DA42 NG AMM r5

AIRCRAFT
DA 42 NG
AIRPLANE MAINTENANCE MANUAL
Copyright © by DIAMOND AIRCRAFT INDUSTRIES, Wiener Neustadt, Austria

Introduction DA 42 NG AMM
AIRCRAFT
This document is protected by copyright. All associated rights, in particular those of translation,
reprinting, radio transmission, reproduction by photo-mechanical or similar means and storing in data
processing facilities, in whole or part, are reserved.
Diamond Aircraft Industries GmbH

N. A. Otto-Str. 5
A-2700 Wiener Neustadt
Austria
Phone: +43-2622-26700
Fax: +43-2622-26780
% E-mail: office@diamondaircraft.com
The technical information contained in this document has been approved under the authority of
DOA No. EASA.21J.052.
DA 42 NG AMM Table of Contents
AIRCRAFT
TABLE OF CONTENTS
Ch/Sect Title
01-00 Introduction
02-00 Organization and Handling of the Manual
03-00 General Description of the Airplane
04-00 Airworthiness Limitations
05-00 Time Limits and Maintenance Checks
05-10 Time Limits
05-20 Scheduled Maintenance Checks
05-21 Flight-Line Checks
05-25 Drain Holes Inspection Checklist and Report
05-28 Maintenance Checklist DA 42 NG
05-28-00 Maintenance Checklist DA 42 NG Engines
05-28-50 Maintenance Checklist Airframe
05-28-90 Maintenance Report
05-28-91 Engine Ground Test Record
05-28-92 Check Flight Report
05-28-93 Major Structural Inspection Check Findings Report
05-50 Unscheduled Maintenance Checks
06-00 Dimensions and Areas
07-00 Lifting and Shoring
07-10 Jacking
07-11 Hoisting
08-00 Leveling and Weighing
08-10 Weighing
08-20 Leveling
09-00 Towing and Taxiing
09-10 Towing
09-20 Taxiing
10-00 Parking, Mooring, Storage and Return to Service
10-10 Parking and Storage
10-20 Mooring
10-30 Return to Service
11-00 Placards and Markings
11-20 Exterior Placards and Markings
11-30 Interior Placards and Markings
12-00 Servicing
12-10 Replenishment
12-20 Scheduled Servicing
12-30 Unscheduled Servicing
Doc # 7.02.15 Page i

Rev. 5 CONTENTS 22 Dec 2021
Table of Contents DA 42 NG AMM
AIRCRAFT
20-00 Standard Practices

20-10 Standard Practices - Airframe
20-30 Standard Practices - Electrical
20-70 Standard Practices - Engines
20-90 Standard Practices - Center Wing
21-00 Heating and Ventilation
21-20 Air Distribution
21-40 Heating
21-50 Cooling (OÄM 42-193/c or earlier installed)
21-51 Cooling (OÄM 42-193/d or later installed)
21-60 Temperature Control
22-00 Auto Flight
22-10 Autopilot
23-00 Communications
23-10 Speech Communication
23-15 Satellite Transceiver System (if OÄM 42-215 is carried out)
23-50 Audio Integration
23-60 Static Discharging
24-00 Electrical Power
24-30 DC Generation
24-31 Battery Systems
24-32 Emergency Power
24-33 Additional Alternator
24-40 External Power
24-60 DC Electrical Load Distribution
25-00 Equipment/Furnishings
25-10 Flight Compartment
25-50 Aft Baggage Compartment
25-60 Emergency Equipment
26-00 Fire Protection
27-00 Flight Controls
27-10 Flight Controls - Ailerons and Tabs
27-20 Flight Controls - Rudder
27-21 Flight Controls - Rudder Trim
27-30 Flight Controls - Elevator
27-37 Stall Warning System
27-38 Flight Controls - Elevator Trim - Mechanical
27-39 Flight Controls - Elevator Trim - Electrical
27-50 Flight Controls - Flaps
Page ii Doc # 7.02.15

22 Dec 2021 CONTENTS Rev. 5
DA 42 NG AMM Table of Contents
AIRCRAFT
28-00 Fuel
28-10 Fuel Storage System
28-20 Fuel Distribution
28-21 Fuel Distribution (if MÄM 42-600 is installed)
28-40 Fuel Indicating
29-00 Hydraulic Power
29-10 Main Hydraulic Power
30-00 Ice Protection System
31-00 Indicating Systems
31-10 Instrument and Control Panels
31-20 Independent Instruments
31-40 Central Computers
32-00 Landing Gear
32-10 Main Landing Gear
32-20 Nose Landing Gear
32-30 Extension and Retraction
32-40 Wheels and Brakes
32-50 Steering
32-60 Position and Warning
33-00 Lights
33-10 Lights - Flight Compartment
33-40 Exterior Lights
34-00 Navigation
34-10 Flight Environment Data
34-20 Attitude and Direction
34-30 Landing and Taxiing Aids
34-40 Independent Position Determining
34-41 Stormscope System
34-42 Traffic Advisory System
34-43 Garmin GWX68 or GWX70 Weather Radar System
34-50 Dependent Position Determining
34-56 Transponder (XPDR)
35-00 Oxygen System
35-10 Pressure Gauge and Oxygen System
51-00 Standard Practices/Structures
51-10 Investigation
51-20 Repair Processes
51-30 Materials
51-40 Fasteners
51-60 Control Surface Balancing
51-80 Lightning Protection
Doc # 7.02.15 Page iii

Rev. 5 CONTENTS 22 Dec 2021
Table of Contents DA 42 NG AMM
AIRCRAFT
52-00 Doors
52-10 Canopy and Passenger Door
52-30 Front Baggage Compartment Doors
52-40 Access Panels
53-00 Fuselage
53-10 Fuselage Structure
55-00 Stabilizers
55-10 Horizontal Stabilizer
55-20 Elevator
55-30 Lower Fin
55-40 Rudder and Trim Tab
56-00 Windows
56-10 Flight Compartment Windows
57-00 Wings
57-10 Wing Structure
57-50 Flaps
57-60 Ailerons
61-00 Propeller
61-10 Propeller Assembly
61-20 Propeller Control
71-00 Power Plant
71-10 Engine Cowlings
71-11 Engine Cowlings (if MÄM 42-600 is installed)
71-20 Engine Mounting
71-50 Electrical Cables in the Engine Compartment
71-60 Air Intakes
71-61 Air Intakes (if MÄM 42-600 is installed)
71-70 Engine Drains
71-71 Engine Drains (if MÄM 42-600 is installed)
72-00 Engine
73-00 Engine Fuel and Control
75-00 Liquid Cooling System
76-00 Engine Controls
77-00 Engine Indicating
77-40 Engine Indicating System
78-00 Exhaust
79-00 Oil Cooling
80-00 Starting
81-00 Turbo Charger
81-01 Turbo-Charger (if MÄM 42-600 is installed)
92-00 Wiring Diagrams
Page iv Doc # 7.02.15

22 Dec 2021 CONTENTS Rev. 5
DA 42 NG AMM Record of Revision
AIRCRAFT
Record of Revision
1. Record of Revision
Use this check list to record and control all of the revisions which you put in this Airplane Maintenance
Manual (AMM). Put the affected pages of the revision into the AMM as soon as you get them. Remove
and destroy the pages which are superseded. Complete the table below when you have put the
revision in the AMM.
Revision Date Inserted Inserted Revision Date Inserted Inserted

Number Issued On By Number Issued On By
Original 18 Feb 2009
1 15 Oct 2009
2 31 Mar 2012
3 16 Aug 2016
4 15 Mar 2018
% 5 22 Dec 2021
Doc # 7.02.15 Page v

Rev. 5 ROR 22 Dec 2021
Record of Revision DA 42 NG AMM
AIRCRAFT
2. Record of Incorporated Temporary Revisions
The following Temporary Revisions are incorporated into the DA 42 NG AMM by Revision 1:
Temporary Revision Number Description of Temporary Revision
AMM-TR-OÄM-42-142 Sun Visors for Tall Canopy
AMM-TR-MÄM-42-353 Removal of Check Valves in Nacelle
AMM-TR-MÄM-42-357 Limitation Placard
AMM-TR-MÄM-42-364 Gear Up Landing Check
AMM-TR-MÄM-42-366 Change of the Resistor for the Feathering System
AMM-TR-MÄM-42-388 Isolationdiodes for ECU
AMM-TR-MÄM-42-319 Main Landing Gear Measurement
AMM-TR-MÄM-42-332 Inspection Intervals Rudder Trim Mechanism
AMM-TR-MÄM-42-334 Improved Maintenance Instructions

for the Passenger Door
AMM-TR-MÄM-42-336 Optimized NLG Actuator
AMM-TR-MÄM-42-356/a Rudder Trim Adjustment
AMM-TR-MÄM-42-384 Alternate Air Valve FOD Screen
AMM-TR-MÄM-42-391 Turbo System Aluminium Tube
AMM-TR-MÄM-42-395 Improved Heating
AMM-TR-MÄM-42-398/a & 450 Change of Breather Line Installation
AMM-TR-MÄM-42-406 Radiator and Intercooler Protection
AMM-TR-MÄM-42-440 Flap Preload Adjustment
AMM-TR-MÄM-42-447 Replacement Instructions MLG Joints
AMM-TR-MÄM-42-448 New Governor Speed Settings
AMM-TR-MÄM-42-451 Engine Shock Mount Torques
AMM-TR-MÄM-42-454 Inspection of MLG Door Hinges
AMM-TR-MÄM-42-462 Additional Drainage in the Static System
AMM-TR-MÄM-42-471 Fuel Pulsation Damper
AMM-TR-MÄM-42-478 Extended Time Limit Oxygen Cylinder
Page vi Doc # 7.02.15

22 Dec 2021 ROR Rev. 5
AIRCRAFT
AMM-TR-MÄM-42-480 Fuel Pumps Check Valves
AMM-TR-MÄM-42-495 Alternative Hydraulic Fluids and Greases
AMM-TR-MÄM-42-515 Safety Walk Adhesive Strips
AMM-TR-MÄM-42-522 Maintenance Interval GFC 700
AMM-TR-MÄM-42-524 & 380 Maintenance Program Phase 1
AMM-TR-MÄM-42-533 Caliper Back Plate Torque Value Correction
AMM-TR-MÄM-42-534 Propeller Shipping Plug Removal
AMM-TR-MÄM-42-535 Gearbox Oil Inspection
AMM-TR-MÄM-42-538 Fuel Drain Valve Mounting Torque
AMM-TR-MÄM-42-550 Routing in Center Wing
AMM-TR-MÄM-42-551 Alternator Regulator E4A-91-200-000
AMM-TR-MÄM-42-570 Large Washer at RH FWD Engine Mounting Arm Bolt
AMM-TR-MÄM-42-594 Alternative Engine Shock Mount
AMM-TR-MÄM-42-600 Performance Enhancement
AMM-TR-MÄM-42-601 Corrections
AMM-TR-MÄM-42-641 Propeller Pitch Information
AMM-TR-OÄM-42-176 & 171 Retrofit Installation of Austro Engine E4-B
AMM-TR-OÄM-42-187 Coated Safety Walk
AMM-TR-OÄM-42-191 Trim Weight
AMM-TR-OÄM-42-193 Recirculating Air-Cabin Cooling (RACC)
AMM-TR-OÄM-42-204/a Additional Alternator
AMM-TR-OÄM-42-205 Emergency Axe
AMM-TR-OÄM-42-207 Short Baggage Extension
AMM-TR-OÄM-42-210 New GFC 700 Autopilot Hardware
AMM-TR-OÄM-42-231 Trim Weight
Doc # 7.02.15 Page vii

AIRCRAFT
AMM-TR-MÄM-42-659 Maximum Landing Mass 1999 kg
AMM-TR-MÄM-42-660/a Engine Gearbox Cooling
AMM-TR-MÄM-42-671 Engine Oil Quick Drain
AMM-TR-MÄM-42-684 Stall Warning System
AMM-TR-MÄM-42-707/a Correction of Aircraft Leveling
AMM-TR-MÄM-42-728 Unfeathering Accu Procedure
AMM-TR-MÄM-42-730 Fuel Level Sensor Installation
AMM-TR-MÄM-42-737 Time Limit Fuel Bypass Valve
AMM-TR-MÄM-42-739 Heating / Defrost
AMM-TR-MÄM-42-742 Trouble Shooting Fuel System
AMM-TR-MÄM-42-743 Governor Nut Torque
AMM-TR-MÄM-42-745/a Coolant Tank Pressure Relief Valve Test
AMM-TR-MÄM-42-746 Coolant System Pressure Test
AMM-TR-MÄM-42-756 Ground Handling
AMM-TR-MÄM-42-823 Protective Pads for Charged Air Hoses
AMM-TR-MÄM-42-852 Coolant Water Tank with Threaded Cap and Larger

Filler Neck
AMM-TR-MÄM-42-875 Replacement of Passenger Door Hinges
AMM-TR-MÄM-42-878 Accessory Power Plug
AMM-TR-MÄM-42-880 Drag Brace Figure Correction
AMM-TR-MÄM-42-881 Additional Elevator Mass
AMM-TR-MÄM-42-885 New Rudder Installation and Rudder Trim
AMM-TR-MÄM-42-893 Inspection of Cardan Joint Bracket
AMM-TR-MÄM-42-895 Improved Lightning Protection of Coolant System
AMM-TR-MÄM-42-900/a Silicate Pouch
AMM-TR-MÄM-42-920 New Type 6 Lubricants
AMM-TR-MÄM-42-933 Alternate Air
AMM-TR-MÄM-42-961 Flap Control System
AMM-TR-MÄM-42-963/a Turbo Charger V-Clamp
Page viii Doc # 7.02.15

AIRCRAFT
AMM-TR-OÄM-42-055 Continuous Flow Oxygen System
AMM-TR-OÄM-42-056/a Auxiliary Fuel Tanks
AMM-TR-OÄM-42-119/b & -273 Garmin GWX 68 and GWX 70 Weather Radar
AMM-TR-OÄM-42-160 Flight Into Known Icing
AMM-TR-OÄM-42-193/b Recirculating Air-Cabin Cooling (RACC)
AMM-TR-OÄM-42-203 TKS Tank in Rear Fuselage
AMM-TR-OÄM-42-204/d Additional Alternator
AMM-TR-OÄM-42-213 Satellite Transceiver Gamin GSR 56
AMM-TR-OÄM-42-222 Whelen LED Position / Anti Collision Lights
AMM-TR-OÄM-42-224 Removal of Unfeathering Accumulator
AMM-TR-OÄM-42-226 ELT, KANNAD 406 AF-Compact
AMM-TR-OÄM-42-231/a Trim Weight
AMM-TR-OÄM-42-251 Diesel Operation
AMM-TR-OÄM-42-259/a Front Seats with Adjustable Backrest Hydrolok
AMM-TR-OÄM-42-270 Mid Continent, MD302 Standby Attitude Module
AMM-TR-OÄM-42-277 Provisions for MÄM 42-678 and MÄM 42-659
AMM-TR-OÄM-42-281/a & -283 RH Stick Removal & Pilot’s Removable Stick
A. Airplanes with OÄM 42-277 installed:
Airplanes with OÄM 42-277 installed have all technical provisions for the operation with
MÄM 42-678 and MÄM 42-659 installed, therefore consider MÄM 42-678 and MÄM 42-659 as
carried out when using the AMM.
Doc # 7.02.15 Page ix

AIRCRAFT
AMM-TR-MÄM-42-961/a & -1007 Flap Control System
AMM-TR-MÄM-42-978 Garmin Hard- and Software Upgrade I
AMM-TR-MÄM-42-989 Conservation of Parts
AMM-TR-MÄM-42-991 Turbo connector Shim
AMM-TR-MÄM-42-994 Door Handle Improvement
AMM-TR-MÄM-42-995 Engine Oils
AMM-TR-MÄM-42-1001/a Colors other than White
AMM-TR-MÄM-42-1004 SG3-0 Hose between Turbo Charger and Intercooler
AMM-TR-MÄM-42-1008 Turbo Charger Hose Installation
AMM-TR-MÄM-42-1024 New Maplight
AMM-TR-MÄM-42-1041 Rudder Balance Mass Increase
AMM-TR-MÄM-42-1049 Horizontal Stabilizer Torque
AMM-TR-MÄM-42-1052 Rudder and Rudder Trim Adjustment
AMM-TR-OÄM-42-194 Canopy Jettison System
AMM-TR-OÄM-42-247 RH ECU Backup Battery in Lower Tail Fin
AMM-TR-OÄM-42-248 Provisions for Tablet Mount
AMM-TR-OÄM-42-304 Emergency Egress Hammer
AMM-TR-OÄM-42-324 AmSafe Seatbelt Airbag V23 System
Page x Doc # 7.02.15

AIRCRAFT
% AMM-TR-MÄM-42-1025 Alternative Emergency Battery Tray
% AMM-TR-MÄM-42-1072/a Garmin Hard- and Software Upgrade II
% AMM-TR-MÄM-42-1073 MLG Tire Clearance
% AMM-TR-MÄM-42-1079/a Fuel Tank Sealant Material
% AMM-TR-MÄM-42-1084 Wheel Track and Camber
% AMM-TR-MÄM-42-1086 Rudder and Rudder Trim Adjustment
% AMM-TR-MÄM-42-1090 Additional Colors
% AMM-TR-MÄM-42-1093 Fire Detector Installation
% AMM-TR-MÄM-42-1094 New Sealing Concept for Map Light Attachment
% AMM-TR-MÄM-42-1099 Improved Filling Procedure for Cooling System
% AMM-TR-MÄM-42-1105 Additional Color Light Blue
% AMM-TR-MÄM-42-1112 Fuel Tank Connection Hoses
% AMM-TR-MÄM-42-1124 Improved Rudder Yoke Bolt Design
% AMM-TR-MÄM-42-1125 Inspection of Airfilter for Manufacturing

% Residues
% AMM-TR-MÄM-42-1126 Definition of Special Torque at Hydraulic Pump

% Unit
% AMM-TR-MÄM-42-1129 Door Warning Switch
% AMM-TR-MÄM-42-1134 New Placard for Painting Scheme
% AMM-TR-MÄM-42-1147 Garmin G1000 NXi Line Maintenance Manual
% AMM-TR-MÄM-42-1157 Improvement of Stall Warning Gauge
% AMM-TR-MÄM-42-1180 Actualisation of Wing Movable Mass
% AMM-TR-MÄM-42-1189 Aileron Controls in the Fuselage
% AMM-TR-MÄM-42-1194 Additional Colors
% AMM-TR-MÄM-42-1220 Door Handle Installation
% AMM-TR-OÄM-42-053 Flight Into Known Icing
% AMM-TR-OÄM-42-056/c Auxiliary Fuel Tanks
% AMM-TR-OÄM-42-160/b Flight Into Known Icing
Doc # 7.02.15 Page xi

AIRCRAFT
% AMM-TR-OÄM-42-204/e Additional Alternator
% AMM-TR-OÄM-42-324/b & 334/a AmSafe Seatbelt Airbag V23 System
% AMM-TR-OÄM-42-343 ELT, KANNAD AF-Integra
% AMM-TR-OÄM-42-349 Avidyne Sky Trax 6xx (TAS 6xxA)Series
% AMM-TR-OÄM-42-356 Alternative MLG Brace Bracket RH
% AMM-TR-OÄM-42-365 Key Hanger
Page xii Doc # 7.02.15

DA 42 NG AMM List of Effective Pages
AIRCRAFT
LIST OF EFFECTIVE PAGES

1. General
The list of effective pages uses this abbreviation:
) TOC = Table of Contents.
) ROR = Record of Revisions
) LOEP = List of Effective Pages
All Sections have a Title Page and a Table of Contents. The TOC can have one page or it can have
many pages.
Each revision to the Airplane Maintenance Manual will have a new List of Effective Pages.
Front Page Revision Front Page Revision Front Page Revision

Matter Date Matter Date Matter Date
TOC i 22 Dec 2021 LOEP 5 22 Dec 2021 LOEP 21 22 Dec 2021
TOC ii 22 Dec 2021 LOEP 6 22 Dec 2021 LOEP 22 22 Dec 2021
TOC iii 22 Dec 2021 LOEP 7 22 Dec 2021 LOEP 23 22 Dec 2021
TOC iv 22 Dec 2021 LOEP 8 22 Dec 2021 LOEP 24 22 Dec 2021
ROR v 22 Dec 2021 LOEP 9 22 Dec 2021 LOEP 25 22 Dec 2021
ROR vi 22 Dec 2021 LOEP 10 22 Dec 2021 LOEP 26 22 Dec 2021
ROR vii 22 Dec 2021 LOEP 11 22 Dec 2021 LOEP 27 22 Dec 2021
ROR viii 22 Dec 2021 LOEP 12 22 Dec 2021 LOEP 28 22 Dec 2021
ROR ix 22 Dec 2021 LOEP 13 22 Dec 2021
ROR x 22 Dec 2021 LOEP 14 22 Dec 2021
ROR xi 22 Dec 2021 LOEP 15 22 Dec 2021
ROR xii 22 Dec 2021 LOEP 16 22 Dec 2021
LOEP 1 22 Dec 2021 LOEP 17 22 Dec 2021
LOEP 2 22 Dec 2021 LOEP 18 22 Dec 2021
LOEP 3 22 Dec 2021 LOEP 19 22 Dec 2021
LOEP 4 22 Dec 2021 LOEP 20 22 Dec 2021
Doc # 7.02.15 Page 1

Rev. 5 LOEP 22 Dec 2021
List of Effective Pages DA 42 NG AMM
AIRCRAFT
Chapter Page Revision Chapter Page Revision Chapter Page Revision

Section Date Section Date Section Date
01-00 Title 1 22 Dec 2021 03-00 2 22 Dec 2021 05-10 1 22 Dec 2021
01-00 Title 2 22 Dec 2021 03-00 3 22 Dec 2021 05-10 2 22 Dec 2021
01-00 TOC 1 22 Dec 2021 03-00 4 22 Dec 2021 05-10 3 22 Dec 2021
01-00 TOC 2 22 Dec 2021 03-00 5 22 Dec 2021 05-10 4 22 Dec 2021
01-00 1 22 Dec 2021 03-00 6 22 Dec 2021 05-10 5 22 Dec 2021
01-00 2 22 Dec 2021 03-00 7 22 Dec 2021 05-10 6 22 Dec 2021
01-00 3 22 Dec 2021 03-00 8 22 Dec 2021 05-10 7 22 Dec 2021
01-00 4 22 Dec 2021 04-00 Title 1 22 Dec 2021 05-10 8 22 Dec 2021
01-00 5 22 Dec 2021 04-00 Title 2 22 Dec 2021 05-20 1 22 Dec 2021
01-00 6 22 Dec 2021 04-00 TOC 1 22 Dec 2021 05-20 2 22 Dec 2021
02-00 Title 1 22 Dec 2021 04-00 TOC 2 22 Dec 2021 05-20 3 22 Dec 2021
02-00 Title 2 22 Dec 2021 04-00 1 22 Dec 2021 05-20 4 22 Dec 2021
02-00 TOC 1 22 Dec 2021 04-00 2 22 Dec 2021 05-21 1 22 Dec 2021
02-00 TOC 2 22 Dec 2021 04-00 3 22 Dec 2021 05-21 2 22 Dec 2021
02-00 1 22 Dec 2021 04-00 4 22 Dec 2021 05-25 1 22 Dec 2021
02-00 2 22 Dec 2021 04-00 5 22 Dec 2021 05-25 2 22 Dec 2021
02-00 3 22 Dec 2021 04-00 6 22 Dec 2021 05-25 3 22 Dec 2021
02-00 4 22 Dec 2021 05-00 Title 1 22 Dec 2021 05-25 4 22 Dec 2021
02-00 5 22 Dec 2021 05-00 Title 2 22 Dec 2021 05-25 5 22 Dec 2021
02-00 6 22 Dec 2021 05-00 TOC 1 22 Dec 2021 05-25 6 22 Dec 2021
02-00 7 22 Dec 2021 05-00 TOC 2 22 Dec 2021 05-25 7 22 Dec 2021
02-00 8 22 Dec 2021 05-00 TOC 3 22 Dec 2021 05-25 8 22 Dec 2021
02-00 9 22 Dec 2021 05-00 TOC 4 22 Dec 2021 05-25 9 22 Dec 2021
02-00 10 22 Dec 2021 05-00 1 22 Dec 2021 05-25 10 22 Dec 2021
03-00 Title 1 22 Dec 2021 05-00 2 22 Dec 2021 05-25 11 22 Dec 2021
03-00 Title 2 22 Dec 2021 05-00 3 22 Dec 2021 05-25 12 22 Dec 2021
03-00 TOC 1 22 Dec 2021 05-00 4 22 Dec 2021 05-25 13 22 Dec 2021
03-00 TOC 2 22 Dec 2021 05-00 5 22 Dec 2021 05-25 14 22 Dec 2021
03-00 1 22 Dec 2021 05-00 6 22 Dec 2021 05-25 15 22 Dec 2021
Page 2 Doc # 7.02.15

