (Refer to Section 56-10).

S Examine the emergency windows and their hinges

for damage.

S Examine the 'pop out' windows and their hinges

% for damage, if installed. Check hinges for
improper friction, correct if necessary.

4. Do a function test of the door unlocked warning light X X X X

system. (Refer to Section 52-10).
% 5. Examine the safety hook mechanism. (Refer to X X X X
% Section 52-10).

Doc # 6.02.01 Page 1

Rev. 7 05-28-50 01 Apr 2013
 NOTE: Please see the TEMPORARY REVISION that revises this page.

Time Limits and DA 40 Series

Maintenance Checks AIRCRAFT AMM

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 6. Examine the carbon hinges for cracks. (Refer to X X X X
% Section 52-10).
% 7. Examine the rear passenger door: X* X X X

% S Make sure the door lock mechanism operates

correctly. (Refer to Section 52-10).

S Examine the acrylic glass window for damage.

Look specially for cracks.

S Examine the bonding between the window and

the door frame. (Refer to Section 56-10).

% 8. Examine the rear window on the RH side: X* X X X

S Examine the acrylic glass window for damage.

Look specially for cracks.

S Examine the bonding between the window and

the frame. (Refer to Section 56-10).

9. Examine all antennas. Look specially for damage and X X X X

incorrect attachment.
10. Remove the wheel fairings. Look for cracks on the X* X X X
fairing mounts. (Refer to Section 32-40).
11. Lift the airplane on jacks. (Refer to Section 07-10). X* X X X
12. Examine the tires. Look specially for cuts and wear. X X X X
Measure the tire pressure. (Refer to Section 12-10).
13. Examine the rims of the main and the nose wheels. X* X X X
Look specially for cracks.
14. Examine the wheel bearings. Look specially for play, X* X X X
corrosion and irregular operation.
15. Remove the main and nose wheels. X* X X X

S Clean and lubricate the bearings (Refer to

Section 12-20).

Install the main and nose wheels (Refer to Section

32-40).
% 16. Examine the brake lining. Look specially for wear. X X X X
% Minimum thickness according to Cleveland/Parker
% Maintenance Manual, latest revision.

Page 2 Doc # 6.02.01

01 Apr 2013 05-28-50 Rev. 7
 Temporary Revision
DA 40 AMM
AIRCRAFT Door Handle Improvement

05-28-50
Maintenance Checklist Airframe

1. Front Fuselage

Item 7 is amended to read:

100 hr items marked X* apply to US registered airplanes only Interval

Inspection Items 100 200 1000 2000 Time Initials
% 7. Examine the rear passenger door: X* X X X

S Make sure the door lock mechanism operates

correctly. (Refer to Section 52-10).

% S If MÄM 40-139 is installed: Do a test of the

% passenger door handle compression gas spring.
% (Refer to Section 52-10).

S Examine the acrylic glass window for damage.

Look specially for cracks.

S Examine the bonding between the window and

the door frame. (Refer to Section 56-10).

Doc # 6.02.01 Page 2a

AMM-TR-MÄM 40-846 05-28-50 07 Dec 2016
Temporary Revision
AIRCRAFT DA 40 AMM
Door Handle Improvement

Intentionally left blank

Page 2aa Doc # 6.02.01

07 Dec 2016 05-28-50 AMM-TR-MÄM 40-846
 DA 40 Series
Time Limits and
AMM
AIRCRAFT Maintenance Checks

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 17. Examine the brake disks. Look specially for wear. X* X X X
% Minimum thickness according to Cleveland/Parker
% Maintenance Manual, latest revision.
18. Remove the access panels for the main landing gear X* X X X
legs. (Refer to Section 52-40).
19. Examine the mounting for the landing gear. Look X* X X X
specially for:

S Incorrect attachment.

S Loose or missing lock devices.

20. Examine the main landing gear. Look specially for X* X X X

cracks and deformation.
21. Do a test for toe-in and camber. (Refer to Section X X
32-10).
22. Examine the wing main bolts. Look specially for X* X X X
incorrect locking.
% 23. Examine these components on LH and RH sides for X
dis-bonding, delamination and damage:

S The center section top and bottom shells.

S The outer faces of the front and rear main

bulkheads. Look specially in the area of the
bushes for the main pins.

S The front, middle and rear outer ribs.

S The main landing gear rib.

S The front and rear closing ribs.

S The rear web.

% 24. Examine the inner faces of the front and rear main X
bulkheads with the wings removed. Look specially in
the area of the bushes for the main bolts. (See also
Paragraph 6).
25. Install the access panels for the main landing gear X* X X X
legs. (Refer to Section 52-40).
26. Install the wheel fairings. X* X X X

Doc # 6.02.01 Page 3

Rev. 7 05-28-50 01 Apr 2013
 NOTE: Please see the TEMPORARY REVISION that revises this page.

Time Limits and DA 40 Series

Maintenance Checks AIRCRAFT AMM

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

27. Remove the access panel for the nose landing gear X* X X X
leg. (Refer to Section 52-40).
28. Examine the nose-wheel assembly. Look specially for X* X X X
incorrect attachment, cracks and deformation.
29. Examine the nose-gear journal-bearings in the bottom X* X X X
of the fuselage. Look specially for play.
30. Examine the journals in the elastomeric spring. Look X X X X
specially for play.
31. Examine the spherical bearing at the top of the X X X X
elastomeric spring. Look specially for play.
32. Examine the elastomeric spring. Look specially for: X X X X

S Looseness. Tighten if necessary. (Refer to

Section 32-20).

S Damage. Replace elastomer donuts if necessary.

(Refer to Section 32-20).

33. Examine the nose-wheel fork. Do a test for play and X X X

caster friction (refer to Section 32-20).

S The friction force should be 30 - 50 N

(6.75 - 11.25 lb) at the axle.