22 Dec 2021 LOEP Rev. 5
AIRCRAFT

05-25 16 22 Dec 2021 05-28-50 11 22 Dec 2021 05-28-50 40 22 Dec 2021
05-28-00 1 22 Dec 2021 05-28-50 12 22 Dec 2021 05-28-50 41 22 Dec 2021
05-28-00 2 22 Dec 2021 05-28-50 13 22 Dec 2021 05-28-50 42 22 Dec 2021
05-28-00 3 22 Dec 2021 05-28-50 14 22 Dec 2021 05-28-50 43 22 Dec 2021
05-28-00 4 22 Dec 2021 05-28-50 15 22 Dec 2021 05-28-50 44 22 Dec 2021
05-28-00 5 22 Dec 2021 05-28-50 16 22 Dec 2021 05-28-50 45 22 Dec 2021
05-28-00 6 22 Dec 2021 05-28-50 17 22 Dec 2021 05-28-50 46 22 Dec 2021
05-28-00 7 22 Dec 2021 05-28-50 18 22 Dec 2021 05-28-50 47 22 Dec 2021
05-28-00 8 22 Dec 2021 05-28-50 19 22 Dec 2021 05-28-50 48 22 Dec 2021
05-28-00 9 22 Dec 2021 05-28-50 20 22 Dec 2021 05-28-50 49 22 Dec 2021
05-28-00 10 22 Dec 2021 05-28-50 21 22 Dec 2021 05-28-50 50 22 Dec 2021
05-28-00 11 22 Dec 2021 05-28-50 22 22 Dec 2021 05-28-50 51 22 Dec 2021
05-28-00 12 22 Dec 2021 05-28-50 23 22 Dec 2021 05-28-50 52 22 Dec 2021
05-28-00 13 22 Dec 2021 05-28-50 24 22 Dec 2021 05-28-50 53 22 Dec 2021
05-28-00 14 22 Dec 2021 05-28-50 25 22 Dec 2021 05-28-50 54 22 Dec 2021
05-28-00 15 22 Dec 2021 05-28-50 26 22 Dec 2021 05-28-50 55 22 Dec 2021
05-28-00 16 22 Dec 2021 05-28-50 27 22 Dec 2021 05-28-50 56 22 Dec 2021
05-28-00 17 22 Dec 2021 05-28-50 28 22 Dec 2021 05-28-90 1 22 Dec 2021
05-28-00 18 22 Dec 2021 05-28-50 29 22 Dec 2021 05-28-90 2 22 Dec 2021
05-28-50 1 22 Dec 2021 05-28-50 30 22 Dec 2021 05-28-91 1 22 Dec 2021
05-28-50 2 22 Dec 2021 05-28-50 31 22 Dec 2021 05-28-91 2 22 Dec 2021
05-28-50 3 22 Dec 2021 05-28-50 32 22 Dec 2021 05-28-92 1 22 Dec 2021
05-28-50 4 22 Dec 2021 05-28-50 33 22 Dec 2021 05-28-92 2 22 Dec 2021
05-28-50 5 22 Dec 2021 05-28-50 34 22 Dec 2021 05-28-92 3 22 Dec 2021
05-28-50 6 22 Dec 2021 05-28-50 35 22 Dec 2021 05-28-92 4 22 Dec 2021
05-28-50 7 22 Dec 2021 05-28-50 36 22 Dec 2021 05-28-92 5 22 Dec 2021
05-28-50 8 22 Dec 2021 05-28-50 37 22 Dec 2021 05-28-92 6 22 Dec 2021
05-28-50 9 22 Dec 2021 05-28-50 38 22 Dec 2021 05-28-93 1 22 Dec 2021
05-28-50 10 22 Dec 2021 05-28-50 39 22 Dec 2021 05-28-93 2 22 Dec 2021
Doc # 7.02.15 Page 3

AIRCRAFT

05-50 1 22 Dec 2021 06-00 8 22 Dec 2021 08-10 3 22 Dec 2021
05-50 2 22 Dec 2021 06-00 9 22 Dec 2021 08-10 4 22 Dec 2021
05-50 3 22 Dec 2021 06-00 10 22 Dec 2021 08-10 5 22 Dec 2021
05-50 4 22 Dec 2021 06-00 11 22 Dec 2021 08-10 6 22 Dec 2021
05-50 5 22 Dec 2021 06-00 12 22 Dec 2021 08-10 7 22 Dec 2021
05-50 6 22 Dec 2021 06-00 13 22 Dec 2021 08-10 8 22 Dec 2021
05-50 7 22 Dec 2021 06-00 14 22 Dec 2021 08-20 1 22 Dec 2021
05-50 8 22 Dec 2021 06-00 15 22 Dec 2021 08-20 2 22 Dec 2021
05-50 9 22 Dec 2021 06-00 16 22 Dec 2021 08-20 3 22 Dec 2021
05-50 10 22 Dec 2021 07-00 Title 1 22 Dec 2021 08-20 4 22 Dec 2021
05-50 11 22 Dec 2021 07-00 Title 2 22 Dec 2021 09-00 Title 1 22 Dec 2021
05-50 12 22 Dec 2021 07-00 TOC 1 22 Dec 2021 09-00 Title 2 22 Dec 2021
05-50 13 22 Dec 2021 07-00 TOC 2 22 Dec 2021 09-00 TOC 1 22 Dec 2021
05-50 14 22 Dec 2021 07-00 1 22 Dec 2021 09-00 TOC 2 22 Dec 2021
05-50 15 22 Dec 2021 07-00 2 22 Dec 2021 09-00 1 22 Dec 2021
05-50 16 22 Dec 2021 07-10 1 22 Dec 2021 09-00 2 22 Dec 2021
05-50 17 22 Dec 2021 07-10 2 22 Dec 2021 09-10 1 22 Dec 2021
05-50 18 22 Dec 2021 07-10 3 22 Dec 2021 09-10 2 22 Dec 2021
06-00 Title 1 22 Dec 2021 07-10 4 22 Dec 2021 09-10 3 22 Dec 2021
06-00 Title 2 22 Dec 2021 07-11 1 22 Dec 2021 09-10 4 22 Dec 2021
06-00 TOC 1 22 Dec 2021 07-11 2 22 Dec 2021 09-20 1 22 Dec 2021
06-00 TOC 2 22 Dec 2021 08-00 Title 1 22 Dec 2021 09-20 2 22 Dec 2021
06-00 1 22 Dec 2021 08-00 Title 2 22 Dec 2021 09-20 3 22 Dec 2021
06-00 2 22 Dec 2021 08-00 TOC 1 22 Dec 2021 09-20 4 22 Dec 2021
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32-50 101 22 Dec 2021 33-00 Title 2 22 Dec 2021 33-40 5 22 Dec 2021
32-50 102 22 Dec 2021 33-00 TOC 1 22 Dec 2021 33-40 6 22 Dec 2021
32-50 201 22 Dec 2021 33-00 TOC 2 22 Dec 2021 33-40 101 22 Dec 2021
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34-00 Title 2 22 Dec 2021 34-10 215 22 Dec 2021 34-42 204 22 Dec 2021
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51-40 202 22 Dec 2021 52-00 TOC 1 22 Dec 2021 52-10 212 22 Dec 2021
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52-30 202 22 Dec 2021 55-00 Title 1 22 Dec 2021 55-40 4 22 Dec 2021
52-30 203 22 Dec 2021 55-00 Title 2 22 Dec 2021 55-40 201 22 Dec 2021
52-30 204 22 Dec 2021 55-00 TOC 1 22 Dec 2021 55-40 202 22 Dec 2021
52-40 1 22 Dec 2021 55-00 TOC 2 22 Dec 2021 55-40 203 22 Dec 2021
52-40 2 22 Dec 2021 55-00 1 22 Dec 2021 55-40 204 22 Dec 2021
53-00 Title 1 22 Dec 2021 55-00 2 22 Dec 2021 55-40 205 22 Dec 2021
53-00 Title 2 22 Dec 2021 55-10 1 22 Dec 2021 55-40 206 22 Dec 2021
53-00 TOC 1 22 Dec 2021 55-10 2 22 Dec 2021 55-40 207 22 Dec 2021
53-00 TOC 2 22 Dec 2021 55-10 201 22 Dec 2021 55-40 208 22 Dec 2021
53-00 1 22 Dec 2021 55-10 202 22 Dec 2021 56-00 Title 1 22 Dec 2021
53-00 2 22 Dec 2021 55-10 203 22 Dec 2021 56-00 Title 2 22 Dec 2021
53-10 1 22 Dec 2021 55-10 204 22 Dec 2021 56-00 TOC 1 22 Dec 2021
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56-10 208 22 Dec 2021 57-50 3 22 Dec 2021 61-00 TOC 2 22 Dec 2021
57-00 Title 1 22 Dec 2021 57-50 4 22 Dec 2021 61-00 1 22 Dec 2021
57-00 Title 2 22 Dec 2021 57-50 5 22 Dec 2021 61-00 2 22 Dec 2021
57-00 TOC 1 22 Dec 2021 57-50 6 22 Dec 2021 61-10 1 22 Dec 2021
57-00 TOC 2 22 Dec 2021 57-50 201 22 Dec 2021 61-10 2 22 Dec 2021
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57-50 1 22 Dec 2021 61-00 Title 2 22 Dec 2021 61-10 217 22 Dec 2021
57-50 2 22 Dec 2021 61-00 TOC 1 22 Dec 2021 61-10 218 22 Dec 2021
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71-00 TOC 1 22 Dec 2021 71-00 218 22 Dec 2021 71-20 101 22 Dec 2021
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71-60 5 22 Dec 2021 71-61 102 22 Dec 2021 73-00 Title 1 22 Dec 2021
71-60 6 22 Dec 2021 71-70 1 22 Dec 2021 73-00 Title 2 22 Dec 2021
71-60 101 22 Dec 2021 71-70 2 22 Dec 2021 73-00 TOC 1 22 Dec 2021
71-60 102 22 Dec 2021 71-70 201 22 Dec 2021 73-00 TOC 2 22 Dec 2021
71-60 201 22 Dec 2021 71-70 202 22 Dec 2021 73-00 1 22 Dec 2021
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71-60 213 22 Dec 2021 72-00 TOC 2 22 Dec 2021 75-00 TOC 1 22 Dec 2021
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75-00 215 22 Dec 2021 76-00 210 22 Dec 2021 78-00 TOC 1 22 Dec 2021
75-00 216 22 Dec 2021 76-00 211 22 Dec 2021 78-00 TOC 2 22 Dec 2021
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75-00 222 22 Dec 2021 77-00 Title 1 22 Dec 2021 78-00 102 22 Dec 2021
76-00 Title 1 22 Dec 2021 77-00 Title 2 22 Dec 2021 78-00 201 22 Dec 2021
76-00 Title 2 22 Dec 2021 77-00 TOC 1 22 Dec 2021 78-00 202 22 Dec 2021
76-00 TOC 1 22 Dec 2021 77-00 TOC 2 22 Dec 2021 79-00 Title 1 22 Dec 2021
76-00 TOC 2 22 Dec 2021 77-00 1 22 Dec 2021 79-00 Title 2 22 Dec 2021
76-00 1 22 Dec 2021 77-00 2 22 Dec 2021 79-00 TOC 1 22 Dec 2021
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79-00 TOC 2 22 Dec 2021 81-00 Title 1 22 Dec 2021 81-01 202 22 Dec 2021
79-00 1 22 Dec 2021 81-00 Title 2 22 Dec 2021 81-01 203 22 Dec 2021
79-00 2 22 Dec 2021 81-00 TOC 1 22 Dec 2021 81-01 204 22 Dec 2021
79-00 101 22 Dec 2021 81-00 TOC 2 22 Dec 2021 81-01 205 22 Dec 2021
79-00 102 22 Dec 2021 81-00 1 22 Dec 2021 81-01 206 22 Dec 2021
79-00 201 22 Dec 2021 81-00 2 22 Dec 2021 81-01 207 22 Dec 2021
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79-00 204 22 Dec 2021 81-00 5 22 Dec 2021 92-00 Title 2 22 Dec 2021
79-00 205 22 Dec 2021 81-00 6 22 Dec 2021 92-00 TOC 1 22 Dec 2021
79-00 206 22 Dec 2021 81-00 101 22 Dec 2021 92-00 TOC 2 22 Dec 2021
80-00 Title 1 22 Dec 2021 81-00 102 22 Dec 2021 92-00 1 22 Dec 2021
80-00 Title 2 22 Dec 2021 81-00 201 22 Dec 2021 92-00 2 22 Dec 2021
80-00 TOC 1 22 Dec 2021 81-00 202 22 Dec 2021 92-00 3 22 Dec 2021
80-00 TOC 2 22 Dec 2021 81-00 203 22 Dec 2021 92-00 4 22 Dec 2021
80-00 1 22 Dec 2021 81-00 204 22 Dec 2021 wiring diagrams as listed in
Chapter 92
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AIRCRAFT
Intentionally left blank
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DA 42 NG AMM Introduction
AIRCRAFT
CHAPTER 01
INTRODUCTION
Doc # 7.02.15 Page 1

Rev. 5 01-TITLE 22 Dec 2021
AIRCRAFT
Page 2
22 Dec 2021 01-TITLE Doc # 7.02.15
Rev. 5
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 01
INTRODUCTION
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Revision Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Warning, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Manual Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. Page Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7. Record of Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8. List of Effective Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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CHAPTER 01
INTRODUCTION
1. General
This Airplane Maintenance Manual contains the data necessary to do the maintenance of the
DA 42 NG airplane. It contains a full description of the systems, trouble shooting procedures,
component removal and installation procedures and maintenance instructions. It does not contain
maintenance data for components removed from the airplane (Maintenance Shop data).
The Airplane Maintenance Manual contains the wiring diagrams for the electrical system.
Use the DA 42 NG Airplane Flight Manual, latest revision with the Airplane Maintenance Manual, and
the related Service Bulletins. Additional maintenance data is referenced in Chapter 05-00.
2. Revision Service
The manufacturer provides a revision service for the Airplane Maintenance Manual. The revision
shows design changes to the airplane or changes in procedures. Each page of the manual shows the
date of issue. If the page has changed, it shows the date of the revision.
3. Warning, Cautions and Notes
Obey all the usual safety precautions and maintenance instructions when doing maintenance.
This Airplane Maintenance Manual also contains warnings, cautions and notes before applicable
instructions:
WARNING: A WARNING TELLS THE PERSON DOING THE MAINTENANCE THAT

INJURY OR DEATH IS POSSIBLE IF THEY DO NOT STRICTLY FOLLOW
THE INSTRUCTIONS.
CAUTION: A CAUTION TELLS THE PERSON DOING THE MAINTENANCE THAT

DAMAGE TO EQUIPMENT IS POSSIBLE IF THEY DO NOT FOLLOW
THE INSTRUCTIONS.
Note: A Note tells the person doing the maintenance how to make the task easier.
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4. Manual Configuration
This manual is written using the regulations of the Air Transport Association of America Specification
iSpec2200. Each system is given a chapter number from the ATA iSpec2200. Where applicable, a
chapter contains sections for each sub-system.
The specification AECMA Simplified English has been used to write this Airplane Maintenance Manual.
This is a mandatory requirement of the ATA iSpec2200.
There are only 3 sources of words available to use in Simplified English (SE).
) Approved words from the SE Guide. These words have defined meanings and selected parts of
speech.
) Technical names as defined in the SE Guide. Used only as adjectives or nouns.
) Manufacturing processes as defined in the SE Guide. Always used as verbs.
To obtain a copy of the SE Guide contact ASD-STAN, Avenue de Tervuren, B-1150 Brussels, Belgium.
Tel: +32-2775-81-26, Fax:+32-2763-35-65, Email: contact@asd-stan.org
This manual does not use the ATA iSpec2200 Airplane Maintenance Task Oriented Support System
(ATMOSS) or the ATA iSpec2200 Production Management Data Base (PMDB).
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A. The ATA iSpec2200 Numbering System
The ATA iSpec2200 numbering system uses 3 pairs of numbers, for example:
57-50-xx
Chapter / System Section / Subsystem Unit / Subject Number

(Wings) (Flaps) (Not normally used)
The first pair of numbers shows the system. System 57 is the wings. Chapter 57 contains the data
for the wings.
The second pair of numbers shows the sub-system. Sub-system 50 is the Trailing Edge Flap.
Chapter 57, Section 50 contains the data for the trailing edge flaps installation.
The third pair of numbers shows a unit. A unit could be the flap itself. Only complex systems use
unit numbers.
For simple systems, the main chapter has all of the data and there are no section/sub-system
break-downs.
B. Groups of Chapters
The chapters are put together in these groups:
Group A Introduction Chapters 01-02
Group B Airplane General Chapters 03-12
Group C Airframe Systems Chapters 20-35
Group D Structure Chapters 51-57
Group E Propeller Chapter 61
Group F Engine Chapters 71-81
A separation sheet divides each chapter. The separation sheet shows the number of the chapter
and the title.
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The main contents of each group of chapters is given below:
(1) Group A - Introduction
Chapter 01 tells you about the Airplane Maintenance Manual, and Chapter 2 tells you how to
use the Airplane Maintenance Manual.
(2) Group B - Airplane General
Chapter 03 gives you a general description of the airplane and its systems.
Chapter 04 gives you data about the Airworthiness Limitations and certification of the airplane.
Chapter 05 contains the Scheduled Maintenance Checklist. Some tasks require a maintenance
procedure. The scheduled maintenance checklist identifies the Section in the manual that gives
the maintenance procedure for the task. It also tells you where to find general information.
Chapters 06 to 10 tell you about the dimensions of the airplane and general procedures such
as towing, parking and weighing.
Chapter 11 tells you about the placards and markings which are important for the safe operation
of the airplane.
Chapter 12 contains servicing tasks such as refueling and lubrication. It also contains data
about cleaning the airplane.
(3) Group C - Airframe Systems
Chapter 20 contains the standard practices for airframe maintenance.
Chapters 21 to 35 tell you about the airframe systems. They include the avionics systems (such
as communications (Chapter 23)) and the mechanical systems (such as flight controls
(Chapter 27)).
Chapter 31 shows the location of the instruments. The chapter which is applicable to the system
gives the details. For example, Chapter 27 gives the details for the flap position indicator.
(4) Group D - Structure
Chapter 51 contains data about the design of the airframe. It also gives instructions for
assessing damage to the airframe and how to do minor repairs.
Chapters 52 to 57 tell you about each part of the structure.
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(5) Group E - Propeller
Chapter 61 contains the maintenance procedures for the propeller. Refer to the propeller
manufacturer’s manual for other data.
(6) Group F - Engine
This group of chapters describes the engine and its systems. It contains the maintenance
procedures for maintenance of the engine on the airplane. Refer to the engine manufacturer’s
manual for other data.
C. Chapter Configuration
The first page of each chapter shows the number of the chapter and the title. The second page
shows the contents. Where applicable, each chapter and section contains the topics that follow:
) Description and Operation.
) Trouble-Shooting.
) Maintenance Practices. Where applicable the maintenance practices give data on these
procedures:
• Servicing.
• Removal and Installation.
• Adjustment/Tests.
• Checking/Testing.
• Cleaning/Painting.
• Repairs.
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5. Page Numbering System
This manual uses the ATA iSpec2200 page block-numbering system. The page number is at the
bottom of the page at the outer edge. It is adjacent to the chapter/section number.
Each topic in a section has numbers from these page blocks:
) Description and Operation - Pages 1 to 99.
) Trouble Shooting - Pages 101 to 199.
) Maintenance Procedures - Pages 201 to 299.
6. Figures
Figures are given numbers in sequence. The first figure in a chapter or section is Figure 1.
7. Record of Revisions
The Airplane Maintenance Manual has a Record of Revisions. Use the Record of Revisions to show
when changes were included in the Airplane Maintenance Manual.
8. List of Effective Pages
This Airplane Maintenance Manual has a List of Effective Pages. The List of Effective Pages shows
you the number and effective date of each page contained in the Airplane Maintenance Manual.
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DA 42 NG AMM Manual Organization
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CHAPTER 02
ORGANIZATION AND HANDLING OF

THE MANUAL
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TABLE OF CONTENTS
CHAPTER 02
ORGANIZATION AND HANDLING OF THE MANUAL
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Temporary Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5. Service Bulletins and Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6. Concession-Reports and Non-Conformance-Reports . . . . . . . . . . . . . . . . . . . . . . 2
7. Document Notifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8. Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9. Conversion Factors and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10. Torque Conversion Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
11. Supplemental Airplane Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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CHAPTER 02
ORGANIZATION AND HANDLING OF THE MANUAL
1. General
For data about a system, look in the list of chapters and find the chapter number. The first page of
each chapter after the title page shows the contents.
2. Applicability
Data applicable to a series of airplane is marked with an applicability note. For example:
Valid for S/N 42.N001 thru 42.N999.
This shows that you can use this data for airplane with serial numbers 42.N001 thru 42.N999 inclusive.
3. Revisions
The manufacturer makes changes to the Airplane Maintenance Manual to show design changes,
maintenance procedure changes or other changes. Each group of changes is called a ‘Revision’.
A manual revision contains these items:
) The changed pages.
) The reason for the revision.
) Instructions for putting the revision into the Airplane Maintenance Manual.
) A new List of Effective Pages (LOEP).
A vertical bar in the left margin of the page shows the changes.
4. Temporary Revisions
Temporary revisions correct errors, or they give temporary instructions. The manufacturer sends them
to the airplane owners quickly. The manufacturer uses yellow pages for temporary revisions. The
manufacturer usually puts the contents of a temporary revision in the next approved revision.
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5. Service Bulletins and Service Instructions
Service Bulletins (SB) regulate modifications carried out on registered, in field operated airplanes.
Service Instructions give the operator technical instruction about the product which are not included
in the standard documentation. This could be for example recommendations for maintenance or
information about SBs of other manufacturers (Austro Engine, mt-Propeller etc.).
Refer to Service Instruction No. SI42-001 for details on the organization of Service Bulletins and
Service Instructions.
6. Concession-Reports and Non-Conformance-Reports
Concession- and Non-Conformance-Reports are tools to approve and document deviations from the
standard manufacturing processes during construction and assembly of an individual airplane (for
example, handling of a mis-drilled hole in the fuselage). In case the operator or the maintenance
organization needs to be informed as a consequence of the deviations for that particular airplane (for
example, the use of a special spare part is necessary or a different limit in a control surface balancing
report applies), these Concession- and Non-Conformance-Reports are contained in the airplane log.
Before you do maintenance, check the airplane log for such Concession- and Non-Conformance
Reports.
7. Document Notifications
Manual Revisions, Temporary Revisions, Service Bulletins and Service Information are announced
via e-mail. The new documents are available for download on the Internet web site of Diamond Aircraft:
www.diamondaircraft.com
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8. Abbreviations
Where possible, the abbreviations used correspond with the related regulations.
ACL Anti-Collision Light (Strobe Lights)
ADF Automatic Direction Finder
A&P Airplane and Power Plant Mechanic
ASI Airspeed Indicator
CFRP Carbon Fiber Reinforced Plastic
DME Distance Measuring Equipment
EECU El. Engine Control Unit
ELT Emergency Locator Transmitter
FRP Fiber Reinforced Plastic
GFRP Glass Fiber Reinforced Plastic
GPS Global Positioning System
G/S Glide Slope
IAU Integrated Avionics Unit
ICS Integrated Cockpit System
IFR Instrument Flight Rules
HSI Horizontal Situation Indicator
LOC Localizer
MSI Major Structural Inspection
OAT Outside Air Temperature
PFD Primary Flight Display
RCPI Remote Control Panel Indicator
SAM Standby Attitude Module
SB Service Bulletin
SI Service Instruction
S/N Serial Number
TBO Time Between Overhaul
TSMOH Time Since Major Overhaul
TTSN Total Time Since New
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TTSO Total Time Since Overhaul
UHF Ultra High Frequency
VFR Visual Flight Rules
VHF Very High Frequency
VOR VHF Omni-Directional Ranging
VSI Vertical Speed Indicator
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9. Conversion Factors and Abbreviations
Dimension Conversion Factor Conversion Factor

Unit [Abbreviation] SI to US/Imperial US/Imperial to SI
Length
Meter [m] [m] / 0.3048 = [ft]
Millimeter [mm] [mm] / 25.4 = [in]
Kilometer [km] [km] / 1.852 = [nm]
[km] / 1.609 = [sm]
Inch [in] [in] x 25.4 = [mm]
Foot [ft] [ft] x 0.3048 = [m]
Nautical mile [nm] [nm] x 1.852 = [km]
Statute mile [sm] [sm] x 1.609 = [km]
Velocity
Kilometers per hour [km/h] [km/h] / 1.852 = [kts]
[km/h] / 1.609 = [mph]
Meters per second [m/s] [m/s] x 196.85 = [fpm]
Miles per hour [mph] [mph] x 1.609 = [km/h]
Knots [kts] [kts] x 1.852 = [km/h]
Feet per minute [fpm] [fpm] / 196.85 = [m/s]
Rotational Speed
Revolutions per minute [RPM] [RPM] = [min-1]
Pressure
Bar [bar] [bar] x 14.5038 = [PSI]
Hectopascal [hPa] = Millibar [mbar] [hPa] / 33.864 = [inHg]
[mbar] / 33.864 = [inHg]
Pounds per square inch [PSI] [PSI] / 14.5038 = [bar]
Inches of mercury column [inHg] [inHg] x 33.864 = [hPa]
[inHg] x 33.864 = [mbar]
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Dimension Conversion Factor Conversion Factor

Unit [Abbreviation] SI to US/Imperial US/Imperial to SI
Force or Weight
Newton [N] [N] / 4.448 = [lbf]
Decanewton [daN] [daN] / 0.4448 = [lbf]
Pound-force [lbf] [lbf] x 4.448 = [N]
[lbf] x 0.4448 = [daN]
Mass ('Weight')
[kg] / 0.45359 = [lb]
Kilogram [kg]
Pound [lb] [lb] x 0.45359 = [kg]
Volume
[l] / 3.7854 = [US gal]
Liter [l]
[l] / 0.9464 = [US qts]
[l] / 4.5461 = [Imp gal]
[l] / 61.024 = [in3]
US gallon [US gal] [US gal] x 3.7854 = [l]
US quart [US qt] [US qt] x 0.9464 = [l]
Imperial gallon [Imp gal] [Imp gal] x 4.5461 = [l]
Cubic inch [in3] [in3] x 61.024 = [l]
Torque
Newton meter [Nm] [Nm] / 1.3558 = [lbf.ft.]
[Nm] x 8.851 = [lbf.in.]
Pound-force foot [lbf.ft.] [lbf.ft.] x 1.3558 = [Nm]
Pound-force inch [lbf.in.] [lbf.in.] / 8.851 = [Nm]
Temperature
Degree Celsius [°C] [°C] x 1.8 + 32 = [°F]
Degree Fahrenheit [°F] ([°F] - 32) / 1.8 = [°C]
Note: In this Airplane Maintenance Manual masses are referred to as weights. The
authors accept, that this is technically incorrect but have used the expression for
simplicity and convenience.
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10.Torque Conversion Factor
Use figure 1 for conversion of torque values Nm - lbf.ft. Use figure 2 for conversion of Nm - lbf.in.
70
65
60
Pound-Force Foot (lbf.lb.)
55
50
45
40
35
30
25
20
15
10
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Newton.Metre (Nm)
Figure 1: Nm - lbf.ft.
Find the Nm value on the horizontal axis. Move vertically to the solid black diagonal line. Then move
horizontally to the vertical axis. Read the value in lbf.ft.
Example: To convert 24 Nm to lbf.ft., find 24 Nm on the horizontal axis (see the dashed line). Follow
the dashed line vertically to the solid black diagonal line. Then follow the dashed line horizontally to
the vertical axis. Read the value of 17.7 lbf.ft.
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90
85
80
75
70
65
Pound-Force Inch (lbf.in.)
60
55
50
45
40
35
30
25
20
15
10
0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0
Newton.Metre (Nm)
Figure 2: Nm - lbf.in.
Find the Nm value on the horizontal axis. Move vertically to the solid black diagonal line. Then move
horizontally to the vertical axis. Read the value in lbf.in.
Example: To convert 4.4 Nm to lbf.in., find 4.4 Nm on the horizontal axis (see the dashed line). Follow
the dashed line vertically to the solid black diagonal line. Then follow the dashed line horizontally to
the vertical axis. Read the value of 39 lbf.in.
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11. Supplemental Airplane Manuals
Supplemental Airplane Maintenance Manuals are used to provide maintenance procedures and
installation instructions for additional equipment.
A. List of Supplemental AMMs
applicable
Doc. No. Title Rev.No. Date
YES NO
O03 - Retrofit Installation of

7.02.15-O03 0 01-Jun-2009 9 9
Austro Engine E4-B
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CHAPTER 03
GENERAL DESCRIPTION OF THE

AIRPLANE
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TABLE OF CONTENTS
CHAPTER 03
GENERAL DESCRIPTION OF THE AIRPLANE
1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Equipment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Handling of Identification Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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CHAPTER 03
GENERAL DESCRIPTION OF THE AIRPLANE
1. Description
The DA 42 NG is a twin-engine, four seat, low wing mono-plane. It has a cantilever wing and a ‘T’ tail.
The airplane structure is fiber reinforced plastic composite. This gives a very strong but lightweight
structure.
Figure 1: DA 42 NG Airplane
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The semi-monocoque fuselage is a carbon-fiber reinforced-plastic (CFRP) shell with glass-fiber

reinforced-plastic (GFRP) bulkheads and stiffeners. The fuselage is constructed in 2 halves that are
bonded together after installation of the fuselage bulkheads and frames. Carbon fiber is used in many
areas to give increased strength and rigidity. A roll-over protection bar forms part of the construction
of the cockpit area. The vertical stabilizer is integral with the fuselage shells.
A wing center section is attached to the bottom of the fuselage center section. The wing center section
has the 2 engine nacelles, the wing stubs and the fuselage center-section floor. The engine nacelles
give the fixing points for the engines. The wing stubs have the attachment points for the outer wings.
Two main spars ('spar bridges') transfer the loads from the wings to the fuselage. Four main bolts and
2 auxiliary bolts attach the wing spar stubs to the wing center section. The center section has the main
landing gear bays and landing gear leg attachments.
The cantilever outer wing is a semi-monocoque structure. Each wing has two I-shaped spars with
webs made from GFRP/rigid foam sandwich and caps made from carbon-fiber reinforced plastic
(CFRP) tapes. Each wing has top and bottom shells made of carbon fiber reinforced plastic-sandwich
construction which are bond to the spars. Carbon fiber reinforced plastic ribs and webs bond to the
spars and shells to complete the structure. Electrically operated flaps and mechanical ailerons are
attached to the trailing edge of the wings.
The horizontal stabilizer is a semi-monocoque structure. It has top and bottom shells made of GFRP
and two main spars. The shells are bonded to the spars and ribs. The trailing edge has a conventional
elevator with both mechanical and electrical trim systems.
The one-piece canopy has a large quantity of wrap-around glazing. This gives a good all-round view
from the cockpit. A glazed rear passenger door on the left side of the airplane gives access to the rear
seats. The passenger door lifts up to give good access and is supported in the open position by a gas
strut.
A two-part acrylic lacquer finish protects the outside skin of the airplane from ultraviolet rays and
humidity.
The tricycle landing gear is fully retractable and hydraulically operated. The main landing gear legs are
attached to mounting points in the wing center-section. The main landing gear retracts into integral
compartments in the wing center section. Landing gear doors seal the landing gear bays when the
gear is retracted. The nose landing gear is steerable and is attached to the lower front of the fuselage.
The nose landing gear bay is integral with the front fuselage and doors seal the bay when the gear is
retracted.
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The flight control system uses conventional ailerons, elevator and rudder. The DA 42 NG has 2 control
sticks (1 on the LH side if OÄM 42-281 is installed. If OÄM 42-283 is installed, the RH control stick is
removable by the pilot) and 2 rudder pedal assemblies to operate the primary flight controls. Push-pull
rods operate the ailerons and the elevator. Cables operate the rudder. An electric motor operates the
flaps via push-pull rods. The elevator has both an electric and a manual trim system. A handwheel and
Bowden cable operate the elevator trim mechanically. The rudder has a mechanical trim system which
uses a rotary drive and Bowden cable to operate a rudder trim tab.
Two Austro Engine E4-B liquid-cooled, in-line four-stroke four cylinder engines with double overhead
camshaft (DOHC) with four valves per cylinder. The valves are actuated by the cam follower. The
direct fuel injection is realized by means of a common rail technique and the engine is charged by a
turbo charger in combination with an intercooler. The propeller is activated by an integrated gearbox
with an integral torsional vibration damper. All engine components are controlled by an EECU system.
The airplane has aluminum fuel tank assemblies in each wing. Each fuel tank has 3 chambers which
are mounted between the wing spars. The outer fuel chamber of each assembly has a fuel filler.
Flexible hoses connect the fuel tanks to the fuel distribution system. Each tank can feed either engine
via a fuel crossfeed system. Fuel level sensors are installed in the inner and outer fuel tank chambers.
The fuel level sensors control the fuel indicating system in the cockpit. The total fuel capacity of the
airplane is approximately 196 liter (51.8 US gal) in the main tanks. If the auxiliary tanks are installed
the total fuel quantity is approximately 300.8 liter (79.4 US gal).
The airplane has two sources of electrical power. A 24 V battery supplies electrical power when the
engines are not running. Engine generators provide electrical power when minimum one of the engines
is running. Switches and circuit breakers control all electrical devices. A key switch controls the engine
starting system.
The DA 42 NG has a full range of flight instruments contained in an integrated cockpit system (ICS).
The ICS has 2 display screens. Both of them are able to show all the airplane flight instrumentation
data, navigation data, engine data and other airplane system data. The ICS also displays all the
airplane warnings, cautions and alerts. The ICS can also be configured to show ground and flight
check lists.
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2. Equipment Data
The table below gives you the names and address of the manufacturers who supply systems and/or
equipment for the DA 42 NG. This will help you to get more data on a system and/or equipment.
"Yes" in the "Direct Shipping Approved" column means that the part can be ordered directly from the
vendor. "No" means that the part must be obtained as a genuine Diamond Aircraft spare part. This is
the case when a part needs to be configured for the DA 42 NG airplane.
In any case, the parts must have exactly the part numbers shown in the Equipment List in Chapter 6
of the Airplane Flight Manual, Doc. No. 7.01.15-E or Doc. No. 7.01.16-E, latest revision.
ATA Equipment/System Manufacturer/Address Direct

Chapter Shipping
Approved
12 Anti-Corrosion Cleaning Chemetall GmbH yes

Agent: Ardrox AV 980 Trakehnerstrasse 3
D-60487 Frankfurt a. M.
Anti-Corrosion Coating:
Germany
Ardrox AV 30
Tel: +49 69 7165-0
Fax: +49 69 7165-3018
Website: www.chemetall.com
Anti-Corrosion Cleaning Socomor yes

Agent: Diestone DLS Zl du Prat - RP 3707
F-56037 Vannes Cedex
Anti-Corrosion Coating:
France
Socopac 65 H
Tel: +33 2 97 43 76 90
Fax: +33 2 97 43 76 86
Website: www.socomor.com
22, 23, Integrated Cockpit System, Garmin International, Inc. yes

31, 34 Autopilot System: 1200 East 151st Street
Olathe, Kansas 66062
USA
Tel: (913) 397-8200

Fax: (913) 397-8282
Website: www.garmin.com
Page 4 Doc # 7.02.15

22 Dec 2021 03-00-00 Rev. 5
AIRCRAFT

Chapter Shipping
Approved
Cooling Fans for Integrated SANDIA aerospace yes

Cockpit System: 3700 Osuna Road NE, Suite 711
Albuquerque, NM 87109
USA
Tel: (505) 341-2930

Fax: (505) 341-2927
Website: www.sandiaaerospace.com
24 Battery: Concorde Battery Corp. yes

2009 San Bernardino Road
West Covina, CA 91790
USA
Tel: (626) 813-1234
Website: www.concordebattery.com
25 Emergency Locator Artex Aircraft Supplies yes

Transmitter (ELT): 14405 Keil Road NE
Aurora, Oregon 97002
USA
Tel: (503) 678-7929

Fax: (503) 678-7930
Website: www.artex.net
25 Safety Belts: Schroth Safety Products GmbH yes

P.O. Box 24 40
59714 Arnsberg
Germany
Tel: +49-2932-9742
Website: www.schroth.com
Doc # 7.02.15 Page 5

Rev. 5 03-00-00 22 Dec 2021
AIRCRAFT

Chapter Shipping
Approved
25 AmSafe Seatbelt Airbag V23 AMSAFE, Inc. yes

th
System 1043 N. 47 Ave.
Phoenix, AZ 85043
USA
Tel: +1 602 850 2850
Fax: +1 602 850 2812
Website: www.amsafe.com
26 Fire Extinguisher: Total Feuerschutz GmbH yes

Industriestr. 13
68526 Ladenburg
Germany
Tel: +49-6203-75-369
Fax: +49-6203-75-265
Website: www.total-feuerschutz.de
Note: The airspeed indicator must have the markings specified in Chapter 2 of the
Airplane Flight Manual, Doc. No. 7.01.15-E or Doc. No. 7.01.16-E, respective
latest revision.
31 Airspeed Indicator, United Instruments Inc. yes

3625 Comotara Avenue
Altimeter:
Wichita, Kansas 67226
USA
Tel: (316) 636-9203

Fax: (316) 636-9243
Website: www.unitedinstrumentsinc.com
31 Attitude Gyro, Mid-Continent Instrument and Avionics yes

th
Standby Attitude Module: 9400 E. 34 Street North,
Wichita, Kansas 67226
USA
Tel: (316) 630-0101
Fax: (316) 630-0723
Website: www.mcico.com
Page 6 Doc # 7.02.15

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AIRCRAFT

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Approved
32 Main Wheels and Brakes: Parker Hannifin Corporation yes

Aircraft Wheel and Brake Division
1160 Center Road
Avon, Cleveland, Ohio 44011
USA
Tel: (440) 937 6211

Fax: (440) 937 6416
Website: www.parker.com
% 33 Position / Anti-Collision Whelen Aerospace Technologies. yes

% Lights: 51 Winthrop Road,
% Chester, CT 06412
% USA
% Tel: (860) 526-9504

% Fax: (860) 526-2009
% Website: www.flyWAT.com
% 33 Landing and Taxi Lights: XeVision yes

% 4245 Airport Rd.
% Ogden, UT 84405
% USA
% Tel: (801) 622-7000

% Fax: (801) 622-7277
% Website: www.xevision.com
Note: The propeller must have the pitch settings specified in Chapter 61 of this
manual.
61 Propeller: mt-Propeller yes

Airport Straubing Wallmühle
D-94348 Atting
GERMANY
Tel: +49-9429-9409-0
E-mail: sales@mt-propeller.com
Website: www.mt-propeller.de
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AIRCRAFT

Chapter Shipping
Approved
72 Engine: Austro Engine GmbH yes

Rudolf Diesel-Straße 11
Austria
Tel: +43-2622-23000
Fax: +43-2622-23000-2711
Website: www.austroengine.at
3. Handling of Identification Data
No person shall remove, change, or place identification information on any airplane, engine, propeller,
propeller blade, or propeller hub, without the approval of the competent national Airworthiness
Authority.
If a deviation from the procedure above is necessary, any person performing maintenance work may
in consultation with the competent national Airworthiness Authority:
) Remove, change, or place the identification plate on any airplane, engine, propeller, propeller
blade, or propeller hub.
) Remove an identification plate, when necessary during maintenance operations.
) No person shall install an identification plate, removed in accordance with the procedures above,
on any airplane, engine, propeller, propeller blade, or propeller hub other than the one from which
it was removed.
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Airworthiness
DA 42 NG AMM
Limitations
CHAPTER 04
AIRWORTHINESS LIMITATIONS
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DA 42 NG AMM
Limitations AIRCRAFT
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Airworthiness
DA 42 NG AMM
Limitations
TABLE OF CONTENTS
CHAPTER 04
1. Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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DA 42 NG AMM
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DA 42 NG AMM
Limitations
CHAPTER 04
THIS AIRWORTHINESS LIMITATIONS SECTION IS APPROVED BY EUROPEAN AVIATION

SAFETY AGENCY (EASA) IN ACCORDANCE WITH THE APPLICABLE CERTIFICATION
PROCEDURES AND THE TYPE CERTIFICATION BASIS. IT SPECIFIES THE AIRWORTHINESS
LIMITATIONS REQUIRED BY JAR 23.
THIS AIRPLANE MAINTENANCE MANUAL CHAPTER 04 (AIRWORTHINESS LIMITATIONS) IS

APPROVED WITH EASA APPROVAL NO. EASA.A.C.09012 AND 10042779.
THE AIRWORTHINESS LIMITATIONS SECTION IS FAA APPROVED AND SPECIFIES

MAINTENANCE REQUIRED UNDER SECS. 43.16 AND 91.403 OF THE FEDERAL AVIATION
REGULATIONS UNLESS AN ALTERNATIVE PROGRAM HAS BEEN FAA APPROVED.
SERVICE BULLETINS OR OTHER DOCUMENTS REVISING THIS SECTION WHICH CONTAIN A

STATEMENT THAT THE DOCUMENT IS AUSTRO CONTROL GMBH (ACG) / EUROPEAN
AVIATION SAFETY AGENCY (EASA ) APPROVED ARE CONSIDERED FAA APPROVED.
Doc # 7.02.15 Page 1

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Airworthiness
DA 42 NG AMM
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Airworthiness
DA 42 NG AMM
Limitations
1. Airworthiness Limitations
This Chapter is approved and shows the mandatory limitations which were established as a result of
the certification process.
The time limits given in Chapter 04 must be applied to ensure Continued Airworthiness of the
DA 42 NG.
Note: Regular inspections of the airplane including replacement and overhaul of certain
components are required to ensure Continued Airworthiness of the DA 42 NG.
For possible airworthiness limitations of engine, propeller, components and vendor equipment refer
to the applicable Maintenance data as listed in Section 05-00.
A. Certification Maintenance Requirements
(1) Component and System Checks
The component and system checks under this Paragraph are also included in Section 05-10.
The following table lists airplane components and systems which require monitoring through
scheduled maintenance.
Where an interval is given in both flight time and calendar years, the limit which is reached first
must be applied.
ATA Component Maintenance Requirement Interval

Ch. hrs. yrs.
7 years,
Electronics Module Assembly calculated
Remove EMA and return to
25 EMA (if OÄM 42-324 is from the
AmSafe for refurbishment.
installed) month of
manufacture*
Bonding system and static Resistance measurements 4 yrs.
51 1000 ± 50
discharging system. (refer to Section 51-80). ± 60 days
*Storage or installation life.
(2) Life Time Limit / Structure Checks
There is no structural life limit.
Note: The DA 42 NG has been designed and tested under a 'damage tolerant structure'
philosophy. Therefore the structural inspections given in Chapter 05 cover all
required structure checks.
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Airworthiness
DA 42 NG AMM
B. Replacement Requirements
The following table lists life limited airplane components which must be replaced at a specific time.
Where an interval is given in both flight time and calendar years, the limit which is reached first
must be applied.
Note: The replacement requirements under this Paragraph are also included in
Section 05-10.
ATA Component Replacement Time

Ch. hrs. yrs.
2 years
± 30 days,
or upon
reaching the
date marked
24 Emergency battery package.
on the
package, or
after use,
whichever
comes first.
1 yr.
24 ECU backup batteries LH/RH.
± 30 days
Installation screws for forward inflators (if OÄM 42-324 is
25 1000 hrs
installed).
14 years,
calculated
25 Electronics Module Assembly (if OÄM 42-324 is installed). from the
month of
manufacture*
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Airworthiness
DA 42 NG AMM
Limitations

Ch. hrs. yrs.
10 years,
calculated
from the
month of
manufacture*
25 Inflator Assembly (if OÄM 42-324 is installed).** (as indicated
in the
expiration
date stamp
on the gas
cylinder)
* Replacement times are shown as service life, defined as total sum of storage life and installation life.
** Return Inflator Assembly to AmSafe for disposal.
C. Paint
(1) For S/N below 42.N300/42.MN100:
It is mandatory to paint the DA 42 NG white with a solar absorptivity not exceeding 0.3. This will
prevent the temperature of the structure from becoming too high. Examples of approved shades
are:
) RAL 9016.
) Mercedes DB 147.
) BMW 218.
) Volvo XG28.
) Volvo BC76.
) Saab 5AC6.
) Alfa Romeo 230.
It is mandatory to paint the DA 42 M-NG white, if OÄM 42-232 is installed light grey (RAL 7035
mat) is also approved.
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Airworthiness
DA 42 NG AMM
Before painting the airplane in a different shade than listed above, the manufacturer must be
contacted. Special paint schemes can be defined in an approved supplement to this AMM.
Only certain areas which are defined in Chapter 51 of this manual (for example, registration
markings, placards and warning markings, trim or striping) may have a different color.
(2) For S/N 42.N300/42.MN100 and above:
It is mandatory to paint the DA 42 NG and DA 42 M-NG in accordance with the color paint
scheme provided in Section 51-20.
Before painting the airplane in a different shade than defined in Section 51-20 of this Manual,
the manufacturer must be contacted.
D. Repairs
Repairs which are not described in Chapter 51 of this manual may only be carried out in
accordance with a repair scheme which must be approved in accordance with the procedures
established by the competent certifying authority.
E. Replacement of Composite Parts
Composite parts made from resin system L285 with part numbers designated only for serial
numbers below 42.N300/42.MN100 must not be installed on serial numbers 42.N300/42.MN100
and above without further approval.
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Time Limits and
DA 42 NG AMM
AIRCRAFT Maintenance Checks
CHAPTER 05
TIME LIMITS AND MAINTENANCE

CHECKS
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Maintenance Checks
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DA 42 NG AMM
TABLE OF CONTENTS
CHAPTER 05
TIME LIMITS AND MAINTENANCE CHECKS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Chapter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section 05-10
Time Limits
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Regulatory Authorities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Scheduled Maintenance Time Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Component Time Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Component Time Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Section 05-20
Scheduled Maintenance Checks
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Maintenance Checklist Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Major Structural Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 05-21
Flight-Line Checks
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Flight-Line Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Post-Flight Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 05-25
Drain Holes Inspection Checklist and Report
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Drain Holes Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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Section 05-28
Maintenance Checklist DA 42 NG
Section 05-28-00
Maintenance Checklist DA 42 NG Engines
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Engine Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Maintenance Checklist Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Section 05-28-50
Maintenance Checklist Airframe
1. Exterior of the Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. Cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3. Interior of the Rear Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4. Center Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5. Tail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6. Wings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Section 05-28-90
Maintenance Report
1. Maintenance Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 05-28-91
Engine Ground Test Record
1. Engine Ground Test Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 05-28-92
Check Flight Report
1. Check Flight Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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Section 05-28-93
Major Structural Inspection Check Findings Report
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 05-50
Unscheduled Maintenance Checks
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Hard Landing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Gear Up Landing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Propeller Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. Engine Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6. Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7. Over Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8. High Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9. Oil Pressure Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
10. Hang Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
11. Overweight Landing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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DA 42 NG AMM
CHAPTER 05
TIME LIMITS AND MAINTENANCE CHECKS
1. General
This Chapter will help you to do the maintenance of the DA 42 NG correctly. Refer to Chapter 04-00
and 05-00 to help you when you do maintenance and inspections.
The times given in this Chapter are times recommended by the airplane manufacturer. Do the
scheduled maintenance at the given times, because they are the minimum required to keep the
airplane in a good technical condition.
These checks do not over-ride the requirements of the Airworthiness Authority of the country where
the airplane is registered. You must make sure that all Airworthiness Directives, Service Bulletins and
any other requirements of the Airworthiness Authority of the country where the airplane is registered
are completed as required.
The airplane manufacturer can change the time between checks. If this happens, the airplane
manufacturer will publish the change as a revision to the Airplane Maintenance Manual.
Time limits and maintenance checks were established for operation in a moderate climate and on
paved runways. For operation under rough conditions (extreme temperatures, saline air, wind-borne
sand, operation on grass runways, etc.) it may be necessary to make changes to the maintenance
requirements given in this Chapter. You can decrease the time between scheduled maintenance
checks if the airplane's operation makes it necessary. You must not extend the time between
scheduled maintenance checks without the approval of the Airworthiness Authority of the country
where the airplane is registered.
2. Chapter Configuration
A. Section 05-10
Section 05-10 contains the recommended time limits for maintenance checks. It also contains the
recommended time between overhaul for components. Use the data in Section 05-10 to find when
to do the maintenance.
B. Section 05-20
Section 05-20 contains information about the maintenance checklist organization.
C. Section 05-21
Section 05-21 contains information about the Flight Line Checks.
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Time Limits and
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D. Section 05-25
Section 05-25 contains the Drain Holes Inspection Checklist.
E. Section 05-28
Section 05-28 contains the Maintenance Checklist for the DA 42 NG airplane. The Section is
subdivided into engine and airframe Sections and provides checklists for the engines, the
propellers, the airframe and the corresponding reports.
(1) Section 05-28-00
DA 42 NG Maintenance Checklist for the engines: Maintenance checks schedule for 100, 200,
1000, and 2000 hour checks on the engine and propeller.
(2) Section 05-28-50
DA 42 NG Maintenance Checklist for the airframe: Maintenance checks schedule for 100, 200,
1000, and 2000 hour checks on the airframe.
(3) Section 05-28-90
DA 42 NG Maintenance Report.
(4) Section 05-28-91
DA 42 NG Engine Ground Test Reports.
(5) Section 05-28-92
DA 42 NG Check Flight Report.
(6) Section 05-28-93
Major Structural Inspection (MSI) Check Findings Report.
F. Section 05-50
Section 05-50 contains the unscheduled maintenance checks. Do these checks after hard landings,
propeller damage, engine fire and lightning strike.
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Time Limits and
DA 42 NG AMM
G. Referenced Maintenance Data
Use latest revision of referenced maintenance data.
Supplier Document Name Document No.