34. Examine the gascolator: X X X X

S Remove and clean the fuel filter bowl.

S Install the filter bowl. (Refer to Section 28-20 for

the Lycoming version or Section 28-21 for the
TAE version).

S Do a check for fuel leakage.

% 35. Examine the fuel pump electrical cables. Look X* X X X

specially for rub marks.
36. Examine the top hat profile. Look specially for dis- X X
bonding, delamination and damage.
37. Install the access panel for the nose landing gear leg. X* X X X
(Refer to Section 52-40).

Page 4 Doc # 6.02.01

01 Apr 2013 05-28-50 Rev. 7
 DA 40 Series Temporary Revision
AMM AIRCRAFT Elastomer Pack Center Tube

CHAPTER 05
TIME LIMITS AND MAINTENANCE CHECKS
Section 05-28-50
Maintenance Checklist Airframe

1. Front Fuselage

Item 32 A is added to the existing table:

Inspection Items 100 200 1000 Time Initials

% 32A. Examine the elastomer pack center tube: X

% S Remove the elastomer pack (refer to Section

% 32-20).

% S Remove the elastomer elements (refer to Section

% 32-20).

% S Examine elastomer pack center tube:

% S If the center tube shows signs of deformation:

% Replace center tube (refer to Section 32-20).

% S If the center tube shows signs of wear:

% Replace center tube if a radial wear limit

% (depth measured) of 0.8 mm is exceeded.
%
% S Replace the elastomer elements in the event that
% they are worn or cracks are found. (Refer to
% Section 32-20).

% S Adjustment and installation of elastomer pack

% (refer to Section 32-20).
%

Doc # 6.02.01 Page 4a

AMM-TR-MÄM-40-808 05-28-50 08 Jul 2015
Temporary Revision DA 40 Series
Elastomer Pack Center Tube AIRCRAFT AMM

Intentionally left blank

Page 4aa
08 Jul 2015 05-28-50 Doc # 6.02.01
AMM-TR-MÄM-40-808
 DA 40 Series
Time Limits and
AMM
AIRCRAFT Maintenance Checks

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 38. If canopy jettison system (OÄM 40-232) is installed: X X 2 yrs.

Perform release test of canopy jettison system. (Refer

to Section 52-10).
% 39. If canopy jettison system (OÄM 40-232) is installed: X X X X

100h maintenance check of canopy jettison system.

(Refer to Section 52-10).

2. Cockpit

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

1. Remove the front seats and the access panels in X* X X

rear seat (if installed). (Refer to Section 25-10).

2. Remove the rear seat shells. X

(Refer to Section 25-10)

3. Examine the seats for damage. X* X X

4. Examine the safety belts. Make sure the lock X X X

mechanism operates correctly.

S Insert the tongue into the buckle.

S Pull on the strap. Make sure the ratchet holds the

tongue in the buckle.

S Operate the release button. The tongue must pull

freely from buckle.

5. Examine the cable ties and electrical connectors. Pull X* X X

lightly to make sure they are not loose.

% 6. Examine the control sticks. Make sure that the control X* X X

stick attachments are not loose and do not catch.

% 7. Examine the control stick stops. X* X X

Doc # 6.02.01 Page 5

Rev. 7 05-28-50 01 Apr 2013

NOTE: Please see the TEMPORARY REVISION that revises this page
 Temporary Revision
DA 40 AMM
AIRCRAFT Adjustable Front Seats

CHAPTER 05
TIME LIMITS AND MAINTENANCE CHECKS

Section 05-28-50
Maintenance Checklist Airframe

2. Cockpit

The following row is inserted in the existing table:

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 Time Initials
% CAUTION: DO NOT LOOSEN THE LEVER FOR THE ADJUSTABLE BACKREST
% OF THE FRONT SEATS UNINTENTIONALLY. THE SPRING LOADED
% BACKREST MAY SNAP FORWARD AND CAN CAUSE INJURY.

%
% 1A. If the adjustable front seats (OÄM 40-252) are installed: X* X X
%
% S Do a test of the backrest adjustment mechanism on
%
% both front seats (refer to Section 25-10).

% S Do a test of the lumbar support mechanism on both

% front seats (refer to Section 25-10).
%

Doc # 6.02.01 Page 5a

AMM-TR-OÄM-40-252 05-28-50 15 May 2013
 Temporary Revision
DA 40 AMM
AIRCRAFT Adjustable Front Seats

Intentionally left blank

Doc # 6.02.01 Page 5aa

AMM-TR-OÄM-40-252 05-28-50 15 May 2013
 Temporary Revision
DA 40 AMM Adjustable Backrest
AIRCRAFT
Hydrolok

CHAPTER 05
TIME LIMITS AND MAINTENANCE CHECKS
Section 05-28-50
Maintenance Checklist Airframe

2. Cockpit

Item 1 of the existing checklist is amended to read:

Inspection Items, Cabin, General 100 200 1000 2000 Time Initials
CAUTION: DO NOT LOOSEN THE LEVER FOR THE ADJUSTABLE BACKREST
OF THE FRONT SEATS UNINTENTIONALLY. THE SPRING LOADED
BACKREST MAY SNAP FORWARD AND CAN CAUSE INJURY.

% 1A. If the adjustable front seats (OÄM 40-252 or OÄM 40- X* X X X

% 375) are installed:

S Do a test of the backrest adjustment mechanism

on both front seats (refer to Section 25-10).

S Do a test of the lumbar support mechanism on

both front seats (refer to Section 25-10).

Doc # 6.02.01 Page 5a

AMM-TR-OÄM-40-375 05-28-50 27 Apr 2015
Temporary Revision
DA 40 AMM
Improved Flap Geometry AIRCRAFT

Intentionally left blank

Page 5aa
27 Apr 2015 05-28-50 Doc # 6.02.01
AMM-TR-OÄM-40-375
 Time Limits and DA 40 Series
Maintenance Checks AIRCRAFT AMM

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

8. Examine the aileron and elevator control system. X* X X X

Look specially for incorrect attachment and loose or
missing lock devices. (Refer to Sections 27-10 and
27-30).

% 9. Examine the Pitot-static system water traps. X* X X X

% 10. If water separators in MAP lines (MÄM 40-474 or 400 1 yr.
% MÄM 40-479) are installed in a DA 40 D airplane: hrs.
%

% Examine the ECU water separator:

% S Disconnect the water separator from the manifold

% pressure tube.

% S Remove the lock wire of the water separator.

% S Unscrew lower part of the water separator.

% S Check drain hole for blockage.

% S Check ball and sealing ring for damage or

% contamination.

% S Tighten lower part of water separator

% approx. 270° against O-ring seal.

% S Secure with lock wire.

% S Connect the water separator to the manifold

% pressure tube.

% 11. Examine the stall-warning hose. Look specially for X* X X X

contamination by water. (Refer to Section 34-20).

% 12. Examine the rudder pedals. Look specially for: X* X X X

%
S Incorrect attachment and function.
%
S Corrosion and damaged surface protection.

S Damaged adjustment mechanism.

S Improper function of adjustable mechanism.

(Refer to Section 27-20).

Page 6 Doc # 6.02.01

01 Apr 2013 05-28-50 Rev. 7
 DA 40 Series
Time Limits and
AMM
AIRCRAFT Maintenance Checks

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 13. Examine the rudder pedals S-tube. Look specially for: X* X X X

% S Wear on cable inlets and outlets.

% S Wear in inner radius of tube (no deformation

% visible or tactile).

% (Refer to Section 27-20).

% 14. Examine the rudder cables and pulleys. Look X* X X X

specially for:

S Incorrect attachment and function.

(Refer to Section 27-20).

S Rub marks.

S Defective safety plates.

S Worn out pulleys.

15. Examine the brake pipes/hoses and components. X X X X

Look specially for leakage.

% 16. Examine the brake fluid reservoirs on the co-pilot's X* X X X

side. Make sure the fluid level is correct.

S The fluid level must be 12 mm to 25 mm (½ to

1 in) below the top face of the reservoir filler hole.

% 17. Examine the instruments. Make sure that: X* X X X

S The markings are clear.

S The function is correct.

S Switches are correctly attached.

S The instrument lights operate correctly.

% 18. Examine the placards. Make sure that: X* X X X

S They are not damaged.

S None are missing. (Refer to Chapter 11).

Doc # 6.02.01 Page 7

Rev. 7 05-28-50 01 Apr 2013
 Time Limits and DA 40 Series
Maintenance Checks AIRCRAFT AMM

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

19. Remove the instrument panel cover. X* X X X

20. Examine the instrument panel. Make sure that: X* X X X

S The wiring is correctly attached.

S The instruments are correctly attached.

S The hoses are correctly attached.

S The circuit breakers are correctly attached.

S The cooling fan is operative and correctly

attached.

% 21. Examine the emergency battery system, if installed: X* X X X

S Measure the voltage of the emergency battery on

the EMERGENCY switch. Replace emergency
battery (all cells) or the battery pack if the voltage
is:

S Below 42 V for the Lycoming version.

S Below 36 V for the Lycoming version with

OÄM 40-179 carried out.

S Below 21 V for the TAE version.

S Below 18 V for the TAE version with G1000.

% 22. Make sure that the seal on the EMERGENCY switch X X X X

% is intact.

23. TAE version only: X X X X

Examine the ECU backup battery:

S Check for leakage, damage, insecure mounting,

and loose connectors.

S Measure voltage (minimum: 12.5 volts).

Page 8 Doc # 6.02.01

01 Apr 2013 05-28-50 Rev. 7
DA 40 Series
Time Limits and
AMM
AIRCRAFT Maintenance Checks

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

24. Examine the alternate static valve, if installed. Make X* X X X

sure that:

S The valve is correctly attached.

S The valve is not blocked.

S The hoses are correctly attached.

25. Examine the compass. Make sure that: X X X

S The compass is correctly attached.

S The fluid level is correct.

26. Examine the controls in the center console. Make X X X X

sure that for each control lever:

S There is full and free movement.

S There is no unusual play.

S The friction is correct.

S The mixture lock-out operates correctly

(Lycoming version only).

27. Inspect universal joints in fuel selector shaft (upper X X

and lower) very carefully for:

S Excessive wear.

S Uneven movement.

S Pins not completely pressed in.

S Loose pins.

Doc # 6.02.01 Page 9

Rev. 7 05-28-50 01 Apr 2013
 Time Limits and DA 40 Series
Maintenance Checks AIRCRAFT AMM

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 28. Examine the control cables in the center console: X* X X X

S Remove the retaining screws for the center

console cover plate.

S Lift the center console cover plate and visually

examine the cables. Look specially for wear and
kinks in the cables.

S Lower the center console cover plate into the

correct position, install the retaining screws.

% 29. Examine the trim control in the center console. Make X* X X X

sure that:

S There is full and free movement.

S There is no unusual play.

% 30. If the autopilot system is installed, then examine the X* X X X

trim servo assembly. Look specially for:

S Wear and corrosion.

S Insecure attachment of servo.

S Damaged, deformed, or worn out cardan shaft

and chain gears.

(Refer to Section 22-10).

Page 10 Doc # 6.02.01

01 Apr 2013 05-28-50 Rev. 7
 DA 40 Series
Time Limits and
AMM
AIRCRAFT Maintenance Checks

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 31. Examine the front cockpit structure. Look for X

dis-bonding, delamination and damage, specially to
these components:

S The fuselage shells.