Aerox Component Maintenance Manual with Illustrated Parts 35-00-01
List, Part Numbers 4110-120 Series
AMSAFE Supplemental Instructions for Continued Airworthiness E509605
AmSafe Seatbelt Airbag V23 System for Diamond
Aircraft, Models DA 40, DA 40 NG, DA 40 F, DA 42,
DA 42 NG, and DA 42 M-NG Inflatable Restraint
System Assy. Series No. 7053 and 7057.
Artex Installation and Maintenance Manual for the 570-1600
ME406 ELT
Austro Engine Austro Engine Operation Manual AE300 E4.01.01
Austro Engine Austro Engine Maintenance Manual AE300 E4.08.04
Cleveland/Parker Cleveland/Parker Maintenance Manual AWBCMM0001-8
Cleveland/Parker Cleveland/Parker Product Catalog AWBPC0001-8
Cleveland/Parker Cleveland/Parker Technician’s Service Guide AWBTSG0001-6
Concorde RG® Series Main Aircraft Batteries Component 5-0171
Maintenance Manual
Garmin Garmin G1000 System Maintenance Manual 190-00907-00
% Garmin G1000 NXi Integrated Avionics System, Line 190-02631-00
% Maintenance Manual
Goodyear Aircraft Tire Care & Maintenance 700-862-931-538
(012096) 10/04
% Hartzell Aircraft Alternator Owner’s Manual ES 1031
Honeywell Honeywell Flightline Maintenance Manual Bendix/King 006-15574-0002
KAP 140 Flight Control System
L-3 Stormscope WX-500 Installation Manual 009-11500-001
% Kannad Installation and Operation Manual for 406 AF- DOC08038
% Compact
% Kannad Operation Manual for AF Integra DOC09078
% Kannad Initial Installation Manual for AF-Integra DOC09081E
Mid Continent Installation Manual and Operating Instructions Model 9017782
MD302 Series SAM
mt-Propeller mt-Propeller Operation and Installation Manual E-124,
ATA 61-01-24
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Time Limits and
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mt-Propeller mt-Propeller Operation and Installation Manual for the E-1048,

Hydraulic Constant Speed Governor ATA 61-20-48
3. Definitions
In this Airplane Maintenance Manual, the words that follow have special meanings:
Adjust. To put to a specified position or condition. For example, adjust the clearance to
1 mm.
Check. A technical name for a group of maintenance tasks. For example, the 100 hour
check.
Examine. To look carefully at an item. It includes steps such as these:
S Make sure that the item:
Is complete.
Is correctly attached.
Has no loose parts.
Shows no signs of leaks.
Is not cracked or damaged.
Is not worn.
S Make sure that:
The surface protection is not damaged.

All locking devices are installed correctly.
S Make sure that items such as pipes and cables:
Look serviceable.
Do not rub against other items.
S For log books and other technical records:
To find outstanding faults.

To make sure they are up-to-date and correctly maintained.
Inspection. The procedure which compares an object with its standard or specification.
Measure. To find out the dimensions, capacity or quantity of something.
Monitor. To look at something over a period of time. For example, monitor the engine
speed indicator.
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Record. (1) Technical name for something that shows what was done. For example,
write the result of the test in the engine record.
(2) The act of making a record. For example, record the result of the test in the
Airplane Maintenance Log.
Replace. To remove an item and install a serviceable item in the same location.
Set. To put equipment into a given adjustment, condition or mode. For example, set
the altimeter scale to 1013 mbar (= 1013 hPa).
Task. An assigned work or a procedure. For example, each step of the task has an
identification letter.
Test. That which you do when you operate or examine an item to make sure that it
agrees with the applicable specifications. For example, disconnect the systems
which are not necessary for the test. Or do an engine test.
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22 Dec 2021 05-00-00 Rev. 5
Time Limits and
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Section 05-10
Time Limits
1. General
All scheduled maintenance checks have time limits. You must do the scheduled maintenance within
the time limits.
The flight time recorded in the airplane log book is the time that is relevant for the time limits.
Some components installed in the airplane have a fixed time between overhaul (TBO). Refer to
Paragraph 4.
2. Regulatory Authorities
The recommended time limits given in this Chapter were created to meet the requirements of the
certification process.
Note: National Regulatory Authorities can have different requirements. You must make
sure that you meet the requirements of the Regulatory Authority of the country
where the airplane is registered.
3. Scheduled Maintenance Time Limits
(Refer to Sections 05-20 through 05-28).
The following recommended hourly and calendar time limits apply to the scheduled maintenance
checks which are necessary to maintain the airplane in a good technical condition. Do the scheduled
maintenance at the intervals and within the tolerances shown below.
A. Recurring Maintenance Inspections
Note: Where an interval is given in both flight hours and calendar years, the limit which
is reached first must be applied. The next interval starts with the Flying Hours and
Calender Time of the latest performed Scheduled Maintenance Check.
Note: National requirements may require different maintenance schedules. For example,
on airplanes registered in the USA a 100 hour inspection must be carried out
annually.
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Scheduled Maintenance Check Interval
Flight Hours Calendar Time
100 Hour Check. 100 ± 10
200 Hour Check. 200 ± 10 12 months ± 30 days
1000 Hour Check. 1000 ± 50
2000 Hour Check. 2000 ± 50
First Major Structural Inspection (MSI). 6000 ± 50 12 years ± 6 months
Subsequent Major Structural Inspections. 4000 ± 50 12 years ± 6 months
The intervals between the inspections must be adhered to within the tolerances shown. These
tolerances must not be added up. For example: if the 100 hour inspection was done at 110 hours,
the next inspection must be done at 200 ±10 hours, not 210 ±10 hours.
If an inspection is carried out earlier than allowed by the specified tolerance, all subsequent
inspection intervals are counted from that inspection. For example: If the 100 hour inspection was
done at 83 hours, the next inspection must be done at 183 ±10 hours.
Some inspection items must be done at other intervals than the standard intervals listed in the table
above. In these cases, the maintenance interval (for example, 800 hrs.) is shown as a number in
the maintenance checklists. Refer to Section 05-20, Paragraph 2.
B. Complete Aircraft Inspection
The Complete Aircraft Inspection consists of a 200 Hour Check.
C. Scope of Maintenance Inspections
For maintenance of airplanes registered in the USA, do the items marked X and the items marked
X* in the Maintenance Checklist.
For maintenance of airplanes registered in other countries, do only the items marked X in the
Maintenance Checklist.
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4. Component Time Limits
Note: Those component time limits which are Airworthiness Limitations are also listed in
Chapter 04.
A. Maintenance Requirements
The following table lists airplane components and systems which require overhaul or specific
checks.
Where an interval is given in both flight time and calendar time, the limit which is reached first must
be applied.
For possible maintenance requirements of engine, propeller, components and vendor equipment
refer to the applicable Maintenance data as listed in Section 05-00.
ATA Maintenance Interval

Component
Ch. Requirement hrs. calendar time
Note: The mechanical check of the autopilot system is mandatory.
22 Autopilot. Mechanical check. - 1 yr ± 30 days

Autopilot.
22 (if OÄM 42-210 (GSM 86 Clutch torque check. - 5 yrs ± 60 days
servo mounts) is installed).
Capacity test. Refer to
Concorde RG® Series Main
24 Main battery Concorde. Aircraft Batteries 1000 ± 100 1 yr ± 30 days
Component Maintenance
Manual, latest revision.
% Self-test, operational test of
% the controls and crash
% sensor and signal
% 25 ELT systen. 1 yr ± 30 days
% transmission test according
% manufacturers
% recommondation
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Component
% Safety harnesses
% equipped with AmSafe
% Seatbelt Airbag System Functional test with
% (if OÄM 42-324 is installed). V23 System diagnostic tool.
% 25 1000 ± 50 1 yrs ± 30 days
% If OÄM 42-334 is installed, Refer to
% only the pilot’s seats are Amsafe Maintenance
% equipped with the AmSafe Documentation.
% Seatbelt Airbag System.
Overhaul by fire
26 Fire extinguisher. extinguisher manufacturer - 10 yrs ± 90 days
(see Chapter 03).
29 Hydraulic reservoir air filter. Check. 1000 ± 50 -
De-icing fluid strainer,
30 Clean. - 1 yr ± 15 days
if installed.
Leakage test (refer to
34 Pitot-static system. 1000 ± 50 2 yrs ± 30 days
Section 34-10).
Airspeed indicators - 4 yrs ± 60 days
34 Ensure correct indication.
(G1000 and backup). - 2 yrs ± 30 days*
Vertical speed indicator - 4 yrs ± 60 days
34 Ensure correct indication.
(G1000). - 2 yrs ± 30 days*
* Only required for airplanes for which 14 CFR § 91.411 and

14 CFR § 91.411 Part 43 Appendix E are applicable.
Altimeters
34 Ensure correct indication. - 2yrs ± 30 days
(G1000 and backup).
34 Magnetic compass. Compensate. - 1 yr ± 30 days
System check (refer to
Transponder (G1000) and G1000 System
34 blind altitude encoder Maintenance Manual 1000 ± 50 2 yrs ± 30 days
(altitude digitizer). 190-00907-00, latest
revision).
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Component
% System check (refer to
% Transponder (G1000 NXi) G1000 NXi Line
% 34 and blind altitude encoder Maintenance Manual 1000 ± 50 2 yrs ± 30 days
% (altitude digitizer). 190-02631-00, latest
% revision).
Oxygen regulator valve
35 Overhaul. - 5 yrs ± 60 days
(if installed).
Oxygen cylinder Hydro test per DOT. -
(if installed).
Manufacture / test dates
before 01-Jul-2006: 3 yrs ± 30 days
35 01-Jul-2006, or later: 5 yrs ± 60 days
(if not otherwise

governed by the
local authority)
Bonding system and static Resistance measurements

51 1000 ± 50 4 yrs ± 60 days
discharging system. (refer to Section 51-80).
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B. Airplane Life-Limited Components
The following table lists life limited airplane components which must be replaced at a specific time.
Where an interval is given in both flight time and calendar time, the limit which is reached first must
be applied.
For possible life-limits of engine, propeller, components and vendor equipment refer to the
applicable Maintenance data as listed in Section 05-00.

Ch. hrs. calendar time
2 years, or upon reaching the
24 Emergency battery package. date marked on the package, or
after use, whichever comes first.
24 ECU backup batteries. - 1 yr ± 30 days
24 V-belt of additional alternator (if installed). 2000 ± 50
% 25 Safety harnesses, front and rear (if OÄM 42-324 is NOT - 12 yrs ± 90 days
% installed).
% Safety harnesses rear (if OÄM 42-324 AND OÄM 42-334

% is NOT installed).
% Note: If OÄM 42-324 is installed, refer to the AmSafe

% Maintenance Documentation for on condition
% inspection requirements.
First aid kit. Upon reaching the date marked
25
Replace aseptic items. on the kit.
Rudder cables, non-stainless steel, 3.2 mm (1/8 in)
27 3000 ± 50 5 yrs ± 60 days
diameter.
27 Rudder cables, stainless steel, 3.2 mm (1/8 in) diameter. On condition.
Note: If material of rudder cables is unknown, assume non-stainless steel.
Electrical fuel pumps LH (2 pcs.)

2400 hours, or after a failure
28 If MÄM 42-480 is carried out: including check valves
of one fuel pump.
(1 pc per pump).
Electrical fuel pumps RH (2 pcs.)
2400 hours, or after a failure
28 If MÄM 42-480 is carried out: including check valves
of one fuel pump.
(1 pc per pump).
28 Fuel tank vent hoses. - 8 yrs ± 60 days
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Fuel hoses interconnecting the individual fuel tank
% 28 - 8 yrs ± 60 days
chambers.
28 Fuel filter elements. 100 ± 10 1 yr ± 30 days
Co-incident
If MÄM 42-471 is carried out:
28 with engine -
Fuel pressure pulsation damper.
TBO.
If MÄM 42-480 is carried out:
28 Check valves of the electrical fuel pumps 2400 ± 50 -
(LH/RH, total 4 pcs.).
Co-incident
If MÄM 42-600 is installed:
28 with engine -
Fuel bypass valve.
TBO.
Metal/paper filter element of high pressure filter between
29 the pressure pipe of the hydraulic pump and the hydraulic 1000 ± 50
control unit.
If the ice protection system is installed:
30 2000 ± 50 -
Filter cartridges on the LH side.
32 Brake fluid. - 3 yrs ± 60 days
32 Hydraulic fluid in landing gear dampers. - 2 yrs ± 30 days
32 Hydraulic fluid in hydraulic system. - 2 yrs ± 30 days

35 Oxygen cylinder (if installed). - 15 yrs ± 90 days
35 Oxygen masks (if installed). - 3 yrs ± 30 days
200 of
35 Oxysaver cannulas (if installed). cumulative -
use.
% Canopy door handle compression gas spring (If MÄM 42-

52 3000 ± 50 6 yrs ± 60 days
% 097 is installed, refer to Section 52-10).
Co-incident
Engine shock mounts (including bolts, washers and lock
71 with engine -
nuts).
TBO.
71 Air filter. 200 ± 10 -
71 Air intake hoses. - 8 yrs ± 60 days
Co-incident
All charge air hoses from turbo charger to engine air
81 with engine -
intake manifold.
TBO.
75 Coolant hoses. - 8 yrs ± 60 days
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Co-incident
75 Coolant silicate pouch. with engine 6 yrs. ± 60 days
TBO.
5. Component Time Tracking
To make sure that components overhaul/replacement is done at the correct time you must record the
data that follows in the Airplane Maintenance Log for each component requiring overhaul/replacement:
- Serial Number.
- Flight hours and date at installation.
- Flight hours and date at removal.
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Section 05-20
Scheduled Maintenance Checks
1. General
Do the scheduled maintenance checks in this Section at the intervals (flight hours and calendar time)
stated in Section 05-10, Paragraph 3.
Note: Only persons or maintenance organizations authorized by national Regulatory

Authorities of the country where the airplane is registered may do these checks.
The inspection level for each item is a general visual inspection unless differently
specified.
Note: Only AE authorized maintenance organizations may carry out maintenance and
inspection work on the AE engine. Any engine malfunction must be reported to AE.
2. Maintenance Checklist Organization
Do the scheduled maintenance checks with reference to the Maintenance Checklist in this Section.
Before starting a check, complete the requirements of Paragraphs 2 and 3 of the checklist. Do all the
applicable tasks on the checklist.
Note: For maintenance of airplanes do the items marked X in the Maintenance Checklist.
Note: The interval columns "100", "200", "1000", and "2000" are used for maintenance
items which must be done at intervals of 100, 200, 1000, or 2000 flight hours.
Note: The interval column "time" is used for

(a) Maintenance items which must be done at certain calendar time intervals.
These items are marked with the explicit time interval.
(b) Maintenance items which must be done during a Major Structural Inspection
(MSI). These items are marked with the term "MSI".
Note: Where an interval is given in both flight time and calendar years, the limit which is
reached first must be applied.
Note: Some inspection items must be done at other intervals than the standard intervals
(100, 200, 1000, or 2000 hrs.). In these cases, the maintenance interval is shown
in the column for the next shorter interval instead of an X. For example, an item
which must be done every 800 hours is identified by the words "800 hrs." in the
200 hrs. column.
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All of the applicable items must be signed by authorized maintenance personnel. Record the
completion of the check in the airplane log book. Complete a copy of the Maintenance Report (refer
to Section 05-28-90).
The Maintenance Checklist is divided into the following Sections:
A. Section 05-28-00: Engine Compartments
All items forward of the firewalls. It includes the cowlings and the propellers.
B. Section 05-28-50 - Airframe
(1) Exterior of the Fuselage
All items on the outside of the fuselage from the nose to the leading edge of the vertical tail. It
includes the nose baggage compartment, the nose landing gear, and the main landing gear.
(2) Cabin
All items inside the fuselage shell from the aft face of the instrument panel frame to the forward
face of the baggage compartment frame. It also includes the internal parts of the flight control
system, the internal pars of the brake system, and the canopy and rear door.
(3) Interior of the Rear Fuselage
All items inside the fuselage shell from the aft face of the baggage compartment frame to the
vertical tail. It includes the control systems and the hydraulic systems in the rear fuselage.
(4) Center Wing
All items between the LH and RH wing root. It includes the engine nacelles aft of the firewalls.
(5) Tail
All items aft of the leading edge of the vertical tail. It includes the vertical stabilizer and the
horizontal stabilizer.
(6) Wings
All items on the left and right wings. It includes the ailerons, flaps, Pitot-static probe, and fuel
tanks.
(7) General
Those items which include more than one zone at the same time. It includes items such as
control checks which need one person in the cockpit and another person at the control surface.
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3. Major Structural Inspection
The Major Structural Inspection (MSI) is an important part of the infinite lifetime concept of the
DA 42 NG. It is required to prove the structural integrity of the airframe. It must be carried out at the
intervals shown in Section 05-10.
Since the MSI is intended to coincide with a 2000 hour inspection, the inspection items are included
in the maintenance checklist, and are identified by the term “MSI” in the ‘time’ column.
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Section 05-21
Flight-Line Checks
1. General
These checks include the pre-flight and post-flight checks. Do these checks each day the airplane is
used.
2. Flight-Line Checks
The Pre-Flight Check must be done before the first flight of the day. It shows the pilot the general
condition of the airplane and the engine. It is important for flight safety. Look in the airplane log-book
for problems before doing the pre-flight check.
WARNING: DO ALL THE STEPS OF THE PRE-FLIGHT CHECK CAREFULLY.