S The firewall.

S The floor.

S The control bulkhead.

S The fuel pipe channels.

S The front main bulkhead.

S The rear main bulkhead.

S The inner faces of the front and rear closing ribs.

% 32. Examine the front cockpit structure. Look for X X

% dis-bonding, delamination and damage of the front
% and rear seat crash elements.

% 33. If the emergency axe (OÄM 40-326) is installed: X X X

S Check attachments for looseness.

S Check release mechanism for interference or

improper function.

34. If the sun visors (OÄM 40-327) are installed: X X X

S Check for obvious damage.

S Check press-studs for lack of retention force.

Doc # 6.02.01 Page 11

Rev. 7 05-28-50 01 Apr 2013

NOTE: Please see the TEMPORARY REVISION that revises this page
 DA 40 Series Temporary Revision
AMM AIRCRAFT Towing Device

Section 05-28-50
Maintenance Checklist Airframe

2. Cockpit

The following row is added to the existing table:

100 hr items marked X* apply to US registered airplanes only Interval

Inspection Items 100 200 1000 Time Initials

% 35. Examine the towing device system (if installed): X* X X

% S Check attachments for looseness.

% S Check release lever for proper function.

%

Doc # 6.02.01 Page 11a

AMM-TR-OÄM-40-063 05-28-50 10 Jul 2013
Temporary Revision DA 40 Series
Towing Device AIRCRAFT AMM

Intentionally left blank

Page 11aa Doc # 6.02.01

10 Jul 2013 05-28-50 AMM-TR-OÄM-40-063
 Temporary Revision
DA 40 AMM Emergency Egress
AIRCRAFT
Hammer

AFFECTED CHAPTERS:
CHAPTER 05
TIME LIMITS AND MAINTENANCE CHECKS

Section 05-28-50
Maintenance Checklist Airframe

2. Cockpit

The following row is added to the existing table:

Interval

Inspection Items 100 200 1000 2000 Time Initials

% 36. Examine the Emergency Egress Hammer X X X

% installation (if OÄM 40-401 is installed):

% S Check attachments for looseness.

% S Check release mechanism for interference or

% improper function.
%

Doc # 6.02.01 Page 11b

AMM-TR-OÄM 40-401 05-28-50 13-Mar-2017
Temporary Revision
Emergency Egress DA 40 AMM
Hammer AIRCRAFT

Intentionally left blank

Page 11bb Doc # 6.02.01

13-Mar-2017 05-28-50 AMM-TR-OÄM 40-401
 Time Limits and DA 40 Series
Maintenance Checks AIRCRAFT AMM

3. Center Fuselage, Internal

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 1. Examine the fire extinguisher. Make sure that: X* X X X

S The fire extinguisher will release from the

mounting bracket.

S The fire extinguisher contents are full.

2. Examine the baggage net. Make sure the spring clips X X X X

operate correctly.

% 3. If the autopilot system is installed, then examine the X* X X X

pitch servo assembly. Look specially for:

S Wear and corrosion.

S Insecure attachment of servo.

S Defective bridle cable assembly.

S Loose bridle cables or clamps on the elevator

push-rod.

(Refer to Section 22-10).

4. Examine the cable ties and electrical connectors. Pull X* X X X

lightly to make sure they are not loose.

5. Examine the push rod guides for the elevator X* X X X

push-rod. Look specially for incorrect attachment and
interference.

6. Examine the flap control mechanism on the aft main X* X X X

bulkhead. Look specially for:

S Damage and corrosion.

S Incorrect attachment and loose or missing lock

devices.

7. Examine the flap-actuator indicator and position X* X X X

switches. Look specially for incorrect attachment and
operation.

Page 12 Doc # 6.02.01

01 Apr 2013 05-28-50 Rev. 7
 DA 40 Series
Time Limits and
AMM
AIRCRAFT Maintenance Checks

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

8. Examine the aileron control system on the aft main X* X X X

bulkhead. Look specially for:

S Damage and corrosion.

S Incorrect attachment and loose or missing lock

devices.

% 9. If the autopilot system is installed, then examine the X* X X X

roll servo assembly. Look specially for:

S Wear and corrosion.

S Insecure attachment of servo.

S Defective bridle cable assembly.

S Loose bridle cables or clamps on the aileron

push-rod.

(Refer to Section 22-10).

10. If the KCS 55A compass system is installed, then X* X X X

examine the directional gyro below the passenger
seats. Make sure that it is attached correctly.

11. Do a cable tension test of the rudder control cable. X* X X X

(Refer to Section 27-20).

12. If the G1000 system is installed: X* X X X

Examine the Garmin G1000 unit behind the baggage

compartment frame. Look specially for:

S Insecure cable ties and connections.

S Insecure attachment.

% 13. Examine the center fuselage structure. Look for X

% dis-bonding, delamination and damage, specially to
% the fuselage shells.

% 14. Examine the baggage compartment frame. Look for X X

% dis-bonding, delamination and damage.

Doc # 6.02.01 Page 13

Rev. 7 05-28-50 01 Apr 2013
Time Limits and DA 40 Series
Maintenance Checks AIRCRAFT AMM

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

15. Do a coin-tap test for delamination of the fuselage MSI

center section top and bottom shells.

Page 14 Doc # 6.02.01

01 Apr 2013 05-28-50 Rev. 7
 DA 40 Series
Time Limits and
AMM
AIRCRAFT Maintenance Checks

4. Rear Fuselage

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 1. Examine the complete surface of the rear fuselage. X* X X X

Look specially for damage (dents, cracks, holes and
delamination).

Examine the paint coat.

2. Do a coin-tap test for delamination of the fuselage MSI

shell.

3. Examine the push rod guides for the elevator X* X X X

push-rod. Look specially for:

S Incorrect attachment.