ACCIDENTS CAN OCCUR IF THE PRE-FLIGHT CHECK IS NOT DONE
CORRECTLY.
The schedule for the pilot's pre-flight check is furnished in the Airplane Flight Manual for the DA 42 NG.
3. Post-Flight Check
Do the post-flight check after the last flight of the day. The post-flight check includes all the steps of
the pre-flight check.
You must also:
Refuel the airplane (Section 12-10).
Record in the log book each problem found in flight and during the post-flight check.
Park the airplane (Sections 10-00 and 10-10).
If necessary, moor the airplane (Section 10-20).
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Section 05-25
Drain Holes Inspection Checklist and Report
1. General
Do a check of the drain holes. The drain holes must not be blocked by dirt or other residues. Make
sure to remove all foreign objects and clean the drain holes to their full diameter. Otherwise the drain
capacity may not be sufficient under certain conditions like heavy rain etc.
All drain holes should be drilled with a diameter of 5 mm (+2 mm/-0 mm) or 0.2 in (+0.08 in/-0.00 in).
The holes should be circular, deburred, not frayed and cleaned.
At drain holes marked with an asterisk (*) the adhesive bonding is recessed.
Refer to the corresponding indication on the figures to identify the locations of the drain holes listed
below.
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2. Drain Holes Inspection Checklist
Drain Holes Inspection Checklist
Ref. Drain Hole Location Hours Initials
1 FUSELAGE
1.01 Lower shell, in front of radar frame (if neither OÄM 42-119 100
nor OÄM 42-273 is installed).
1.02 Lower shell, behind the radar frame, on the left and right 100
side of EPU.
1.03 Lower shell, behind nose gear frame, on the left and right 100
side of nose gear.
1.04 Lower shell under the center console. 100
1.05 In the floor panel rear side, LH and RH. 100
1.06 Lower fuselage shell, aft of baggage compartment frame base. 100
1.07 On lowest point of the fin. 100
1.08 On the back side of the fin. 100
1.09 Bolt in rudder mounting shell (on top of the rudder). 100
1.10 On lowest point of the cowling (LH and RH). 100
1.11 On lowest point of the engine nacelle two holes in the LH 100
and RH nacelle.
1.12 On lowest point of the engine nacelle aft of the front box spar 100
(LH and RH).
1.13 Lower center wing shell, next to landing light. 100
1.14 Lower center wing shell, in front of front box - spar (LH and 100
RH).
1.15 Lower center wing shell, in front of front box - spar center. 100
1.16 Lower center wing shell, aft of the front box - spar four holes 100
in line.
1.17 Lower center wing shell, in front of rear box - spar three 100
holes in line.
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1.18 Flange top at main landing gear in front of rear box - spar 100
(LH and RH).
1.19 Lower center wing shell aft rear spar center position. 100
1.20 Lower center wing shell, fuselage rib reinforcement section 100
LH and RH and one in center position.
1.21 Lower center wing shell, in front of baggage compartment 100

frame base.
1.22 Lower center wing shell, rear bonding flange. 100
1.23 Engine nacelle rear; LH of fuel cooler cover. 100
1.24 Engine nacelle rear; RH of fuel cooler cover. 100
1.25 Through lower (if OÄM 42-119 or OÄM 42-273 is installed) 200
and upper end of radar frame.
1.26 In front of nose baggage compartment floor (LH and RH). 200
1.27 In rear of nose baggage compartment (LH). 200
1.28 Through baggage compartment frame, center position 200

above lower fuselage shell.
1.29 Through lower end of ring frame 1. 200
1.32 In rib of vertical stabilizer, in front of vertical stabilizer front 200

web.
1.33 In rib of vertical stabilizer, in front of vertical stabilizer rear 200

web.
1.34 Lower fuselage shell, aft of vertical stabilizer rear web. 200
1.35 Lower fuselage shell, aft of vertical stabilizer front web. 200
1.36 In the front box spar, to the engine nacelle fuel compartment, 200
(LH and RH).
1.37 In the rear box spar, to the engine nacelle maintenance 200
cap 2 (LH and RH).
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1.38 Through roll over bar duct and baggage compartment frame. 200
1.39 In rear of nose baggage compartment RH. 2000
2 CANOPY AND DOOR
2.01 Lower canopy frame, in front of Bowden cable guide (LH and 100
RH).
2.02 Lower canopy frame, aft of the canopy locking mechanism 100
(LH and RH).
2.03 Inner door shell, below the front locking bolt. 100
3 HORIZONTAL STABILIZER
3.01 Lower shell, next to the mid inspection hole (LH and RH). 100
3.02 Lower shell, next to the front inspection hole (LH and RH). 100
3.03 On the lowest point of the horizontal stabilizer tips (LH and 100
RH).
3.04 Elevator end rib, next to the rear spar, next to lower shell 200
(LH and RH).
3.05 LH and RH rib, in front of the rear spar, above the lower shell. 200
3.06 LH and RH rib, aft of the front spar, above the lower shell. 200
3.07 LH and RH rib, in front of the front spar, above the lower shell. 200
3.08 Mid LH and RH rib, behind the rear spar, above the lower 2000
shell.
3.09 Mid LH and RH rib, behind the front spar, above the lower 2000
shell.
4 ELEVATOR
4.01 Lower shell, leading edge section (LH and RH). 100
4.02 Lower shell, in front of trailing edge (LH and RH). 100
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5 ELEVATOR TRIM TAB
5.01 Lower shell, leading edge section (LH and RH). 100
5.02 Lower shell, in front of trailing edge bonding (LH and RH). 100
6 RUDDER
6.01 Lower edge of the rudder shell. 100
6.02 Lower edge of the trim rudder shell. 100
7 WINGS
7.01 In outer wing end rib at aileron mass balance cut out. 100
7.02 Wing tip in front of rear bonding (LH and RH wing). 100
7.03 First fuel tank rib, next to front and rear spar bonding and 200
lower shell (LH and RH wing)*.
7.04 In flap rib rear spar next to lower shell (LH and RH wing). 200
7.05 In rear root rib next to rear spar and lower shell (LH and RH 200
wing)*.
7.06 In aileron rib next to rear spar and lower shell (LH and RH 200
wing)*.
7.07 Second fuel tank rib, next to front and rear spar and lower 200
shell (LH and RH wing)*.
7.08 Third fuel tank rib, next to front and rear spar and lower shell 200
(LH and RH wing)*.
7.09 Fourth fuel tank rib, next to front and rear spar and lower 200
shell (LH and RH wing)*.
7.10 Fifth fuel tank rib, next to front and rear spar bonding and 200
lower shell (LH and RH wing).
7.11 In front root rib, next to front spar and lower shell (LH and 2000
RH wing).
7.12 Vent hole on face side of wing spar (LH and RH). 2000
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8 FLAPS
8.01 Root rib, next to trailing edge bonding (LH and RH). 100
8.02 Inner flap root rib, next to trailing edge bonding (LH and RH). 100
8.03 Inner flap root rib, at the leading edge (LH and RH). 100
9 AILERONS
9.01 Inner root rib, next to the trailing edge bonding (LH and RH). 100
9.02 Lower shell, aft of mass balance weight (LH and RH). 100
9.03 Lower shell, in front of mass balance hinge line (LH and RH). 100
9.04 Outer root rib, at the leading edge (LH and RH). 100
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1.25
1.25
1.27
1.05
1.01 1.25 1.02

1.03
1.04
Drainage Holes 11mm
View from below
1.39
1.03 1.05
1.26
1.25
1.04
1.26
1.03
1.05
1.27
Drainage Holes 11mm
X 100 Hours Check Horizontal Drainage Hole
X 200 Hours Check Vertical Drainage Hole
X 2000 Hours Check Exterior Drainage Hole
Drainage Hole Inside the Structure
Figure 1: Drain Holes Fuselage (Part 1)
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1.33
To be checked only
in production or repair 1.09
1.32
1.38
1.30 1.31 1.31

1.29
1.28
To be checked only 1.07 1.35 6.2
1.06 in production or repair
1.08
6.1
Figure 2: Drain Holes Fuselage (Part 2)
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2.02
2.01
2.01
2.02
Figure 3: Drain Holes Canopy
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2.03
Figure 4: Drain Holes Door
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3.07 3.02 3.07
3.06 3.06
3.09 3.09
3.05 3.01 3.05
3.08 3.04 3.04 3.08
4.01 4.01
4.02 4.02
3.03 3.07
5.01 5.01
5.02 5.02
Figure 5: Drain Holes Horizontal Stabilizer, Elevator and Elevator Trim Tab
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6.02
6.01
Figure 6: Drain Holes Rudder
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6.02
6.01
Figure 7: Drain Holes Rudder (if MÄM 42-600 is installed)
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In Cowling Base VIEW FROM UNDER In Cowling Base
1.10 1.10
1.13
1.11 1.11
To be checked only in To be checked only in
Production or Repair 1.15 Production or Repair
1.14 1.14
1.36 1.36
1.12 1.12
1.18 1.16 1.16 1.18
1.17 1.17
1.37 1.37
To be checked only in 1.19 To be checked only in

Production or Repair Production or Repair
8.03 8.03
1.24 1.20
1.20 1.20
1.22 8.02 8.02 1.22 1.23

1.21
Figure 8: Drain Holes Center Wing
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Maintenance Access Maintenance Access
7.11
7.09 7.08 7.07
7.12
7.10 A A A 7.03
7.01 9.02
7.09 7.08 7.07 7.12
9.04 7.06 7.04 7.05
9.03
7.02 9.01
8.01
View A
7.06 to 7.09
Figure 9: Drain Holes Wings, Flaps and Ailerons
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Section 05-28
Maintenance Checklist DA 42 NG
Section 05-28-00
Maintenance Checklist DA 42 NG Engines
1. General
Enter the applicable data in the blocks below:
Registration : _________________ Date : _________________
LH RH
Airplane S/N : _________________ Engine S/N : _______ _______
Airplane Engine hours, LH RH
Operating Hours : _________________ TTSN : _______ _______
LH RH
Inspection : _________________
Propeller S/N : _______ _______
(100, 200, 1000, 2000 hr, Annual Insp.) Propeller hours, LH RH

TTSN : _______ _______
2. Preparation
Do the following items before you start the applicable check:
Inspection Items 100 200 1000 2000 Initials

1. Before you do the inspection: X X X X
S Read the applicable Airworthiness Directives.
S Read the applicable Service Bulletins.
2. Examine the Log Books. Look specially for: X X X X
S Life limited parts.
S Reported problems.
3. Clean the airplane fully. (Refer to Section 12-30). X X X X
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3. Engine Ground Test
Do an engine ground test as follows (complete a copy of the Engine Ground Test Record as part of
the engine ground test. (Refer to Section 05-28-91)):
Interval
Inspection Items 100 200 1000 2000 Time Initials
WARNING: DO NOT LET PERSONS GO 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.
1. Set the parking brake to ON. X X X X

2. Put the chocks against the airplane main wheels. X X X X
3. Do an engine ground run. (Refer to Section 71-00 X X X X

and AE Maintenance Manual, latest revision).
4. Check engine instruments. X X X X
5. Do a test of the crossfeed system. X X X X
(Refer to Section 28-20).
6. Do a test of the feathering and unfeathering X X X X
system. (Refer to Section 61-20).
7. Shut engines down. X X X X
8. If auxiliary tanks are installed do a test of the X X X X
auxiliary fuel transfer system. (Refer to Section
28-20).
9. Examine the engine for oil/fuel/coolant leaks. X X X X
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4. Maintenance Checklist Engines
A. LH Engine
100 hr items marked * apply to US registered airplanes only Interval
Inspection Items, LH Engine 100 200 1000 2000 Time Initials
WARNING: MAKE SURE THE EXHAUST SYSTEM IS COOL BEFORE YOU DO

MAINTENANCE ON THE ENGINE. THE EXHAUST SYSTEM CAN BE
HOT. THIS CAN CAUSE INJURY TO PERSONS.
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.
1. Remove the top and bottom cowlings. (Refer to X X X X

Section 71-10). Examine the cowlings. Make sure that
the fasteners are serviceable. Look for cracks and
areas that have got too hot. Check rubber seals.
2. Clean the engine and engine compartment. X X X X
Refer to Section 12-30 and the AE Maintenance

3. Do engine maintenance in accordance with AE X X X X

Maintenance Manual, latest revision.
4. Cut open the used oil filter: X X X X 1 yr.

±
S Look for contamination and metal abrasion.
30
S If the filter contains particles of metal, refer to the days
engine manufacturer.
5. Verify proper mixture ratio of the coolant. X* X X X
Refer to the AE Maintenance Manual, latest revision.
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6. Examine the fuel inline filter element in the rear X X

nacelle (if auxiliary tanks are installed):
S If filters are damaged replace them.
S If filters are contaminated flush filter mesh with

clean fuel.
7. Check fuel pre-filter elements (2 pcs.). X X
8. Test auxiliary fuel pumps (if auxiliary tanks are X X

installed). (Refer to Section 28-20).
9. Test solenoid and check valves (if auxiliary tanks are X X

10. Examine the exhaust end pipe incl. muffler (if X X X X

installed). Look specially for cracks and heat damage
or incorrect attachment.
11. Examine the mounting bracket, pulley assembly and X X X X

electrical connections of the additional alternator
(if OÄM 42-204 is carried out):
S Visual inspection of mounting bracket and pulley

assembly for corrosion and cracks.
S Examine the electrical connections. Look

especially for rub marks, damage and corrosion.
Pull lightly to make sure they are not loose.
12. Examine the v-belt of the additional alternator X X X X

(if OÄM 42-204 is carried out):
S Visual inspection for damage and material

deterioration.
S Check the v-belt tension. Refer to Chapter 61.
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13. Examine the air intake hoses: X X X X
S Look specially for signs of damage.
S Make sure the air hoses are correctly attached

and that the torque seal on the hose clamps is
intact.
14. Examine the cable ties and all electrical connectors in X X X X

the engine area:
S Look specially for rub marks and damage.
S Pull lightly to make sure they are not loose.
15. Examine the bonding cables and their connectors in X X X X

the engine area:
16. Examine the oil breather line. X X X X
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17. Examine the propeller control system: X X X X
Refer also to mt-Propeller Operation and Installation

manual, latest revision.
S Examine the hose and hose connection. Look

specially for leakage and damage.
S Examine the un-feathering pressure accumulator.

Look specially for:
S Leakage and damage.
S Insecure attachment.
S Nitrogen pressure accumulator.

Refer to mt-Propeller Operation and Installation
S Check accumulator nitrogen pressure:
S Set valve under current (open).
S Remove the cap from the charging valve.
S Connect a suitable nitrogen supply to the

charging valve and charge the accumulator to
the correct pressure 10.4 bar (150 PSI). Follow
the manufacturer’s instructions for the nitrogen
supply.
S Disconnect the nitrogen supply.
S Install the cap onto the charging valve.
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18. Examine the air intake and turbo-charging system. X X X X

Look specially at these items:
S Air filter.
S Hose from air filter to turbo-charger.
S Turbo-charger.
On the pressure side of the turbo-charger:
S Hoses and hose clamps.
S Aluminum pipes.
S Make sure the air hoses and ducts are correctly

attached and that the torque seal on the hose
clamps is intact.
S Intercooler.
Do NOT re-tighten the worm drive clamps once they

have been installed unless they are loose.
Re-tightening of worm drive clamps will lead to
damage of silicone hoses and possible loss of engine
power.
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Inspect the v-clamp on the pressure side of the turbo

charger:
S Inspect for positive clearance between the flanges

of the turbo charger/aluminum charged air tube
and the base of the v-clamp on the complete
circumference. If there is NO positive clearance:
replace the v-clamp.
S Inspect for signs of cracks in the edges of the

ends of the v-bands of the v-clamp with flashlight
and mirror.
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19. Check cooling system for leaks. Look specially at X X X X

these items:
S Aluminum pipes.
20. Examine the coolant radiators: X X X X
S Look specially for leakage, damage, and insecure

attachment.
S Make sure the cooling fins are not blocked.
21. Examine the coolant tank: X X X X
S Look specially for leakage and damage.
S Check the attachment for cracks.
22. Perform a coolant tank pressure relief valve test. X X X X
23. Examine the alternate air valve assembly: X X X X
S Check correct movement when the alternate air

lever in the cockpit is operated.
S Examine the FOD screen for contamination.

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24. Examine the engine mounts. Look specially for: X X X X
S Cracks or corrosion. No cracks or corrosion

allowed.
S Damaged surface protection. Repair damaged

surface protection.
S Mounting bolts:
S Incorrect attachment.
S Damage. No damage allowed.
S Incorrect torque value. (Refer to Section 20-10).
S Loose or missing lock devices.
S Damaged shock mounts. Replace damaged

shock mounts.
25. Check bolts mounting engine mount to firewall. X

Torque to the value given in Section 20-10
S At the first 100 hrs. check. (X)
26. Check the overheat detector for damage, loose X X X X

connectors, and insecure attachment.
27. Do a function test of the overheat detector. (Refer to X X X X

Section 26-00).
28. Do an engine ground test run. X X X X
After the engine test run, read the EECU data out and
send them via email to Austro Engine GmbH.
Refer to AE Maintenance Manual, latest revision.
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B. RH Engine
Inspection Items, RH Engine 100 200 1000 2000 Time Initials
WARNING: MAKE SURE THE EXHAUST SYSTEM IS COOL BEFORE YOU DO

MAINTENANCE ON THE ENGINE. THE EXHAUST SYSTEM CAN BE
HOT. THIS CAN CAUSE INJURY TO PERSONS.
1. Remove the top and bottom cowlings. (Refer to X X X X

Section 71-10). Examine the cowlings. Make sure that
the fasteners are serviceable. Look for cracks and
areas that have got too hot. Check rubber seals.
2. Clean the engine and engine compartment. X X X X
Refer to Section 12-30 and the AE Maintenance

3. Do engine maintenance in accordance with AE X X X X

4. Cut open the used oil filter: X X X X 1 yr.

±
S Look for contamination and metal abrasion.
30
S If the filter contains particles of metal, refer to the days
5. Verify proper mixture ratio of the coolant. X* X X X
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6. Examine the fuel inline filter element in the rear X X

nacelle (if auxiliary tanks are installed):
S If filters are damaged replace them.
S If filters are contaminated flush filter mesh with

clean fuel.
7. Check fuel pre-filter elements (2 pcs.). X X
8. Test auxiliary fuel pumps (if auxiliary tanks are X X

9. Test solenoid and check valves (if auxiliary tanks are X X

10. Examine the exhaust end pipe incl. muffler (if X X X X

installed). Look specially for cracks and heat damage
or incorrect attachment.
11. Examine the air intake hoses: X X X X
S Make sure the air hoses are correctly attached

and that the torque seal on the hose clamps is
intact.
12. Examine the cable ties and all electrical connectors in X X X X

the engine area:
13. Examine the bonding cables and their connectors in X X X X

the engine area:
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14. Examine the oil breather line. X X X X

15. Examine the propeller control system: X X X X
Refer also to mt-Propeller Operation and Installation

manual, latest revision.
S Examine the hose and hose connection. Look

specially for leakage and damage.
S Examine the un-feathering pressure accumulator.

Look specially for:
S Leakage and damage.
S Nitrogen pressure accumulator.

Refer to mt-Propeller Operation and Installation
S Check accumulator nitrogen pressure:
S Connect a suitable nitrogen supply to the

charging valve and charge the accumulator to
the correct pressure 10.4 bar (150 PSI). Follow
the manufacturer’s instructions for the nitrogen
supply.
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16. Examine the air intake and turbo-charging system. X X X X

Look specially at these items:
S Air filter.
S Hose from air filter to turbo-charger.
S Turbo-charger.
On the pressure side of the turbo-charger:
S Aluminum pipes.
S Make sure the air hoses and ducts are correctly

attached and the torque seal on the hose clamps
is intact.
S Intercooler.
Do NOT re-tighten the worm drive clamps once they

have been installed unless they are loose.
Re-tightening of worm drive clamps will lead to
damage of silicone hoses and possible loss of engine
power.
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Inspect the v-clamp on the pressure side of the turbo

charger:
S Inspect for positive clearance between the flanges

of the turbo charger/aluminum charged air tube
and the base of the v-clamp on the complete
circumference. If there is NO positive clearance:
replace the v-clamp.
S Inspect for signs of cracks in the edges of the

ends of the v-bands of the v-clamp with flashlight
and mirror.
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17. Check cooling system for leaks. Look specially at X X X X

these items:
S Aluminum pipes.
18. Examine the coolant radiators: X X X X

attachment.
19. Examine the coolant tank: X X X X
S Look specially for leakage and damage.
S Check the attachment for cracks.
20. Perform a coolant tank pressure relief valve test. X X X X
21. Examine the alternate air valve assembly: X X X X
S Check correct movement when the alternate air

lever in the cockpit is operated.
S Examine the FOD screen for contamination. Refer

to Section 71-60.
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22. Examine the engine mounts. Look specially for: X X X X
S Cracks or corrosion. No cracks or corrosion

allowed.
S Damaged surface protection. Repair damaged

surface protection.
S Mounting bolts:
S Incorrect torque value. (Refer to Section 20-10).
S Damaged shock mounts. Replace damaged

shock mounts.
23. Check bolts mounting engine mount to firewall. X

Torque to the value given in Section 20-10
S At the first 100 hrs. check. (X)
24. Check the overheat detector for damage, loose X X X X

connectors, and insecure attachment.
25. Do a function test of the overheat detector. (Refer to X X X X

Section 26-00).
26. Do an engine ground test run. X X X X
After the engine test run, read the EECU data out and
send them via email to Austro Engine GmbH.
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5. Propellers
A. LH Propeller

Inspection Items, LH Propeller 100 200 1000 2000Time Initials
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
TURN THE PROPELLER.
1. Inspection in accordance with mt-Propeller X* X X X

B. RH Propeller

Inspection Items, RH Propeller 100 200 1000 2000Time Initials
TURN THE PROPELLER.
1. Inspection in accordance with mt-Propeller X* X X X

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Section 05-28-50
Maintenance Checklist Airframe
1. Exterior of the Fuselage
A. General

Inspection Items, Exterior Fuselage, General 100 200 1000 2000Time Initials
1. Examine the complete surface of the fuselage. Look X* X X X
specially for damage (dents, cracks, holes and
delamination).
Examine the surface protection system.

2. Check the static source holes for blockage. X X X X
3. Do a coin-tap test for delamination of the entire MSI
fuselage shell from the nose to the vertical tail. (Refer
to Section 51-10).
4. Do a coin-tap test for defects in the entire fuselage MSI

tube bonding (top and bottom). (Refer to Section
51-10).
5. Examine all antennas. Look specially for damage, X X X X
incorrect attachment, and cracks in the fuselage skin.
6. Examine the exterior placards. Make sure that: X* X X X
S They are not damaged.
S None are missing. (Refer to Chapter 11).
7. Lift the airplane on jacks. (Refer to Section 07-10). X* X X X
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B. Nose Landing Gear

Inspection Items, Nose Landing Gear 100 200 1000 2000Time Initials
1. Examine the composite structure to which the nose X X X X
landing gear assembly is attached. Look specially for
cracks and delamination.
2. Examine the forward part of the steering linkage. Look X X X X
specially for:
S Damage and corrosion.
S Damaged surface protection.
S Incorrect attachment and loose or missing lock

devices.
S Defective bonding strap.
3. Examine the cardan joint bracket. Look specially for X X X X

corrosion, cracks and damage.
4. Examine the nose wheel centering device. Look X X X X
specially for damage, excessive wear, and looseness.
5. Examine the nose landing gear actuator. Look X X X X
specially for leakage. (Refer to Section 32-20).
6. Examine the damper and the hydraulics. Look X X X X
specially for leakage. (Refer to Section 32-20).
7. Examine the nose landing gear doors: X X X X
S Check for damage to the doors.
S Check for cracked hinges.
S Examine the door operating rods.
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Inspection Items, Nose Landing Gear 100 200 1000 2000Time Initials
8. Disassemble and examine the nose landing gear leg: X
S Remove the nose landing gear leg.
S Remove the nose landing gear damper assembly.
S Remove the nose landing gear mounting bracket.
S Clean all parts.
S Examine all parts. Look specially for deformation,

cracks, wear, corrosion and damaged surface
protection.
S Install the nose landing gear mounting bracket.
S Install the nose landing gear damper assembly.
S Install the nose landing gear assembly.

9. Examine the nose landing gear for damage (nose X X X X
landing gear leg assembly, folding stay assembly,
mounting bracket assembly). Look specially for cracks,
deformation, wear, corrosion and damaged surface
protection.
10. Ensure correct gas pressure in the damper with the X* X X X
wheel off the ground:
S 16 bar / 232 PSI.
S 10 bar / 145 PSI (if MÄM 42-659 is carried out).
For more information refer to Section 32-20.