S Interference.

4. Examine the rudder-control cables and turnbuckles. X* X X X

Look specially for:

S Corrosion and wear.

S Incorrect lock devices.

% 5. Examine the rear fuselage structure. Look for X

disbonding, delamination and damage specially to
these components:

S The fuselage shells.

S Ring frames 1, 2 and 3.

6. If the autopilot static source (OÄM 40-267) is installed: X X X X

S Check static source holes for blockage.

Doc # 6.02.01 Page 15

Rev. 7 05-28-50 01 Apr 2013
 Time Limits and DA 40 Series
Maintenance Checks AIRCRAFT AMM

5. Tail

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 1. Examine the complete surface of the aft part of the X* X X X

fuselage, vertical stabilizer, and horizontal stabilizer.
Look specially for damage (dents, cracks, holes and
delamination).

Examine the paint coat.

% 2. Examine the lower fin. Look specially for: X* X X X

S Damage to the bottom of the fin.

S Incorrect attachment.

% 3. Remove the rudder. Lubricate the hinge bushes. X* X X X

(Refer to Section 55-40).

4. Examine the inside of the vertical stabilizer. X X X

5. Inspect the inner skin of the vertical stabilizer through MSI

all access holes with mirror and flashlight. Check for
damage, cracks and delamination. Refer to Section
53-10.

6. Inspect the interior structure of the vertical stabilizer MSI

through all access holes with mirror and flashlight.
Check for damage, cracks, delamination and disbonding
from the vertical stabilizer skin. Look specially at these
components:

S Front web.

S Rear web.

S Lower rib (front and rear).

S Structure next to holes for mounting brackets.

Refer to Section 53-10.

% 7. Examine the rudder mounting and control cable X* X X X

connections.

% 8. Examine the rudder support bracket. X* X X X

Page 16 Doc # 6.02.01

01 Apr 2013 05-28-50 Rev. 7
 DA 40 Series
Time Limits and
AMM
AIRCRAFT Maintenance Checks

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 9. Examine the bottom edge of the rudder. Look specially X* X X X

for cracks and deformation.

% 10. Examine the rudder-stop reinforcement bars. Look X* X X X

specially for cracks and corrosion.

% 11. Examine the trim mechanism. Look specially for: X* X X X

S Incorrect attachment.

S Wear.

% 12. Examine the trim tab for damage. Look specially for X* X X X
incorrect attachment and loose or missing lock
devices. (Refer to Section 55-20).

13. Adjust the friction of the trim mechanism. X* X X X

% 14. Examine the horizontal stabilizer: X* X X X

S Remove the fairing for the horizontal stabilizer.

S Examine the mounting brackets. Look specially at

the attachment bolts for corrosion.

(Refer to Section 55-10).

% 15. Remove the tips from the horizontal stabilizer. X

S Examine the interior of the horizontal stabilizer.

Look specially for dis-bonding, delamination and
damage to the shells, spars and ribs.

(Refer to Section 55-10).

16. Remove the horizontal stabilizer. Refer to Section MSI

55-10.

17. Inspect the inner skin of the horizontal stabilizer MSI

through all access holes with mirror and flashlight.
Check for damage, cracks, and delamination.
Refer to Section 55-10.

Doc # 6.02.01 Page 17

Rev. 7 05-28-50 01 Apr 2013
 Time Limits and DA 40 Series
Maintenance Checks AIRCRAFT AMM

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

18. Inspect the interior structure of the horizontal stabilizer MSI

through all access holes with mirror and flashlight.
Check for damage, cracks, delamination and disbonding
from the horizontal stabilizer skin. Look specially at
these components:

S Front spar.

S Rear spar.

S Trailing edge web.

S All interior ribs and stiffeners.

S Structure next to holes for mounting brackets.

Refer to Section 55-10.

% 19. Examine the elevator for damage. Look specially for X* X X X

incorrect attachment and loose or missing lock
devices. (Refer to Section 55-20).

% 20. Examine the elevator hinges and control horn. Look X* X X X

specially for too much play.

Play allowed:

S Axial ± 1.00 mm (± 0.04 in).

S Radial ± 0.25 mm (± 0.01 in).

% 21. Examine the elevator push-rod: X

S Remove the elevator push-rod which goes through

the rear fuselage.

S Look specially for rub marks.

S Install the push-rod.

(Refer to Section 27-30).

% 22. Examine the structure of the vertical stabilizer. Look X

specially for dis-bonding, delamination and damage to
the shells, spars and ribs.

Page 18 Doc # 6.02.01

01 Apr 2013 05-28-50 Rev. 7
 DA 40 Series
Time Limits and
AMM
AIRCRAFT Maintenance Checks

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

23. Inspect the inner skin of the rear fuselage through all MSI
access holes with mirror and flashlight. Check for
damage, cracks, delamination and disbonding from the
sandwich foam. Refer to Section 53-10.

24. Inspect the interior structure of the rear fuselage MSI

through all access holes with mirror and flashlight.
Check for damage, cracks, delamination and
disbonding from the fuselage skin. Look specially at
these components:

S Ring frames 1, 2 and 3.

Refer to Section 53-10.

25. Install the horizontal stabilizer. Refer to Section MSI

55-10.

% 26. Install the HT tips. X

% 27. Install the fairing for the horizontal stabilizer. (Refer to X* X X X

Section 55-10).

% 28. Install the rudder. (Refer to Section 55-40). X* X X X

Doc # 6.02.01 Page 19

Rev. 7 05-28-50 01 Apr 2013

NOTE: Please see the TEMPORARY REVISION that revises this page
 DA 40 Series Temporary Revision
AMM AIRCRAFT Towing Device

5. Tail

The following row is added to the existing table:

100 hr items marked X* apply to US registered airplanes only Interval

Inspection Items 100 200 1000 Time Initials

% 29. Examine the towing device system (if installed): X* X X

% S Clean and lubricate the system

% S Check attachments for looseness.