11. Apply grease to the actuator bearing. (Refer to X X X X
Sections 12-20 and 32-20).
12. Apply a small amount of oil to the bearings of the X X X X
torque links. (Refer to Sections 12-20 and 32-20).
13. Examine the up-lock and the down-lock X X X X
micro-switches. (Refer to Section 32-20).
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C. Main Landing Gear

Inspection Items, Main Landing Gear 100 200 1000 2000Time Initials
1. Examine the composite structure to which the main X X X X
landing gear assembly is attached. Look specially for
cracks and delamination.
2. Examine the bearings for the main landing gear X X X X
assemblies in the center wing. Look specially for play.
3. Examine the landing gear legs and trailing arms. Look X X X X
specially for cracks, deformation, corrosion, and
damaged surface protection.
4. Examine the hydraulic lines of the brake system for X X X X
damage, leakage, and loose or defective connectors.
5. Examine the main landing gear actuators and X X X X
hydraulics. Look specially for leakage. (Refer to
Chapter 32).
6. Examine the damper. Look specially for leakage. X X X X
7. Examine the main landing gear doors: X X X X
S Check for cracked hinges.
S Examine the door operating rods.
8. Remove the dampers, trunnions, and trailing arms X

from the legs. (Refer to Section 32-10).
9. Examine these bearings: X
S Plain bearings in the trailing arm.
S Upper and lower bearings for the dampers.
10. Examine the bolt that attaches the trailing arm to the X
leg. Look specially for deformation and cracks.
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Inspection Items, Main Landing Gear 100 200 1000 2000Time Initials
11. If MÄM 42-659 is NOT installed, examine the interior of X
the dampers:
S Disassemble the dampers. (Refer to Section

32-10).
S Clean all parts.
S Examine all parts. Look specially for deformation

and cracks.
S Reassemble the dampers. (Refer to Section

32-10).
12. Reinstall the dampers, trunnions, and trailing arms to X

the legs. (Refer to Section 32-10).
13. Ensure correct gas pressure in the dampers (19 bar / X* X X X
276 PSI with the wheel off the ground). (Refer to
Chapter 32).
14. Apply grease to the actuator bearing. (Refer to X X X X
Sections 12-20 and 32-20).
15. Examine the up-lock and the down-lock micro X X X X
switches. (Refer to Chapter 32).
16. Examine the Weight-on-Wheels switches. X* X X X
S Look specially for:
S Verify proper operation.
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D. Wheels

Inspection Items, Wheels 100 200 1000 2000Time Initials
1. Examine the tires: X X X X
S Look for cuts and wear.
S Check slip marks.
S Ensure correct inflation pressure in the nose

wheel:
S 6 bar / 87 PSI.
S 6.1 bar / 88 PSI, if MÄM 42-659 is carried out.
S Ensure correct inflation pressure in the main

wheels:
S 4.7 bar / 68 PSI.
2. Examine the main wheel brakes: X X X X
S Check brake linings for excessive wear.
S Check brake disks for distortion and excessive

wear.
S Check brake cylinders for leaks.
3. Remove all 3 wheels. X* X X X

4. Examine the wheel axles. Look specially for cracks X* X X X
and corrosion.
5. Examine the wheel bearings. Look specially for play, X* X X X
corrosion and irregular running.
6. Clean and lubricate all bearings at the wheels. (Refer X* X X X
to Section 12-20).
7. Examine the rims of all 3 wheels. Look specially for X X X X
cracks.
8. Install all 3 wheels. X* X X X
9. Do a test for wheel track and camber. (Refer to Section X X
32-10).
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E. Fuselage Nose

Inspection Items, Fuselage Nose 100 200 1000 2000Time Initials
1. Examine the nose baggage doors: X* X X X
S Check for defective hinges.
S Make sure that the locks operate correctly.
S Check operation of door warning switches.
2. Close only one nose baggage door and test the lock of X X X
the other one by pushing from inside. Repeat the
procedure for the other side.
3. Remove the covers from the rear wall of the nose X* X X X
baggage compartment.
4. Examine the cable ties and all electrical connectors: X* X X X
5. Do a check of the airplane battery. Refer to the X X X

Maintenance Manual of the Battery for additional
instruction. Look specially for:
S Corrosion, pitting, burn marks or damage on

battery terminals.
S Incorrect mounting. (Refer to Section 24-31).
6. Examine the battery area. Clean the area. X X X
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7. Visually inspect the interior structure of the front X
fuselage (forward of instrument panel frame). Use
mirror and flashlight where necessary. Check for
damage, cracks, delamination and disbonding from the
fuselage skin. Inspect the following components:
S Instrument panel frame.
S Nose compartment floor.
S Nose frame.
8. If installed, check the spraybar for the de-icing fluid for X* X X X

damage.
9. If the oxygen system is installed (OÄM 42-055), X X X X

visually inspect the ventilation of the nose baggage
compartments (oxygen, battery, and TKS
compartment). Especially check both ventilation caps,
installed on the LH and RH side of the nose landing
gear.
10. If the oxygen system is installed (OÄM 42-055), X X

visually inspect all oxygen tubes installed in the oxygen
and battery compartment. Check for improper fixture,
chafing, leakage and improper ventilation of the high
pressure tube.

visually inspect the cylinder regulator valve installed on
the oxygen cylinder. Check for damage, dust and
corrosion.
12. If the oxygen system is installed (OÄM 42-055), X X X X

visually check the front baggage compartment for
residues of oil, TKS fluid and grease. Clean up if
necessary.
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13. If the GWX 68 or GWX 70 weather radar system X X X
(OÄM 42-119 or OÄM 42-273) is installed:
Examine the airplane nose cone:
S Check for structural damage.
S Check attachment screws (16 pieces).
S Check lightning protection strips (4 pieces) for

proper mounting.
14. If the GWX 68 or GWX 70 weather radar system X X 1 yr.

(OÄM 42-119 or OÄM 42-273) is installed:
Examine the GWX 68 or GWX 70 installation on the

radar bulkhead:
S Check radar antenna visually.
S Check bracket attachment screws.
S Check lightning protection bonding for proper

mounting.
S Examine the wire harness and electrical

connectors for chafing, damage and proper
attachment. Pull lightly to make sure they are not
loose.
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2. Cabin
A. Cabin, General
Inspection Items, Cabin, General 100 200 1000 2000 Time Initials
1. Remove the inspection hole covers. Remove front and X* X X X

rear seat shells. Refer to Section 25-10.
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.
2. If adjustable front seats (OÄM 42-067 or OÄM 42-259) X* X X X

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).
3. Examine the emergency axe installation X X X

(if OÄM 42-205 is installed):
S Check attachments for looseness.
S Check release mechanism for interference or

improper function.
4. Examine the emergency egress hammer installation X X X

(if OÄM 42-304 is installed):
S Check attachments for looseness.
S Check release mechanism for interference or

improper function.
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B. Canopy, Doors, and Windows
Inspection Items, Canopy, Doors, and Windows 100 200 1000 2000Time Initials
1. 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 Inspect the acrylic glass window for crazing and

scratches. No crazing and scratches are
acceptable which affect sight of the pilots.
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. Check hinges for improper friction,
correct if necessary.
2. If OÄM 42-194 carried out:
Perform release test of canopy jettison system (refer to x

Section 52-10)
2
Replace canopy jettison assemblies (refer to x
yrs.
Section 52-10)
Perform 100 h Maintenance Check of canopy jettison x x x x

system (refer to Section 52-10)
5. Do a function test of the door unlocked warning light X X X X

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

Section 52-10).
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Rev. 5 05-28-50 22 Dec 2021
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Inspection Items, Canopy, Doors, and Windows 100 200 1000 2000Time Initials
7. Examine the carbon hinges for cracks. (Refer to X X X X

Section 52-10).
8. Examine the rear passenger door: X* X X X
S Make sure the door lock mechanism and the

safety hook mechanism operate correctly. (Refer
to Section 52-10).
S If MÄM 42-097 is installed: Do a test of the

passenger door handle compression gas spring.
S Examine the carbon hinges for cracks. (Refer to

Section 52-10).


door frame. (Refer to Section 56-10).
9. Examine the rear window on the RH side: X* X X X


frame. (Refer to Section 56-10).
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C. Cabin Structure
Inspection Items, Cabin Structure 100 200 1000 2000Time Initials
1. Visually inspect the inner skin of the front fuselage MSI

(forward of baggage compartment frame). Use mirror
and flashlight where necessary. Check for damage,
cracks, delamination and disbonding from the
sandwich foam.
2. Check front and rear main spars for damage, cracks, X X X

delamination and disbonding from the center wing
skin.
3. Visually inspect the interior structure of the front X

fuselage (from instrument panel frame to baggage
compartment frame). Use mirror and flashlight where
necessary. Check for damage, cracks, delamination
and disbonding from the fuselage skin. Inspect the
following components:
S Front main spar.
S Rear main spar.
S Control bulkhead.
S Floor element.
S Top-hat profile for rudder lever.
4. Visually inspect the interior structure of the front X X

fuselage. Use mirror and flashlight where necessary.
Check for damage, cracks, delamination and
disbonding from the fuselage skin. Inspect the
S Baggage compartment frame.
S Roll bar.
S Front and rear seat crash elements.
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Rev. 5 05-28-50 22 Dec 2021
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Maintenance Checks
Inspection Items, Cabin Structure 100 200 1000 2000Time Initials
5. Visually inspect the bolts that attach the center wing to X X

the fuselage. Look specially for:
S Damage or looseness.
S Cracks in the fuselage structure around the holes

for the bolts.
D. Instrument Panel and Electrical System in Cabin
Inspection Items, Instrument Panel and 100 200 1000 2000Time Initials
Electrical System in Cabin
1. Examine the Pitot-static system water traps (below the X* X X X

pilot's seat and below the aft baggage compartment).
2. Examine all cable ties and electrical connectors in the X* X X X

cabin. Pull lightly to make sure they are not loose.
3. 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 fans are operative and correctly

attached.
S The Pitot static lines are not sharply bent or

chafed.
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4. Examine the attachments of the instrument panel. X* X X X

Make sure that:
S The rubber damper elements are not damaged or

porous.
S The rubber damper elements are firmly attached to

the instrument panel and angle supports
(4 elements in the front, 1 element on each side).
5. Examine the instrument panel for cracks. X X X
6. Examine the emergency battery system: X* X X X
S Measure the voltage of the emergency battery

pack on the EMERGENCY switch. Replace
emergency battery pack if the voltage is below
30 V.
7. Make sure that the seal on the EMERGENCY switch is X X X X

intact.
8. Examine the backup instruments. Make sure that: X* X X X
S The markings are clear (if OÄM 42-270 is NOT

installed).
S The function is correct.
S Connectors / fittings are correctly attached.
S The instrument lights operate correctly (on the

instrument panel cover).
9. Examine the alternate static valve. Make sure that: X* X X X
S The valve is correctly attached.
S The valve is not blocked.
S The hoses are correctly attached.
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Rev. 5 05-28-50 22 Dec 2021
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10. Examine the compass. Make sure that: X X X
S The compass is correctly attached.
S The fluid level is correct.
E. Flight Control System in Cabin
Inspection Items, Flight Control System in Cabin 100 200 1000 2000Time Initials
1. Examine the control sticks. Make sure that the control X* X X X

stick attachments are not loose and do not catch.
2. If OÄM 42-283 is installed: X* X X X
Make sure that the connection of the removable control

stick has no play and wear.
Make sure that the safety pin snaps on the rim of the
sleeve nut.
3. Examine the control stick stops. X* X X X
4. Examine the variable elevator stop: X* X X X
S Check actuator for damage and insecure

mounting.
S Check actuator wiring for rub-marks and loose

connectors.
S Check actuator lever for damage and excessive

wear.
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5. Examine the aileron and elevator control system. Look X* X X X

specially for:
S Corrosion and damaged surface protection.
(Refer to Sections 27-10 and 27-30).
6. Examine the centering springs for the aileron control X* X X X

system. Look specially for damage and looseness.
7. 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 adjustment mechanism.
8. 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).
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Rev. 5 05-28-50 22 Dec 2021
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9. Examine the rudder cables and pulleys. Look specially X X X

for:
S Incorrect attachment and function. (Refer to

Section 27-20).
S Defective cable eyes.
S Defective rubber sleeves.
S Corrosion.
S Rub marks.
S Defective safety plates.
S Worn out pulleys.
S Broken strands.
10. Examine the elevator trim control in the center console. X* X X X

Make sure that:
S There is full and free movement.
S There is no unusual play.
11. Examine the rudder trim control in the center console. X* X X X

Make sure that:
S There is full and free movement.
S There is no unusual play.
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12. Examine the rear part of the steering linkage. Look X* X X X

specially for:
S Defective linkage buffer.

devices.
S Defective bonding strap.
13. Examine the push rod guides for the elevator push-rod. X* X X X
Look specially for incorrect attachment and
interference.
14. Examine the flap control mechanism on the rear main X* X X X

spar. Look specially for:

devices.
15. Examine the aileron control system on the rear main X* X X X

spar. Look specially for:

devices.
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Rev. 5 05-28-50 22 Dec 2021
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Maintenance Checks
16. Check the following components of the autopilot X* X X X

system for wear and/or corrosion:
S Servos.
S Servo mounts (capstans).
S Bridle cable assemblies.
F. Other Cockpit Controls
Inspection Items, Other Cockpit Controls 100 200 1000 2000Time Initials
1. Examine the brake hoses and components. Look X X X X

specially for leakage.
2. 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 (1/2 in to

1 in) below the top face of the reservoir filler hole.
3. Examine the power levers: X X X
S Check for damage.
S Verify full travel (0-100%) with AE Software Tool

‘AE 300-Wizard’.
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4. Examine the fuel selector valve controls (FUEL X* X X X

CONTROL):
S Check levers for damage.
S Check safety guards for the OFF position for

damage.
S Move the controls through their operating range.

Check for restricted movement, interference, and
unusual play.
5. Examine the PARKING BRAKE lever in the center X* X X X

console:
S Check for damage.
S Move the lever through its operating range. Check

for restricted movement, interference, unusual
play, and incorrect bounce.
6. Examine the ALTERNATE AIR lever: X* X X X
S Check for damage.
S Move the lever through its operating range. Check

for restricted movement, interference, unusual
play, and incorrect bounce.
7. Examine the CABIN and DEFROST levers: X* X X X
S Check for damage.
S Move the levers through their operating range.

Check for restricted movement, interference,
unusual play, and incorrect bounce.
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Rev. 5 05-28-50 22 Dec 2021
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8. Examine the control cables in the center console: X* X X X
S Examine visually the cables in the center console.

Look specially for wear and kinks in the cables and
for foreign objects.
G. Miscellaneous Items in Cabin
Inspection Items, Cabin, Miscellaneous 100 200 1000 2000Time Initials
1. Examine the interior placards. Make sure that: X* X X X
2. 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.
Do a check of the extinguisher expiry date. (Refer to

Section 26-00).
3. If the sun visors (OÄM 42-101 or OÄM 42-142) are X X X

installed:
S Check for obvious damage.
S Check press-studs for lack of retention force.
4. If the oxygen system is installed (OÄM 42-055), X X X

visually inspect each oxygen outlet port. Check for
dust, damage and corrosion.
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Inspection Items, Cabin, Miscellaneous 100 200 1000 2000Time Initials
5. If the oxygen system is installed (OÄM 42-055), X X X

visually inspect the oxygen pressure gauge in the
cabin. Check for flaws and compare the indicated
pressure with the pressure of the filling unit, installed in
the nose baggage compartment.
6. If the oxygen system is installed (OÄM 42-055), check X X X

the oxygen push-pull knob Bowden-cable assembly.
Check for interference and corrosion.
CAUTION: OIL, GREASE OR OTHER LUBRICATIONS IN CONTACT WITH

OXYGEN CREATE A SERIOUS HAZARD. SUCH CONTACT MUST BE
AVOIDED WHEN HANDLING WITH ANY PART OF THE OXYGEN
SYSTEM.

visually inspect all oxygen tubes installed in the
oxygen- and battery compartment. Check for improper
fixture, chafing, leakage and improper ventilation of the
high pressure tube.
9 If the oxygen system is installed: X X
S Perform a functional check of the oxygen system.
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Rev. 5 05-28-50 22 Dec 2021
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3. Interior of the Rear Fuselage
A. Interior Structure of the Rear Fuselage
Inspection Items, Interior Structure of the Rear 100 200 1000 2000Time Initials
Fuselage
1. Examine the cabin baggage compartment. Look X X X

specially for damage and insecure attachment. Inspect
the following components:
S Baggage compartment structure.
S Baggage restraint net.
S D-rings for the attachment of the baggage restraint

net.
S Door to the baggage extension.
S Lid for the tray on the floor.
2. If OÄM 42-203 is carried out: X
Remove the de-icing fluid tank. Refer to Chapter

30-00.
3. Visually inspect the inner skin of the rear fuselage (aft X

of baggage compartment frame) with mirror and
flashlight. Check for damage, dents, cracks,
delamination and disbonding from the sandwich foam.
4. Visually inspect the interior structure of the rear X

fuselage (aft of baggage compartment frame) through
all access holes with mirror and flashlight. Check for
damage, cracks, delamination and disbonding from the
fuselage skin. Inspect the following components:
S Ring frames 1, 2, and 3.
5. Check structure in the area of the RACC inlets and X X MSI

outlets for cracks, delamination and disbonding (if
OÄM 42-193 is carried out).
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Fuselage
6. Examine the RACC air inlets and outlets X* X X X

(if OÄM 42-193/c or earlier is carried out):
S One air inlet on the bottom.
S Check the air inlet filter for contamination.
S Two air outlets to the LH and RH side of the upper

fuselage.
Examine the RACC air inlets and outlets

(if OÄM 42-193/d or later is carried out):
S One air outlet on the bottom.
S Check the RACC compartment ventilation filter on

the LH side fuselage for contamination.
S One air inlet on the LH side of fuselage.
S Check evaporator drain on the bottom for

blockage.
7. Examine the RACC central unit (if OÄM 42-193 is X* X X X

carried out). Look specially for:
S Insecure attachment of hoses, shrouds and cables.
S Leakage of hoses.
S Cleanness of drain tubes.
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Rev. 5 05-28-50 22 Dec 2021
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Fuselage
8. Examine the RACC central unit (if OÄM 42-193 is X X

S Defective bonding of the side brackets.
S Incorrect attachment of the mounting panel.
S Lack of mechanical stability of the mounting panel.
S Insecure attachment of RACC components to the

mounting panel.
9. Perform a leakage test. (Refer to Chapter 21). 1 yr.
10. If OÄM 42-193/c or earlier is carried out: X* X X X
Check the compartment fan for incorrect operation.
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B. Hydraulic System in the Rear Fuselage
Inspection Items, 100 200 1000 2000Time Initials

Hydraulic System in the Rear Fuselage
1. Check hydraulic module platform for improper or X X X

insecure attachment.
2. Check hydraulic components for damage and leakage. X* X X X
3. Ensure correct level of hydraulic fluid. X* X X X
4. Check condition of reservoir air filter. X X
5. Check accumulator for inner leakage and pre fill X* X X X

pressure.
C. Control System in the Rear Fuselage

Control System in the Rear Fuselage
1. Examine the push rod guides for the elevator push-rod. X* X X X

Look specially for:
S Interference.
2. Examine the elevator push-rod. Look specially for X* X X X

corrosion and damaged surface protection.
3. Examine the rudder-control cables and turnbuckles. X* X X X

Look specially for:
S Corrosion and wear.
S Incorrect lock devices.
4. Do a cable tension test of the rearward rudder control X* X X X

cables. (Refer to Section 27-20).
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Rev. 5 05-28-50 22 Dec 2021
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Maintenance Checks
D. Miscellaneous Items in the Rear Fuselage

Miscellaneous Items in the Rear Fuselage
1. Do an inspection of the ELT system. (Refer to Section X* X X X 1 yr.

25-60).
2. Examine the Garmin G1000 units behind the baggage X* X X X

compartment frame. Look specially for:
S Insecure cable connections.
3. If OÄM 42-191 is installed: X X X
Examine the trim weight installation and retighten the

attachment screws of the trim weight:
S Remove trim weight assembly (Refer to Section

53-10).
S Check the attachment structure in vertical tail for

cracks, damage, and loose or missing anchor nuts.
S Retighten attachment bolts of lead weight.
S Reinstall trim weight assembly to vertical tail

% 4. If MÄM 42-231 is installed: X X X
Examine the trim weight installation. Look specially for

cracks in vertical rib and bonding gap. Check
attachment bolts for corrosion and ensure tight fit.
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Miscellaneous Items in the Rear Fuselage
5. Examine the RACC central unit (if OÄM 42-193 is X* X X X

S Defective bonding of side brackets.
S Incorrect attachment of mounting panel.
S Lack of mechanical stability of mounting panel.
S Insecure attachment of RACC components to

mounting panel.
6. Check the condenser and evaporator for X* X X X

contamination and remove any accumulation of dust
and dirt (if OÄM 42-193 is carried out).
7. If OÄM 42-203 is carried out: X
Install the de-icing fluid tank. (Refer to Chapter 30-00).
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Rev. 5 05-28-50 22 Dec 2021
Time Limits and
Maintenance Checks
4. Center Wing
A. Center Wing, Exterior
Inspection Items, Center Wing, Exterior 100 200 1000 2000Time Initials
1. Remove all access panels in the center wing and the X* X X X
engine nacelles.
2. Examine the complete surface of the center fuselage, X* X X X
center wing, and engine nacelles. Look specially for
damage (dents, cracks, holes and delamination).

3. Do a coin-tap test for delamination of the entire center MSI
wing top and bottom shells. (Refer to Section 51-10).
4. Examine the air inlets for blockage: X X X X
S In the engine nacelles.
S In the RH center wing nose.
5. Visually inspect the wing main bolts. Look specially for X* X X X

play between the bolts and the bushes.
6. De-fuel the airplane. (Refer to Section 12-10). X X
7. Do a function test of the fuel low-level switches: X X
S Set the ELECT. MASTER switch to ON.
S The L/R FUEL LOW caution messages must

appear on the G1000 PFD.
S Set the ELECT. MASTER switch to OFF.
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Inspection Items, Center Wing, Exterior 100 200 1000 2000Time Initials
8. Remove the wings from the center wing. (Refer to X

Section 57-10):
S Examine the main bolts. Look specially for

deformation, cracks, scratches, and corrosion.
S Examine the main bolt bushes in the center wing

spars. Look specially for deformation, cracks, and
scratches and looseness.
S Grease the main bolts.
S Examine the A-bolts. Look specially for

S Grease the A-bolts.
S Examine the B-bolts. Look specially for

S Grease the B-bolts.
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Rev. 5 05-28-50 22 Dec 2021
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Maintenance Checks
B. Center Wing, Interior
Inspection Items, Center Wing, Interior 100 200 1000 2000Time Initials
1. Visually inspect the inner skin of the center wing MSI
through all access holes with mirror and flashlight.
disbonding from the sandwich foam.
2. Visually inspect the interior structure of the center wing X
disbonding from the wing skin.
Inspect the following components:
S Front spar, inner and outer surfaces, specially in

the area of the bushes for the main bolts.
S Rear spar, inner and outer surfaces, specially in

the area of the bushes for the main bolts.
S Firewall (LH and RH).
S Ribs in center wing nose, behind firewall

(2 LH, 2 RH).
S Root ribs (LH and RH; middle and rear).
S Attachment ribs to fuselage (LH and RH; front,

middle and rear).
S Landing gear ribs (LH and RH).
S Rib for landing gear lock struts (LH and RH).
S Rib for wing flap bellcrank (LH and RH).
S Rib connecting rear spar to trailing edge spar

(LH; outboard of rib for flap bellcrank).
S Guiding rib for flap push-rod (RH; inboard of rib for

flap bellcrank).
S Trailing edge spar (LH, RH).
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Inspection Items, Center Wing, Interior 100 200 1000 2000Time Initials
3. Examine the outer surfaces of the front and rear main X X X
spars, specially in the area of the bushes for the main
bolts.
4. Examine the cable ties and electrical connectors. Look X* X X X
specially for rub marks. Pull lightly to make sure they
are not loose.
C. Inner Flaps
Inspection Items, Inner Flaps 100 200 1000 2000Time Initials
1. Examine the inner flaps. Look specially for damage X* X X X

(dents, cracks, holes and delamination).
2. Examine the inner flap hinges and horn. Look specially X* X X X

for too much play. (Refer to Section 27-00.)
Play allowed:
S Axial ± 1.00 mm (± 0.04 in).
S Radial ± 0.25 mm (± 0.01 in).
3. Examine the inner flap control system. Look specially X* X X X

for incorrect attachment and loose or missing lock
devices. (Refer to Sections 27-10 and 27-50).
4. Examine the inner flap push-rods: X
S Remove the inner flap push-rods from the center

wing.
S Check for corrosion and damaged surface

protection.
S Look specially for rub marks.
S Install the inner flap push-rods.
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Rev. 5 05-28-50 22 Dec 2021
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Maintenance Checks
D. Miscellaneous Items in Center Wing & Nacelles
Inspection Items, Center Wing, Miscellaneous 100 200 1000 2000Time Initials
1. Examine all fuel system components firewall aft: X* X X X
S Look specially for signs of leakage and damage,

chafings or material deterioration.
S Make sure they are correctly attached.
2. Examine the fuel cooler: X* X X X

attachment.
5. Tail
A. Tail, General
Inspection Items, Tail, General 100 200 1000 2000Time Initials
1. If MÄM 42-600 is installed: X X X
Examine the rudder gap seal.
2. Remove the fairing for the horizontal stabilizer. (Refer X* X X X

to Section 55-10).
3. Check rudder hinges for excessive play. X* X X X
4. Remove the rudder. (Refer to Section 55-40). X* X X X
5. Remove the elevator push-rod II. (Refer to Section X

27-30).
6. Remove the horizontal stabilizer. (Refer to Section MSI

55-10).
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B. Structure of the Vertical Tail
Inspection Items, Structure of the Vertical Tail 100 200 1000 2000Time Initials
1. Examine the complete surface of the vertical stabilizer. X* X X X

Look specially for damage (dents, cracks, holes and
delamination).
2. Examine the tail fin (lower strake) on the bottom side of X* X X X

the fuselage tube. Look specially for:
S Damage to the bottom of the fin.
S Cracks at the junction to the fuselage.
3. Visually inspect the inner skin of the vertical stabilizer MSI