% S Check release lever for proper function.

% Refer also to release device manufacturer’s manual.

Doc # 6.02.01 Page 19a

AMM-TR-OÄM-40-063 05-28-50 10 Jul 2013
Temporary Revision DA 40 Series
Towing Device AIRCRAFT AMM

Intentionally left blank

Page 19aa Doc # 6.02.01

10 Jul 2013 05-28-50 AMM-TR-OÄM-40-063
 Time Limits and DA 40 Series
Maintenance Checks AIRCRAFT AMM

6. Wings

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 1. Examine the complete surface of the wings. Look X* X X X

specially for damage (dents, cracks, holes and
delamination).

Examine the paint coat.

% 2. Examine the ailerons. Look specially for damage X* X X X

(dents, cracks, holes and delamination).

% 3. Examine the aileron hinges and horn. Look specially X* X X X

for too much play.

Play allowed:

S Axial ± 1.00 mm (± 0.04 in).

S Radial ± 0.25 mm (± 0.01 in).

% 4. Examine the aileron mass balance. X* X X X

% 5. Examine the flaps. Look specially for damage (dents, X* X X X

cracks, holes and delamination).

% 6. Examine the flap hinges and horn. Look specially for X* X X X

too much play. Play allowed:

S Axial ± 1.00 mm (± 0.04 in).

S Radial ± 0.25 mm (± 0.01 in).

% 7. Examine the flap mass balance. X* X X X

Page 20 Doc # 6.02.01

01 Apr 2013 05-28-50 Rev. 7
 NOTE: Please see the TEMPORARY REVISION that revises this page.
DA 40 Series
Time Limits and
AMM
AIRCRAFT Maintenance Checks

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 8. Remove the flap and aileron bellcrank access panels X* X X X

in the wing (Refer to Section 52-40).

S Examine the aileron and flap control system. Look

specially for incorrect attachment and loose or
missing lock devices (Refer to Sections 27-10 and
27-50).

S Visually check fuel tank bonding system through

access panels for improper connections and
damaged strips.

S Install the access panels.

9. Examine the Pitot head. Look specially for: X X X X

S Incorrect attachment.

S Damage.

S Foreign objects.

% 10. Remove the wing tips. (Refer to Section 57-10). X

% 11. Remove the wings. (Refer to Section 57-10). X

S Examine the main bolts.

S Grease the main bolts.

S Examine the A-bolts.

S Grease the A-bolts.

S Examine the B-bolts.

S Grease the B-bolts.

(Refer to Section 12-20).

Doc # 6.02.01 Page 21

Rev. 7 05-28-50 01 Apr 2013
 DA 40 Series Temporary Revision
AMM AIRCRAFT Fuel Tank Maintenance

Affected Chapters:
CHAPTER 05
TIME LIMITS AND MAINTENANCE CHECKS
Section 05-28-50
Maintenance Checklist Airframe
6. Wings

Item 10A is added to the existing table:

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 10A. Defuel the airplane (refer to Section 12-10). X X

Item 23 amended to read:

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 23. Remove the fuel tanks. X

Doc # 6.02.01 Page 21a

AMM-TR-MÄM 40-841 05-28-50 02-May-2016
Temporary Revision DA 40 Series
Fuel Tank Maintenance AIRCRAFT AMM

Intentionally left blank

Page 21aa
02-May-2016 05-28-50 Doc # 6.02.01
AMM-TR-MÄM 40-841
 Time Limits and DA 40 Series
Maintenance Checks AIRCRAFT AMM

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 12. Inspect the wing shells: X

S Look carefully for signs of damage.

S Look for dis-bonding between the shells and each

spar, rib and web.

S Do a coin-tap test for delamination of the shells.

(Refer to Section 51-10 and 57-10).

% 13. Examine the aileron push-rods: X

S Remove the aileron push-rods from the wings.

S Look specially for rub marks.

S Install the aileron push-rods.

(Refer to Section 27-10).

% 14. Examine the flap push-rods: X

S Remove the flap push-rods from the wings.

S Look specially for rub marks.

S Install the flap push-rods.

(Refer to Section 27-50).

WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE. DO
NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN CAUSE
INJURY TO PEOPLE AND DAMAGE TO EQUIPMENT.

% 15. Examine the fuel tank outlets: X

S Clean the finger filters.

S Look for foreign matter.

S Look for defective lock wire.

% 16. Remove the access covers. X X X

% 17. Check condition of tank interconnecting hoses. X X X

% 18. Check for leaks. X X X X

Page 22 Doc # 6.02.01

01 Apr 2013 05-28-50 Rev. 7
 NOTE: Please see the TEMPORARY REVISION that revises this page.
DA 40 Series
Time Limits and
AMM
AIRCRAFT Maintenance Checks

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 19. Collect a drain sample: X X X X

% S If sample is contaminated flush tank with removed

% drain valve.
%

% 20. Flush the tank: X X

% S Remove the drain valve.

% S Flush the fuel tank.

% S Check for debris and foreign objects.

% S Install the drain valve.

%

% 21. Install the access covers. X X X

% 22. Examine the fuel tank vents for blockage. X X X X

% S Open fuel filler cap and carefully blow through the

% LH-forward and RH-aft vent lines from outside into
% the tank with compressed air.

% 23. Defuel the airplane (refer to Section 12-10) and X

remove the fuel tanks::

S Defuel the airplane. (Refer to Section 12-10).

S Remove the fuel tanks.

% 24. Examine the fuel tanks: X

S Look specially for corrosion, leaks and other

damage.

S Look for foreign objects in the tanks.

% S Look for material deterioration or damage of the

% flexible fuel hoses connecting the fuel tank
% chambers.
%

Doc # 6.02.01 Page 23

Rev. 7 05-28-50 01 Apr 2013
 Temporary Revision
DA 40 AMM
AIRCRAFT Vent Line Routing

CHAPTER 05
TIME LIMITS AND MAINTENANCE CHECKS
Section 05-28-50
Maintenance Checklist Airframe

6. Wings

Item 22 is amended to read:

100 hr items marked X* apply to us registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

% 22. Examine the fuel tank vents for blockage: X X X X

% S Open fuel filler caps and carefully blow

% through the forward vent lines located on the
% lower wing shell vent cap from outside into the
% tank with compressed air.
%

Doc # 6.02.01 Page 23a

AMM-TR-MÄM-40-860 05-28-50 28 Jun 2016
Temporary Revision
DA 40 AMM
Vent Line Routing AIRCRAFT

Intentionally left blank

Page 23aa
28 Jun 2016 05-28-50 Doc # 6.02.01
AMM-TR-MÄM-40-860
 Time Limits and DA 40 Series
Maintenance Checks AIRCRAFT AMM

100 hr items marked X* apply to US registered airplanes only

Inspection Items 100 200 1000 2000 Time Initials

25. Inspect the inner wing skin through all access holes MSI
with mirror and flashlight. Check for damage, cracks,
delamination and disbonding from the sandwich foam.
Refer to Section 57-10.

26. Inspect the interior structure of the wing through all MSI
access holes with mirror and flashlight. Check for
damage, cracks, delamination and disbonding from
the wing skin. Look specially at these components:

S Front spar.

S Rear spar.

S Rear web.

S Root rib (front, middle and rear).

S End rib.

S All interior ribs and stiffeners.

Refer to Section 57-10.

% 27. Install the fuel tanks. X

(Refer to Section 28-10 for the Lycoming version or

Section 28-11 for the TAE version).

% 28. Install the wings. (Refer to Section 57-10). X

% 29. Install the wing tips. (Refer to Section 57-10). X

30. If the G1000 system is installed: X X

Do a function test of the fuel low-level switches:

S Set the ELECTRIC MASTER key switch to ON.

S The FUEL LOW caution message must appear on

the G1000 PFD.

S Set the ELECTRIC MASTER key switch to OFF.

7. General

Page 24 Doc # 6.02.01

01 Apr 2013 05-28-50 Rev. 7
 DA 40 Series
Time Limits and
AMM
AIRCRAFT Maintenance Checks

50 hour inspection items apply to airplanes with Lycoming engine only.

100 hr items marked X* apply to US registered airplanes only Interval

Inspection Items 50 100 200 1000 2000 Time Initials

1. If necessary, inspect optional equipment. Refer X X X X

to Chapter 9 of the Airplane Flight Manual
(Supplements).

2. If necessary, inspect Additional Equipment X X X X

(equipment which is installed but is not listed in
Section 6.5 of the Airplane Flight Manual).

3. Lubricate the airplane. (Refer to Section 12-20). X X X X

% 4. Measure the play in the aileron and elevator X* X X X

controls with the control surfaces locked (Refer
to Section 27-30). Look specially for too much
play. Do the test at the top of the control stick.

S Maximum play allowed ± 2.5 mm (± 0.1 in).

(Refer to Section 27-10).

% 5. Check flight controls and engine controls for X* X X X

% improper operation and installation.

% 6. Do a function test of the aileron control system. X

(Refer to Section 27-10).

% 7. Do a function test of the rudder control system. X

(Refer to Section 27-20).

% 8. Do a function test of the elevator control system. X

(Refer to Section 27-30).

% 9. Do an function test of the trim-system. Look X

specially for incorrect operation and indication.
(Refer to Section 27-38).

% 10. Do a function test of the flap system. (Refer to X

Section 27-50). Look specially at the pre-load.
With the flaps set to UP:

S Correct pre-load 3 - 5 daN (6.7 - 11.2 lb).

Doc # 6.02.01 Page 25

Rev. 7 05-28-50 01 Apr 2013
Time Limits and DA 40 Series
Maintenance Checks AIRCRAFT AMM

100 hr items marked X* apply to US registered airplanes only Interval

Inspection Items 50 100 200 1000 2000 Time Initials

11. Lower the airplane off jacks. X* X X X

(Refer to Section 07-10).

12. Do an operational test of the external lights. X X X X

13. Do an operational test of the Pitot heat. X X X X

14. Examine the airplane. Look specially for loose X X X X X

items and tools. Close all access panels. Install
these items:

S Engine cowlings.

S The instrument panel cover.

S The seat shells.

S The control-stick boots.

S The engine cowlings.

WARNING: DO NOT LET PERSONS INTO THE DANGER AREA OF THE

PROPELLER. PROPELLERS CAN CAUSE INJURY OR DEATH.

WARNING: SET THE PARKING BRAKE TO ON. IF YOU DO NOT DO THIS THE
AIRPLANE CAN MOVE. THIS CAN CAUSE INJURY OR DEATH.

15. Put the chocks against the main airplane X X X X X

wheels.

16. Do the post maintenance engine test. X X X X X

S For the engine run procedures refer to the

Airplane Flight Manual.

S Record the data (Refer to Paragraph 7,

Engine Ground Test Record).

17. Examine the engine for leakage. X X X X X

18. Make sure the engine oil filter is tight. (Refer to X X X X X

Section 79-00 for the Lycoming version or
Section 79-01 for the TAE version).

Page 26 Doc # 6.02.01

01 Apr 2013 05-28-50 Rev. 7
 DA 40 Series
Time Limits and
AMM
AIRCRAFT Maintenance Checks

100 hr items marked X* apply to US registered airplanes only Interval

Inspection Items 50 100 200 1000 2000 Time Initials

% 19. Do a test flight. Put the engine ground test and X* X X X

the flight test reports in the Airplane
Maintenance Log.