Check for damage, cracks, and delamination.
4. Visually inspect the interior structure of the vertical X

stabilizer through all access holes with mirror and
flashlight. Check for damage, cracks, delamination and
disbonding from the vertical tail skin. Inspect the
S Front web.
S Rear web.
S Lower rib (front and rear).
S Rib for upper hinge.
S Strake.
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Rev. 5 05-28-50 22 Dec 2021
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Maintenance Checks
C. Structure of the Horizontal Stabilizer
Inspection Items, 100 200 1000 2000 Time Initials

Structure of the Horizontal Stabilizer
1. Examine the complete surface of the horizontal X* X X X

stabilizer. Look specially for damage (dents, cracks,
holes and delamination).
2. Do a coin-tap test for delamination of the entire top MSI

and bottom shell of the horizontal stabilizer. (Refer to
Section 51-10).
3. Examine the mounting brackets for the horizontal X* X X X

stabilizer. Look specially for cracks, deformation, and
corrosion. Check the attachment bolts for corrosion.
4. Examine the horizontal stabilizer tips. Look specially X* X X X

for cracks, dents, and loose or missing attachment
screws.
5. Remove the tips from the horizontal stabilizer. (Refer X

to Section 55-10).
6. Visually inspect the inner skin of the horizontal MSI

flashlight. Look specially for damage, cracks, and
delamination.
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DA 42 NG AMM
Inspection Items, 100 200 1000 2000 Time Initials

Structure of the Horizontal Stabilizer
7. Visually inspect the interior structure of the horizontal X

flashlight. Look specially for damage, cracks,
delamination and disbonding from the horizontal tail
skin. Inspect the following components:
S Front spar.
S Rear spar.
S Trailing edge web.
S Longitudinal ribs (LH and RH; front, middle, rear).
S VT attachment box.
8. Install the tips to the horizontal stabilizer. (Refer to X

Section 55-10).
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Rev. 5 05-28-50 22 Dec 2021
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Maintenance Checks
D. Rudder
Inspection Items, Rudder 100 200 1000 2000Time Initials
1. Examine the rudder skin. Look specially for: X* X X X
S Dents, cracks, holes, dis-bonding, and

delamination.
S Cracks and deformation on the bottom edge.
S Damage to the surface protection system.
2. Examine the lower bracket on the rudder. Look X* X X X

specially for:
S Cracks and deformation.
S Excessive wear on brass bushes.
S Defective stop-screws.
S Defective powder coating.
3. Check the upper hinge pin on the rudder for X* X X X

deformation, cracks, and corrosion.
4. Examine the rudder trim tab. Look specially for: X* X X X
S Damage to the tab structure.
S Incorrect attachment to the rudder.
S Cracks in hinges.
S Wear or excessive play of hinges.
S Poor condition of the hinge wire.
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E. Rudder Hinges and Control System in Vertical Tail
Inspection Items, Rudder Hinges and Control 100 200 1000 2000Time Initials
System in Vertical Tail
1. Examine the rudder control cables. Look specially for: X* X X X
S Broken strands.
S Defective or worn-out cable eyes.
S Corrosion.
S Poor general condition.
2. Examine the support for the lower rudder hinge. Look X* X X X

specially for:
S Cracks and deformation.
S Cracks, deformation or corrosion of stops.
S Defective powder coating.
3. Check the rudder hinges (top and bottom) for X* X X X

corrosion, insecure mounting, and poor general
condition.
4. Examine the rudder trim mechanism. Look specially X* X X X

for:
S Deformation.
S Wear.
S Corrosion.
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Maintenance Checks
Inspection Items, Rudder Hinges and Control 100 200 1000 2000Time Initials
System in Vertical Tail
5. Check the friction of the rudder trim mechanism. Verify X* X X X

smooth running on trim knob and proper function.
S Correct friction force at the rudder trim friction rod:

3 daN - 5 daN (6.7 - 11.2 lbf.).
S If the friction exceeds 5 daN (11.2 lbf.) polish the

tube.
S In case of new springs, cut up to 1.5 winds of the

spring to reach friction value.
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F. Elevator and Elevator Hinges
Inspection Items, Elevator and Elevator Hinges 100 200 1000 2000Time Initials
1. Examine the elevator skin. Look specially for: X* X X X
S Dents, cracks, holes, dis-bonding, and

delamination.
2. Examine the fitting bushes for corrosion and X

looseness.
3. Check elevator horn for damage, deformation and X* X X X

cracks.
4. Check elevator balancing masses for insecure X* X X X

attachment.
5. Examine the elevator hinges. Look specially for: X* X X X
S Damage, cracks, and corrosion.
S Excessive play. Play allowed:
S Axial ± 1.00 mm (± 0.04 in).
S Radial ± 0.25 mm (± 0.01 in).
6. Examine the elevator trim tab. Look specially for: X* X X X
S Damage to the tab structure.
S Damage to the surface protection elevator.
S Incorrect attachment to the elevator.
S Cracks in hinges.
S Wear or excessive play of hinges.
S Poor condition of the hinge wire.
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G. Elevator Control System in Tail
Inspection Items, Elevator Control System in Tail 100 200 1000 2000Time Initials
1. Examine the elevator push-rods: X* X X X
S Check for damage, deformation, cracks, and

corrosion.
S Check for rub marks and defective powder coating.
S Check rod end bearings for looseness and

damage.
S Check for insecure connection to the bellcrank or

elevator horn.
S Check for loose or missing lock devices.
2. Examine the centering springs for the elevator control X* X X X

system. Look specially for damage and looseness.
3. Examine the elevator push-rod which was removed X

from the rear fuselage. Look specially for rub marks.
4. Examine the elevator bellcrank in the vertical tail: X* X X X
S Check for damage, deformation, and cracks.
S Check for insecure mounting.
S Check for loose or missing lock devices.
5. Examine the elevator trim mechanism. Look specially X* X X X

for:
S Deformation.
S Wear.
S Corrosion.
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Inspection Items, Elevator Control System in Tail 100 200 1000 2000Time Initials
6. Adjust the friction of the elevator trim mechanism. X* X X X
H. Miscellaneous Items in Tail
Inspection Items, Miscellaneous Items in Tail 100 200 1000 2000Time Initials
Note: The examination of the VHF antenna is not actually a part of the major structural
inspection (MSI). It is however carried out at the same time because it can only
be done with the horizontal stabilizer removed from the airplane.
1. Examine the VHF antenna. MSI
2. Install the horizontal stabilizer. (Refer to Section MSI

% 55-10).
3. Install the elevator push-rod which goes through the X

rear fuselage. (Refer to Section 27-30).
4. Install the rudder. Lubricate the rudder hinge bushes. X* X X X

Apply grease to the cable eyes. (Refer to Section
55-40).
5. Install the fairing for the horizontal stabilizer. (Refer to X* X X X

Section 55-10).
6. If installed, check porous panels of the ice protection X* X X X

system on the horizontal and vertical tail for damage.
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6. Wings
A. Wings, General
Inspection Items, Wings, General 100 200 1000 2000Time Initials
1. Remove the winglets. (Refer to Section 57-10). X
2. Remove the fuel tanks from the wings. (Refer to X

Chapter 28):
S Remove the main fuel tanks from the wings.
S If installed, remove the auxiliary fuel tanks from the

engine nacelles (OÄM 42-056 carried out).
3. Remove the flap and aileron bell-crank access panels X* X X X

in the wing. (Refer to Section 52-40).
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B. Wings, Structure
Inspection Items, Wings, Structure 100 200 1000 2000Time Initials
1. Examine the complete surface of the wings. Look X* X X X

specially for damage (dents, cracks, holes and
delamination).
2. Examine the winglets. Look specially for cracks, dents, X* X X X

and loose or missing attachment screws.
3. Do a coin-tap test for delamination of the entire top and MSI

bottom wing shell. (Refer to Section 51-10).
4. Visually inspect the inner skin of the LH and RH wing MSI

through all access holes with mirror and flashlight or
endoscope. Check for damage, cracks, delamination
and disbonding from the sandwich foam.
5. Examine the wing spar stubs (inboard of the root rib). X

Look specially for damage, cracks, delamination and
disbonding.
6. Examine the main bolt bushes in the wing spar stubs. X

Look specially for damage, deformation, cracks, and
scratches and looseness.
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Inspection Items, Wings, Structure 100 200 1000 2000Time Initials
7. Visually inspect the interior structure of the LH and RH X

wing through all access holes with mirror and flashlight
or endoscope. Check for damage, cracks,
delamination and disbonding from the wing skin.
Inspect the following components:
S Front spar.
S Rear spar.
S Rear web.
S Root rib (front, middle and rear).
S End rib (on outboard edge).
S 6 fuel tank attachment ribs.
S Rib supporting aileron bellcrank.
S Rib supporting flap bellcrank.
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C. Ailerons and Outer Flaps
Inspection Items, Ailerons and Outer Flaps 100 200 1000 2000Time Initials
1. Examine the ailerons. Look specially for damage X* X X X

2. Examine the outer flaps. Look specially for damage X* X X X

3. Examine the aileron mass balance. Look specially for X* X X X

cracks.
4. Examine the aileron hinges and horn. Look specially X* X X X

for:
S Excessive play.
Play allowed:
S Axial ± 1.00 mm (± 0.04 in).
S Radial ± 0.25 mm (± 0.01 in).
5. Examine the outer flap hinges and horn. Look specially X* X X X

for:
S Excessive play.
Play allowed:
S Axial ± 1.00 mm (± 0.04 in).
S Radial ± 0.25 mm (± 0.01 in).
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Inspection Items, Ailerons and Outer Flaps 100 200 1000 2000Time Initials
6. Examine the aileron and flap control system. Look X* X X X

specially for incorrect attachment and loose or missing
lock devices. (Refer to Sections 27-10 and 27-50).
7. Examine the aileron push-rods: X
S Remove the aileron push-rods from the wings.

protection.
S Install the aileron push-rods.
8. Examine the outer flap push-rods: X
S Remove the outer flap push-rods from the wings.

protection.
S Install the flap push-rods.
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D. Fuel Tanks
Inspection Items, Fuel Tanks 100 200 1000 2000Time Initials
Note: The inspection items shown in this table must also be applied to the auxiliary
fuel tanks.
1. Visually check fuel tank bonding system through X* X X X

access panels for improper connections and damaged
strips.
2. Examine the fuel tank outlets: X
S Clean the finger filters.
S Look for foreign matter.
S Look for defective lock wire.
3. Remove the access covers. X X X
4. Check condition of tank interconnecting hoses. X X X
5. Check for leaks. X X X X
6. Collect a drain sample: X X X X
S If sample is contaminated flush tank with removed

drain valve.
7. 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.
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Inspection Items, Fuel Tanks 100 200 1000 2000Time Initials
8. Install the access covers. X X X
9. 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.
S If MÄM 42-577 is installed: Open fuel filler cap and

carefully blow through the vent all lines from
outside into the tank with compressed air.
10. If the auxiliary fuel tanks are installed (OÄM 42-056): X X X X
Examine the auxiliary fuel tank vents for blockage:
S Open fuel filler cap and blow through the vent line
from outside into the tank with compressed air.
S Check vent hole in the fuel tank cap for blockage.
11. Examine the fuel tanks: X
S Look specially for corrosion, leaks and other

damage.
S Look for foreign objects in the tank.
S Look for material deterioration, chafings or damage

of the flexible fuel hoses connecting the fuel tank
chambers.
(Refer to Section 28-10)
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E. Wings, Miscellaneous
Inspection Items, Wings, Miscellaneous 100 200 1000 2000 Time Initials
1. Examine the Pitot-static probe. Look specially for: X X X X
S Damage.
S Foreign objects.
2. Install the fuel tanks to the wings. (Refer to X

Chapter 28):
S If incorporated (OÄM 42-056), install the auxiliary

fuel tanks into the engine nacelles.
S Install the main fuel tanks into the wings.
3. Install the wings. (Refer to Section 57-10). X
4. Install the winglets. (Refer to Section 57-10). X
5. Examine the stall warning sensor in the LH wing. Do a X X X X

function test of the sensor.
6. Examine the placards on the wings. Make sure that: X* X X X
7. If installed, check porous panels of the ice protection X* X X X

system on the wings for damage.
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7. General
Inspection Items, General 100 200 1000 2000 Time Initials
1. Examine the Pitot-static system. X X
S Clean the Pitot-static system. (Refer to Section

34-10).
2. If necessary, inspect optional equipment. Refer to: X X X X
S Chapter 6 of the Airplane Flight Manual

(Equipment List).
S Chapter 9 of the Airplane Flight Manual

(Supplements).
S Chapter 05-00 of the Airplane Maintenance

Manual (Referenced Maintenance Data).
3. Lubricate the airplane. (Refer to Section 12-20). X X X X
4. Measure the play in the aileron and elevator controls X* X X X

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).

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

operation and installation.
6. Do a function test of the aileron control system. (Refer X

to Section 27-10).
7. Do a function test of the rudder control system. (Refer X

to Section 27-20).
8. Do a function test of the elevator control system. X

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9. Do an operational test of the variable elevator stop. X

10. Do a function test of the rudder trim system. Look X

specially for incorrect operation and indication. (Refer
to Section 27-21)
11. Do a function test of the elevator trim system. Look X

specially for incorrect operation and indication. (Refer
to Section 27-38).
12. Do a function test of the flap system. (Refer to Section X

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 lbf).
13. Do a function test of the landing gear system. (Refer to X* X X X

Chapter 32):
S Verify proper operation of the pressure

accumulator (the hydraulic pump must stop
operating after the pressure has built up).
S Verify proper retraction and extension.
S Verify correct landing gear indication.
S Do a test of the landing gear warning with the flaps

in LDG position, both power levers above 25 %.

in UP position, LH power lever below 25 %, and
RH power lever above 25 %.

in UP position, RH power lever below 25 %, and
LH power lever above 25 %.
S Do a test of the emergency extension. (Refer to

Section 32-30).
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14. Do a test of the steering linkage and nose wheel X* X X X

centering device:
S Move the nose wheel to the left and right.
S Verify proper operation of the steering linkage (to

the rudder control system).
S Verify the nose wheel returns to the neutral

position.
15. Examine the anti-corrosion coating of exterior parts. X X X

Replace coating on condition.
16. Lower the airplane off jacks. (Refer to Section 07-10). X* X X X
17. Do an operational test of the external lights. X* X X X
18. Do an operational test of the Pitot heat. X* X X X
19. LH/RH ECU backup battery fuses (32 A) and wiring X* X X X

check.
20. If installed, do an operational test of the de-icing X* X X X

system. (Refer to Chapter 30).
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21. Examine the airplane. Look specially for foreign X X X X

objects, for example loose items and tools. Install
these items, if previously removed:
S All access panels. (Refer to Section 52-40).
S The cabin baggage compartment (refer to Section

25-50).
S The instrument panel cover (refer to Section

25-10).
S The seat shells. (Refer to Section 25-10).
S The control-stick boots.
S The engine cowlings. (Refer to Section 71-10).
WARNING: DO NOT LET PERSONS INTO THE DANGER AREA OF THE

WARNING: SET THE PARKING BRAKE TO ON. IF YOU DO NOT DO THIS THE
AIRPLANE CAN MOVE. THIS CAN CAUSE INJURY OR DEATH.
22. Put chocks against the main airplane wheels. X X X X
23. Do the post maintenance engine test: X X X X
S For the engine run procedures refer to the Airplane

Flight Manual.
S Record the data. (Refer to Section 05-28-91,

Engine Ground Test Record).
24. Examine the engines for leakage. X X X X
25. Make sure the engine oil filters are tight (LH and RH X X X X
engine). (Refer to Section 79-00).
26. Do a maintenance check flight. Put the engine ground X* X X X

test and the maintenance check flight reports in the
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27. Complete the Maintenance Report and put it in the X X X X

Note: The manufacturer will use the completed Structural Findings Report for the
continuous improvement of the Major Structural Inspection (MSI).
28. Complete the Structural Findings Report. Put one copy MSI
in the Airplane Maintenance Log. Send another copy
to the manufacturer, i.e.,

Office of Airworthiness
N. A. Otto-Str. 5
Austria
by mail, fax (+43-2622-26780) or e-mail

(airworthiness@diamond-air.at).
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Section 05-28-90
Maintenance Report
1. Maintenance Report
Complete a copy of the Maintenance Report after all of the applicable maintenance tasks in the
Maintenance Checklist have been initialed.
DA 42 NG
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
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Section 05-28-91
Engine Ground Test Record
1. Engine Ground Test Record
Do the engine test in accordance with Section 71-00 and record results and comments.
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.

THE PROPELLER CAN CAUSE DEATH OR INJURY TO PERSONS.
TURN THE PROPELLER. MAKE SURE THAT:
- THE ELECT. MASTER SWITCH IS SET TO "OFF".
- THE ENGINE MASTER SWITCH IS SET TO "OFF".
- THE POWER LEVER IS SET TO "IDLE".
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.
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Section 05-28-92
Check Flight Report
1. Check Flight Report
Note: The maintenance check flight must be done in accordance with the applicable
national regulations.
MAINTENANCE CHECK FLIGHT DA 42 NG

AIRCRAFT (See Maintenance Checklist for Applicability) Page 1 of 6
Registration: Pilot: Airdrome:
Date: Take-Off: Landing:
Findings
Functional Check, Flight Behavior
N/A NO YES
ON GROUND, ENGINES OFF
Pre-flight inspection in accordance with AFM.
Front baggage doors: mechanism, key lock, open door warning.
Front canopy: locking mechanism, key lock, general condition / optics,

open door warning.
Rear door: mechanism, key lock, open door warning.
Seat belts (4x): function, locking device, general condition.
Front seats: fixed, general condition.
Rear seats: locking mechanism, general condition.
Baggage compartment: general condition.
First aid kit.
Flight controls: safety lacquer, centering springs.
Trims: correct deflection.
AFM: on board.
Power levers, friction control.
Instrument lighting and flood light.
Map / reading lights.
G1000 manual dim.
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CHECK FLIGHT DA 42 NG
AIRCRAFT
(See Maintenance Checklist for Applicability) Page 2 of 6
Findings
Functional Check, Flight Behavior N/A NO YES
Oxygen system (if installed).
ON GROUND, ENGINES ON
Engine start in accordance with AFM.
Starting behavior.
Warning / caution / advisory alerts.
Engine parameters (indications): engine oil pressure / temperature,

gearbox oil temperature, coolant temperature.
Load / RPM (indications).
Fuel quantity / temperature / fuel flow.
Battery voltage / ammeters.
Alternators.
Altimeters (G1000 and backup).
Airspeed indicators (G1000 and backup).
Vertical speed indicator.
Compass (G1000: slaved directional gyro; magnetic compass).
Turn indicator.
Attitude, bank (G1000 and backup).
OAT (outside air temperature).
G1000 emergency backup (red button).
Flaps: full travel / intermediate position.
Variable elevator stop.
TKS annunciator test.
Gear unsafe warning light.
Fire test.
Fuel cross feed.
Electrical trim.
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AIRCRAFT
Findings
Autopilot (disconnect).
Audio panel / intercom.
COM 1 / COM 2.
ELT.
Moving map: satellite status, GPS position, terrain information.
TAXIING (in accordance with AFM)
Compass (G1000 and magnetic compass).
Turn indicator.
Attitude, bank.
Brakes, pilot & co-pilot side.
Taxiing behavior.
BEFORE TAKE-OFF CHECK (in accordance with AFM)
ECU test: normal behavior and warning sequence.
ECU VOTER test.
Available power check.
Idle RPM.
TAKE-OFF (in accordance with AFM)
Gear retraction: hydraulic pump.
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AIRCRAFT
Findings
CLIMB (in accordance with AFM)
Trim (pitch, direction).
CRUISE (in accordance with AFM)
Control behavior.
Trim (pitch, direction).
Engine parameters (indications): oil pressure / temperature, gearbox

oil temperature, coolant temperature.
Load / RPM (indications).
Fuel quantity / temperature / fuel flow.
Airspeed indicator (G1000 and backup).
Altimeter (G1000 and backup).
Alternate static valve.
Vertical speed indicator.
Compass (G1000: slaved directional gyro; magnetic compass).
Turn indicator.
Attitude, bank (G1000 and backup).
If OÄM 42-224 is NOT installed:

Propeller feathering (engine shut down).

Propeller unfeathering (engine restart): starting behavior.
Emergency gear test.
Stall warning test.
Flight behavior at low airspeeds (according to AFM).
Flight behavior at high airspeeds (according to AFM).
Alternate air test.
OAT (outside air temperature) / TAS / ground speed.
NAV 1 / 2, DME, ILS (LOC, GS, MKR) (if required).
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AIRCRAFT
Findings
ADF (if required).
Transponder.
Moving map / GPS position.
Autopilot:
S Wings level mode.
S HDG mode.
S FD (flight director).
S YD (yaw damper).
S GA (go around mode).
S NAV mode (if required) (on VLOC and GPS).
S ALT / VS preselect and hold.
S FLC mode.
S CWS (control wheel steering) button.
S Disconnect (red button).
Cabin ventilation.
Cabin heating.
Cabin leaks / sounds.
TKS system (if installed).
TAS system (if installed).
Stormscope (if installed).
Aux. fuel transfer indication (if installed).
Aux. fuel empty indication (if installed).
Aux. fuel pump via main tank indication (if installed).
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AIRCRAFT
Findings
DESCENT AND LANDING (in accordance with AFM)
Function of flaps.
Function of landing gear.
Landing behavior.
Braking action.
AFTER LANDING CHECK AND SHUT-DOWN

(in accordance with AFM)
ELT.
Engine shut-down behavior.
Engine starting behavior, warm, LH and RH.
OUTSIDE INSPECTION
Damage.
Engine oil / coolant / fuel / hydraulic leaks.
Findings:
Signature Pilot: ________________________
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Section 05-28-93
Major Structural Inspection Check Findings Report
1. General
Complete the Structural Findings Report after each Major Structural Inspection (MSI). Record the
following:
) Structural defects found during the MSI.
) All structural defects that were detected and repaired since new or since the last MSI.
STRUCTURAL FINDINGS REPORT DA 42 NG

AT MAJOR STRUCTURAL INSPECTION (MSI)
Registration : __________________ Date : _______________
Airplane
Airplane S/N : _________________
Operating Hours : _______________
AMM Rev.
Maintenance used for check : _______________
Organization:
Signature : _______________
no. structural defect/finding repair method, remarks at TSN
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no. structural defect/finding repair method, remarks at TSN
All defects have been repaired. The airplane is airworthy with respect to its maintenance condition.
Place: _____________________________________
Date: _____________________________________
Authorized: _____________________________________
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Section 05-50
Unscheduled Maintenance Checks
1. General
Unscheduled maintenance checks are necessary after any incident that could cause damage to the
airplane.
2. Hard Landing Check
Figure 1 shows the hard landing check areas. You must do a hard landing check when the pilot makes
a report of a hard landing. Or when ground handling applies unusual loads.
A. Equipment
Item Quantity Part No.
Slide sheets. 4 Commercial.
B. Procedure
Detail Steps/Work Items Key Items
(1) Remove the access panels for the main and Refer to Section 52-40.
nose landing gear.
(2) Examine the landing gear fittings. Look specially Use a mirror and a flashlight.
for cracks.
(3) Examine the fuselage and center wing structure Refer to Section 32-10.
where the landing gear attaches. Look specially
for:
S Disbonds.
S Delamination of the CFRP structure.
S Damage to the mounting brackets.
(4) Examine the landing gear struts. Look specially Refer to Section 32-10.
for:
S Bending.
S Cracks.
(5) Do a test of wheel track and camber. Refer to Section 32-10.
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(6) Examine the tires. Look specially for cuts in the Refer to Section 32-40.
side walls.
(7) Examine the brake discs. Look specially for

damage. Turn the wheel and make sure the disc
is not bent.
(8) Remove the load from the nose-gear and

examine it. Look specially for more than the
usual play.
CAUTION: IF YOU THINK THE AIRPLANE HAS DAMAGE TO AN AREA THAT