Note: If a Major Structural Inspection (MSI) was done, you must complete the Findings
Report for the Major Structural Inspection (MSI). Refer to Section 05-28-93.

Doc # 6.02.01 Page 27

Rev. 7 05-28-50 01 Apr 2013
Time Limits and DA 40 Series
Maintenance Checks AIRCRAFT AMM

Intentionally left blank

Page 28 Doc # 6.02.01

01 Apr 2013 05-28-50 Rev. 7
 DA 40 Series
Time Limits and
AMM
AIRCRAFT Maintenance Checks

Section 05-28-90
Maintenance Report

Complete a copy of the Maintenance Report after all of the applicable maintenance tasks in the
Maintenance Checklist have been initialed.

9 DA 40 9 DA 40 D 9 DA 40 F

Airplane Serial Number: Registration Number:

% Check: __________ (100 hr., 200 hr., 1000 hr., 2000 hr., Annual)

REMARKS:

The airplane is airworthy with respect to its maintenance condition.

_________________ _________________ _________________

Place Date Authorized

Doc # 6.02.01 Page 1

Rev. 7 05-28-90 01 Apr 2013
Time Limits and DA 40 Series
Maintenance Checks AIRCRAFT AMM

Intentionally left blank

Page 2 Doc # 6.02.01

01 Apr 2013 05-28-90 Rev. 7
 DA 40 Series
Time Limits and
AMM
AIRCRAFT Maintenance Checks

Section 05-28-91
Engine Ground Test Record

1. Engine Ground Test Record - Lycoming Version

WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.

THE PROPELLER CAN CAUSE DEATH OR INJURY TO PERSONS.

WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
TURN THE PROPELLER. DISCONNECT THE SPARK PLUG LEADS.
MAKE SURE THAT:
- THE IGNITION SWITCH IS SET TO "OFF".
- THE THROTTLE LEVER IS SET TO "IDLE".
- THE MIXTURE CONTROL IS SET TO "LEAN CUT-OFF".

WARNING: DO NOT GET OIL ON YOU. OIL CAN CAUSE SKIN DISEASE.

WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE. DO
NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN CAUSE
INJURY TO PEOPLE AND DAMAGE TO EQUIPMENT.

WARNING: WHEN YOU COMPLETE AN INSPECTION, MAKE SURE THAT YOU

REMOVE ALL LOOSE ITEMS/TOOLS FROM THAT AREA. LOOSE
ITEMS/TOOLS CAN PREVENT FULL MOVEMENT OF THE AIRPLANE
CONTROLS. THIS CAN CAUSE DEATH OR INJURY TO PERSONS.

CAUTION: YOU MUST ATTACH BLANKS/CAPS TO HOLES/PIPES WHEN YOU

REMOVE COMPONENTS. IF YOU DO NOT DO THIS, UNWANTED
DEBRIS CAN ENTER THE HOLES/PIPES. THIS CAN CAUSE
BLOCKAGE TO THE AIRPLANE SYSTEMS.

Doc # 6.02.01 Page 1

Rev. 7 05-28-91 01 Apr 2013
Time Limits and DA 40 Series
Maintenance Checks AIRCRAFT AMM

System Check (Lycoming Engine) Result

Note: Set the engine mixture control to full RICH to do the engine checks unless you
are told differently.

CAUTION: BEFORE YOU RUN THE ENGINE AT MORE THAN 1800 RPM MAKE
SURE THE OIL TEMPERATURE HAS RISEN TO 75 ºF, AND THE
CHT HAS RISEN TO 200 °F. THIS WILL PREVENT POSSIBLE
DAMAGE/TOO MUCH WEAR TO THE ENGINE.

Start the engine.

Set the propeller to fine pitch.

Set engine manifold pressure to 50-65 % power for sufficient time to do these checks:

S Record fuel pressure.

S Record RPM drop for left magneto.

S Record RPM drop for right magneto.

(Limit: Not more than 50 RPM difference, with a maximum drop of 175 RPM for each magneto).

Set engine RPM to full power for sufficient time to do these checks:

S Record fuel pressure.

S Record oil pressure.

S Record oil temperature.

S Record cylinder head temperature (CHT).

S Record alternator output.

S Record full power RPM.

Page 2 Doc # 6.02.01

01 Apr 2013 05-28-91 Rev. 7
DA 40 Series
Time Limits and
AMM
AIRCRAFT Maintenance Checks

System Check (Lycoming Engine) Result

CAUTION: THE MAGNETO OFF CHECK MUST BE DONE AT IDLE RPM. THIS
WILL PREVENT DAMAGE TO THE ENGINE.

CAUTION: DO NOT SHUT THE ENGINE DOWN UNTIL THE CHT GOES BELOW
300 ºF.

Set engine RPM to IDLE.

Record IDLE RPM.

Record fuel pressure.

Record oil pressure.

Record oil temperature.

Set the ignition switch to OFF for a short time. Then set the ignition switch to BOTH. If the engine
continues to run when the ignition switch is set to OFF, refer to Section 74-00 of the AMM.

Do a mixture setting check. (Limit: 25 - 50 RPM)

S Do a function test of the fuel tank selector. Set the fuel tank selector to
LEFT for a minimum of 3 minutes, the engine must continue to run. Set
the fuel tank selector to RIGHT for a minimum of 3 minutes, the engine
must continue to run.

S Do a positive fuel cut-off check.

Set the engine mixture control to LEAN/CUT OFF.

When the propeller stops rotating:

S Set the ignition switch to OFF.

S Set the ALT/BAT switch to OFF.

Doc # 6.02.01 Page 3

Rev. 7 05-28-91 01 Apr 2013