TRANSMITS A LOAD, YOU MUST ASK THE AIRPLANE
MANUFACTURER FOR ADVICE.
(9) Examine the structure in the bottom of the

fuselage nose for delamination. Look specially in
the area of the bearings for the nose-gear
assembly.
(10) Examine the control surfaces. Look specially for:
S Correct attachment of the hinges.
S Correct attachment of the mass balance to

the structure.
(11) Examine the leading edge of the wing for

damage.
(12) Examine the area of the spar attachments to the

wing shells. Look specially for cracks.
(13) Examine the leading edge of the horizontal and

vertical stabilizers for damage.
(14) Examine the engine mounts.
(15) Examine the engine mount points on the firewall.
(16) Examine the propellers. Look specially to see if a

propeller has touched the ground.
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If the adjustable front seats (OÄM 42-067 or OÄM-42-259) are installed:
CAUTION: DO NOT LOOSEN THE LEVER FOR THE ADJUSTABLE BACKREST

OF THE FRONT SEATS UNINTENTIONALLY. THE SPRING LOADED
(17) If the adjustable front seats (OÄM 42-067 or

OÄM-42-259) are installed:
Do a test of the backrest adjustment mechanism

on both front seats. (Refer to Section 25-10).
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Front Main Bulkhead

Folding Stay Pivot Plate
Folding Stay Rib
Rear Main Bulkhead
Main Landing
Gear Rib
Front Closing Rib
Rear Mounting
Front Mounting
Main Landing Gear Leg
LH Shown,
RH Similar
Figure 1: Hard Landing Check Areas - Main Landing Gear
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Bearings for Nose

Gear Assembly
Bulkhead
Folding Stay Mounting
Nose Gear Assembly
Figure 2: Hard Landing Check Areas - Nose Landing Gear
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Time Limits and
Maintenance Checks
3. Gear Up Landing Check
(1) Perform a hard landing check. Refer to Paragraph 2, Hard Landing

Check.
(2) Examine the nose cone in the propeller area for

external damages.
(3) Examine the fuselage to center wing attachment

screw joint on lower surface.
(4) Examine the foot step attachment structure

inboard and outboard:
S Remove the aft baggage compartment. Refer to Section 52-50.
(5) Examine the fuselage bonded joints: Refer to Section 51-10.
S Between LH and RH fuselage shell for

cracks.
S Between fuselage tube shell and ventral fin.
S On leading edge of the ventral fin.
S Between vertical stabilizer front, rear web,

and fuselage shell.
In case of doubt do a coin tap test.
(6) Examine the antennas for damage.
(7) Examine the engine nacelle structure and

bonding surfaces in- and outboard for cracks
and delamination.
(8) Examine the engine mount for damages.
(9) Examine the engine cowlings and cowling

attachment surface for cracks.
(10) If auxiliary fuel tanks (OÄM 42-056) are installed,

examine auxiliary tank belt holding angle bracket
for cracks.
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22 Dec 2021 05-50-00 Rev. 5
Time Limits and
DA 42 NG AMM
4. Propeller Strike
A propeller strike can be a moving propeller (engine running) which has hit a solid object. Or it can be
a moving object that hits a propeller that is not moving.
A. Propeller Strike with the Engine Running
If the propeller has hit a solid object while the engine was running:
(1) Remove the propeller. Refer to Chapter 61.
(2) Proceed according to Austro Engine

(3) Do an inspection of the engine mount. Refer to Section 71-20.
(4) Do an inspection of the propeller. Refer to the Propeller Owner's Manual.
B. Propeller Hit by a Moving Object
If a propeller which is not moving is hit by a moving object:
(1) Do an inspection of the propeller. Refer to the Propeller Owner's Manual.
If the propeller must be removed to do a repair

other than minor dressing of the blades, you
must do the inspection procedure specified for a
moving propeller strike.
(2) Inspect the airplane for damage.
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Time Limits and
Maintenance Checks
5. Engine Fire
WARNING: BEFORE YOU DO WORK ON THE AIRPLANE MAKE SURE THE FIRE
HAS BEEN EXTINGUISHED. LET THE ENGINE COOL AND
DISCONNECT THE BATTERY.
WARNING: FIRE CAN SERIOUSLY WEAKEN CFRP. IF YOU FIND ANY DAMAGE TO
CFRP, DO NOT OPERATE THE AIRPLANE. ASK THE MANUFACTURER
FOR ADVICE.
(1) Remove the engine cowlings. Refer to Section 71-10.
(2) Disconnect the airplane batteries (main battery Refer to Section 24-31.
and ECU backup batteries).
(3) Examine the engine cowlings. Look specially for

signs of fire damage.
(4) Examine the electrical cables. Look specially for Replace damaged cables.
signs of fire damage.
(5) Examine the fuel lines. Look specially for signs Replace damaged fuel lines.
of fire damage to the fire-protection sleeves.
(6) Examine the engine oil lines. Look specially for Replace damaged oil lines.
signs of fire damage to the fire-protection
sleeves.
(7) Examine the engine. Look specially for: Make a record of the damage you find
and ask the engine manufacturer for
S Damage to the engine air filter.
advice before you repair or operate the
S Damage to gaskets and seals. engine.
S Damage to the engine shock mounts.
S Damage to the engine mount.
S Damage to pipes/hoses.
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Time Limits and
DA 42 NG AMM
(8) Examine the engine nacelles. Look specially for:
S Blisters on the paint or burn marks.
S Disbonding of the nacelle skin from the

firewall.
If you find any damage, ask the airplane

manufacturer for advice.
WARNING: DO NOT GET FIRE EXTINGUISHER PARTICLES ON YOU. THE

CHEMICALS USED TO EXTINGUISH A FIRE CAN BE
CAUSTIC/POISONOUS. WHEN YOU CLEAN THE ENGINE REFER TO
THE FIRE EXTINGUISHER MANUFACTURER'S SAFETY
INSTRUCTIONS. USE SAFETY MASKS AND GLOVES AS
RECOMMENDED.
(9) Clean the engine. Make sure you clean all the Refer to the manufacturer of the fire
fire extinguisher particles from the engine. extinguisher.
(10) Connect the airplane batteries (main battery and Refer to Section 24-31.
ECU backup batteries).
(11) Trouble-shoot the engine. Find the cause of the Ask the engine manufacturer for advice
engine fire. Repair the defect if possible. before you repair or operate the engine.
(12) Install the engine cowlings. Refer to Section 71-10.
(13) Do an engine test. Refer to the AE Maintenance Manual,

latest revision.
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Time Limits and
Maintenance Checks
6. Lightning Strike
A lightning strike usually enters the airplane at one point and leaves the airplane at another point.
These points are called "attachment points". You usually find these points at the extremities of the
airplane. You will often find the most damage to the airplane occurs at the attachment points. There
can be more than two attachment points.
When a lightning strike is reported you must do the inspection procedure at Sub-paragraph D before
the next flight.
A. Group 1 Damage
Group 1 damage is the direct damage caused by the lightning strike. To find this damage you must
carefully examine all the external surface of the airplane. Look specially for burn marks, holes,
discoloration or other physical damage. If you find this damage you must remove panels or
equipment to look for damage on the inside of the airplane. Look specially around the area of the
external damage.
You must also examine the airplane lightning protection system. Look specially for signs of heat
damage or distortion to the conduction tubes and bonding strips. Also look for heat damage in the
structures around the conduction tubes and bonding strips. Refer to Section 51-80 for data about
the lightning protection system.
B. Group 2 Damage
Group 2 damage is the indirect damage caused by the lightning strike. It is mostly caused by the
electromagnetic fields associated with lightning strikes. The electromagnetic fields can induce
temporary voltages into the wiring system. These temporary voltages can cause damage to the
electrical and electronic components of the airplane. Refer to the Wiring Diagrams for data about
the electrical wiring.
Note: If you find any lightning damage you must make a record of the damage and ask
Diamond Aircraft for advice before you repair or operate the airplane.
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Time Limits and
DA 42 NG AMM
C. Equipment
Item Quantity Part No.
Bonding tester. 1 Commercial.
D. Lightning Strike Inspection
(1) Examine the surface of the complete fuselage If you find any damage you must
assembly. Look specially in these areas: examine the airplane internally, specially
in the area of the external damage.
S Propellers and spinners.
Make a record of the damage you find
S Exhaust pipes. and ask Diamond Aircraft for advice
S Engine breather. before you repair or operate the
airplane.
S Canopy handles.
If you find any sign of a lightning strike
S Antennas.
on the propellers, spinners, exhaust
S Static discharge wicks. pipes or engine breather remove the
S Vertical fin tip. engine from the airplane and send it

back to Austro Engine GmbH.
S Rudder. Refer to Section 71-00 for engine
S Lower fin. removal.
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Rev. 5 05-50-00 22 Dec 2021
Time Limits and
Maintenance Checks
(2) Examine the surface of the left wing for lightning If you find any damage you must
damage. Look specially in these areas: examine the airplane internally, specially
S Pitot-static probe.
S Stall warning switch. and ask Diamond Aircraft for advice
S Static discharge wicks. before you repair or operate the
airplane.
S Winglet.
S Wing tip light assembly.
S Wing trailing edge.
S Aileron trailing edge.
S Flap trailing edge.
S Aileron horn.
S Flap horn.
(3) Examine the surface of the right wing for If you find any damage you must
lightning damage. Look specially in these areas: examine the airplane internally, specially
S Winglet.
S Static discharge wicks. and ask Diamond Aircraft for advice
S Wing tip light assembly. before you repair or operate the
airplane.
S Wing trailing edge.
S Aileron trailing edge.
S Flap trailing edge.
S Aileron horn.
S Flap horn.
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Time Limits and
DA 42 NG AMM
(4) Examine the surface of the horizontal stabilizer If you find any damage you must
for lightning damage. Look specially in these examine the airplane internally, specially
areas: in the area of the external damage.
S Horizontal stabilizer tip.
and ask Diamond Aircraft for advice
S Static discharge wicks. before you repair or operate the
S Trailing edge. airplane.
S Elevator trailing edge.
S Trim tab.
(5) Examine the main landing gear. Look specially in Refer to Section 32-10.
these areas:
S Main gear leg attachment points.
(6) Examine the nose landing gear. Look specially in Refer to Section 32-20.
these areas:
S Nose gear attachment points.
(7) Operate the flight controls through their complete Refer Section 27-00.
range of movement. Look specially for:
S Stiff or unusual feel during movement.
S Restriction of movement.
S Noisy operation.
(8) Examine the metal conduction tubes and Make a record of any damage you find
bonding strips in the fuselage and in the wings. and ask Diamond Aircraft for advice
Look specially for: before you repair or operate the
airplane.
S Heat damage or discoloration.
S Fusion of bonding joints.
S Burn or scorch marks to the structure around Refer to Section 51-80.

the conduction tubes.
Use the bonding tester when you are not able to Follow the instructions of the tester
see the whole length of a tube or bonding strip. manufacturer. The resistance must be in
accordance with Section 51-80.
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Maintenance Checks
(9) Do a test of these lighting systems:
S External lights:
Refer to Section 33-40.
S Position lights.
S Strobe lights.
S Landing light.
S Taxi light.
S Ice detection light (if installed).
S Internal lights: Refer to Section 33-10.
S Instrument panel lights.
S Instrument flood lights.
S Map reading lights.
(10) Do a test of the Pitot heat system. Refer to Section 34-10.
(11) Do a test of all functions on the G1000 system.
(12) If OÄM 42-270 is installed:
Do a test of all functions of the Standby Attitude

Module MD302.
(13) Operate the engine power levers through their Refer to Section 76-10.
S Noisy operation.
(14) Do a visual check of engine bondings and

wirings.
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22 Dec 2021 05-50-00 Rev. 5
Time Limits and
DA 42 NG AMM
(15) Operate the cockpit heating controls through Refer to Section 21-40.
their range of movement. Look specially for:
S Noisy operation.
(16) Operate the parking brake control through its Refer to Section 32-40.
S Noisy operation.
(17) Do an engine run-up. Look specially for Refer to Section 71-00.

abnormal operation of the following systems:
S Engine indicating systems. Refer to Section 31-00.
S DC generation. Refer to Section 24-30
(18) Do an ECU test. Refer to Section 76-00.
(19) Do an ECU VOTER test. Refer to Section 76-00.
(20) Visually check engine-sensors, harness and Ask the engine manufacturer for advice.
-systems for damages caused by indirect effects
of lightning.
(21) Do a compass check swing.
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Rev. 5 05-50-00 22 Dec 2021
Time Limits and
Maintenance Checks
7. Over Temperature
(1) Check the fluid level and leakage.
(2) Check data and oil sample and send it to

Austro Engine GmbH.
8. High Oil Consumption
(1) Check engine for oil leakage.
(2) Check the compression.
9. Oil Pressure Loss
(1) Check the oil quantity.
(2) Check the indication.
(3) Check the wiring.
(4) Check if negative g-load flights have been

conducted. (Visual inspection of the breather
outlet for oil contamination).
10. Hang Start
(1) Check voltage.
(2) Check battery condition.
(3) Read out data and send to Austro Engine

GmbH.
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22 Dec 2021 05-50-00 Rev. 5
Time Limits and
DA 42 NG AMM
11. Overweight Landing Check
You must do an overweight landing check when the pilot makes a report of a landing with a mass in
excess of the maximum landing mass (overweight landing). In case the pilot reports a hard and
overweight landing, refer to Paragraph 2, Hard Landing Check.
A. Equipment
None.
B. Procedure
(1) Examine the landing gear fittings. Look specially Use a mirror and a flashlight.
for cracks.
(2) Examine the fuselage and center wing structure Refer to Section 32-10.
where the landing gear attaches. Look specially
for:
S Disbonds.
S Delamination of the CFRP structure.
S Damage to the mounting brackets.
(3) Examine the landing gear struts. Look specially Refer to Section 32-10.
for:
S Bending.
S Cracks.
(4) Examine the tires. Look specially for detoriation Refer to Section 32-40.
on the inner the side walls.
(5) Examine the brake discs. Look specially for

damage. Move the airplane to turn the wheel
and make sure the disc is not bent.
(6) Examine the structure in the bottom of the

fuselage nose for delamination. Look specially in
the area of the bearings for the nose-gear
assembly.
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Time Limits and
Maintenance Checks
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22 Dec 2021 05-50-00 Rev. 5
DA 42 NG AMM Dimensions and Areas
AIRCRAFT
CHAPTER 06
DIMENSIONS AND AREAS
Doc # 7.02.15 Page 1

Dimensions and Areas DA 42 NG AMM
AIRCRAFT
Page 2
22 Dec 2021 06-TITLE Doc # 7.02.15
Rev. 5
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 06
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Adjustment Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Weight and Static Moments of Control Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Doc # 7.02.15 Page 1

AIRCRAFT
Page 2 Doc # 7.02.15

AIRCRAFT
CHAPTER 06
1. General
The DA 42 NG uses the System Internationale (SI) for dimensions and areas. Imperial dimensions are
also given in brackets. For example: Wing span 13.42 m (44.03 ft).
Conversions between SI units and imperial units are given in Chapter 02.
Doc # 7.02.15 Page 1

Rev. 5 06-00-00 22 Dec 2021
AIRCRAFT
3.50 m (11 ft 6 in.)

Ø 1870 mm (6 ft 2 in.)
Ø 1900 mm (6 ft 3 in.)
2.95 m (9 ft 8 in.)
13.42 m (44 ft 0 in.)
13.55 m (44 ft 5 in.)

2.205 m (7 ft 3 in.)
2.49m (8 ft 2 in.)
1.95 m (6 ft 5 in.)
1.735 m (5 ft 8 in.)
Figure 1: DA 42 NG Overall Dimensions (Approximate Values)
Page 2 Doc # 7.02.15

22 Dec 2021 06-00-00 Rev. 5
AIRCRAFT
2. Dimensions
DA 42 NG Dimensions
Overall Dimensions
Wing span 13.42 m (44 ft)
13.55 m (44 ft 5 in) including ACL

Length 8.56 m (28 ft 1 in)
Height (nominal) 2.49 m (8 ft 2 in)
Wing Outer
Airfoil Wortmann FX63-137/20-W4
Wing area (each wing, without winglets, 3.91 m² (42.09 ft²)
flaps and aileron)
Winglets (each) 0.40 m² (4.31 ft²)
Dihedral (nominal) 5.5°
Aspect ratio 11.06
Sweep back 1°
Wing Center Section
Area (total without inner flaps) 6.16 m² (66.31 ft²)
Inner Flaps
Span 2 x 1.42 m (2 x 4 ft 8 in)
Area 2 x 0.43 m² (2 x 4.63 ft²)
Horizontal Tail Surfaces
Span 3.50 m (11 ft 6 in)
Area (with tips, without elevator) 1.79 m² (19.27 ft²)
Angle of incidence -1°
Elevator
Span 2.96 m (9 ft 9 in)
Area (without trim-tab) 0.58 m² (6.24 ft²)
Trim-tab 0.08 m² (0.86 ft²)
Doc # 7.02.15 Page 3

Rev. 5 06-00-00 22 Dec 2021
AIRCRAFT
DA 42 NG Dimensions
Aileron
Span 2 x 1.67 m (2 x 5 ft 6 in)
Area 2 x 0.33 m² (2 x 3.55 ft²)
Outer Flaps
Span 2 x 2.83 m (2 x 9 ft 3 in)
Area 2 x 0.65 m² (2 x 7.00 ft²)
Rudder
Span 1.55 m (5 ft 1 in)
Area 0.79 m² (8.50 ft²)
Rudder Trim-Tab
Span 0.71 m ( 2 ft 4 in)
Span (if MÄM 42-600 is installed) 0.77 m (2 ft 6 in)
Area 0.06 m² (0.65 ft²)
Area (if MÄM 42-600 is installed) 0.087 m² (0.94 ft²)
Landing Gear (typical static, normal load)
Wheel track 2.95 m (9 ft 8 in)
Wheel base 1.735 m (5 ft 8 in)
Main Wheel
Tire: Goodyear 15x6.0-6, 6 PR, TT, 160 mph, FS II

Only if MÄM 42-659 is installed:
15x6.0-6, 6 PR, TT, 160 mph, FS II / FC III
Tire inflation pressure 4.7 bar (68 PSI)
Damper gas pressure (unloaded) 19 bar (276 PSI)
Nose Wheel
Tire: Goodyear 5.00-5, 10 PR, TT, 120 mph, FS II
Tire inflation pressure 6 bar (87 PSI)

6.1 bar (88 PSI)
Damper gas pressure (unloaded) 16 bar (232 PSI)

10 bar (145 PSI)
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22 Dec 2021 06-00-00 Rev. 5
AIRCRAFT
3. Adjustment Reports
The measurements of the DA 42 NG are recorded on an Adjustment Report and the Main Landing
Gear Wheel Track and Camber Report at the factory when the airplane is built. See Figures 2 thru 10.
These reports become part of the airplane records.
When you measure the dimensions, use the Adjustment Report as reference to show any deviations.
4. Weight and Static Moments of Control Surfaces
WARNING: IF YOU REPAINT (OR DO REPAIRS TO) THE CONTROL SURFACES,

YOU MUST MAKE SURE THAT THE WEIGHT AND STATIC MOMENTS
OF THE CONTROL SURFACES ARE IN THE LIMITS GIVEN IN THE
CONTROL SURFACE BALANCE REPORT. THIS WILL PREVENT
CONTROL SURFACE FLUTTER.
To measure the static moments you must remove the control surface from the airplane. Refer to
Section 51-60 for the measuring procedure.
If the values are not within the limits in the Control Surface Balance Report, you must ask the
manufacturer for advice before you adjust the balancing weight.
Doc # 7.02.15 Page 5

Rev. 5 06-00-00 22 Dec 2021
AIRCRAFT
(1) Control Surface Adjustment Reports
Flaps Ailerons
Take-Off Up Neutral
left right left right left right left right left right left right
0 +8/-0 81 +16/-8 (see A) 167 +12/-4 (see B) 87 ±7 (see E) 0 ±3.5
0 +0.32/-0 3.43 ±0.27 (see E) 0 ±0.14
0 +2/-0* 0 ±1
3-10 (6.6-22.0 lbf) 3-5 (6.6-11.0 lbf)
* difference LH/RH < 1°

** difference LH/RH < 2°
E G
A C
R F H
R 233
B D
20
0
Figure 2: Control Surface Adjustment Report - Flaps and Ailerons
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22 Dec 2021 06-00-00 Rev. 5
AIRCRAFT
Elevator Rudder
up down left right
up with variable
elevator stop active
R 49
0
is
e r Ax
A C
d
Rud
B D
R Top View
24
0
F H
R 490
E
G
Figure 3: Control Surfaces Adjustment Report - Elevator and Rudder
Doc # 7.02.15 Page 7

Rev. 5 06-00-00 22 Dec 2021
AIRCRAFT
Elevator Trim
Elevator 10° Up Elevator Neutral Elevator 10° Down
Nose
Linear Measurements
Neutr
Dow
al
Nose
up n
R9
5
Figure 4: Control Surfaces Adjustment Report - Elevator Trim
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22 Dec 2021 06-00-00 Rev. 5
AIRCRAFT
Rudder Trim
Rudder 20° LH Rudder neutral Rudder 20° RH
Travel Limits [mm] 61 ±6 15 ±4 25 ±6 51 ±4 7 ±2 47 ±4 47 ±6 3 ±4 58 ±6
Travel Limits [in.] 2.40 ±0.24 0.59 ±0.16 0.98 ±0.24 2.01 ±0.16 0.28 ±0.08 1.85 ±0.16 1.85 ±0.24 0.12 ±0.16 2.28 ±0.24
Travel Actual
Angle Limits [°]

Angle Actual [°]
LH
Trim
al
utr
Ne
Trim RH
67
Rudder R
RH Trim LH
Trim RH
Rudder
LH
Ne
utra
l
Trim RH
Figure 5: Control Surfaces Adjustment Report - Rudder Trim
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Rev. 5 06-00-00 22 Dec 2021
AIRCRAFT
%
Rudder Trim
%
%
%
%
%
% 40 ±5*
15 ±3* 26 ±5* 48 ±3 6 ±3 36 ±5 3 ±3*
%
%
%
%
%
%
Neutral Trim LH
%
% Trim RH
%
%
R65
% Rudder
% RH Trim LH
%
%
Trim RH
%
Rudder
% LH
Neutral
%
% Trim LH
% Neutral
Trim RH
%
%
%
% * Needs only be checked, if rudder trim system components are replaced.
Figure 6: Control Surfaces Adjustment Report - Rudder Trim (if MÄM 42-600 and MÄM 42-885
are installed)
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22 Dec 2021 06-00-00 Rev. 5
AIRCRAFT
Rudder Trim
40 ±6 1 ±4 42 ±6 50 ±4 4 ±2 45 ±4 54 ±6 8 ±4 31 ±5
35 ±5 1 ±3 36 ±5 43 ±3 3 ±2 39 ±5 47 ±5 7 ±3 27 ±5
Neutral Trim LH
Trim RH
R67
Rudder
RH Trim LH
Trim RH
Linear Measurement
on top of Trim Tab
Rudder
LH
Trim LH
Neutral
Trim RH
Figure 7: Control Surfaces Adjustment Report - Rudder Trim

(if MÄM 42-600 is installed and MÄM 42-885 is NOT installed)
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Rev. 5 06-00-00 22 Dec 2021
Page 12
22 Dec 2021
Horizontal Stabilizer Reference Plane Wing
Angle of Incidence Symmetry Floor LH Sweep Dihedral Angle of Incidence
Dimensions and Areas
Required angle [°] 1.0° ± 0.3° 0° ± 0.5° 0° ± 0.5° left right left right left right left right
Actual angle [°] Required movement [mm] (98 ± 15) (430 ± 20)
Actual movement [mm]
Measurement of dihedral with Datum point for Required angle [°] 1° ± 0.2° 5.5° ± 0.25° 3° ± 0.15°
wings supported (main bolts unloaded) wing dihedral Actual angle [°]
Datum point for Deviation-Max 0.25° 50 [mm]
wing dihedral
Deviation-actual
06-00-00
430 ± 20
5.5° ± 0.25
Datum point for
0
diagonal measurement
45
1° ± 0.3
Baggage-hold floor top-surface LH
R H Dia
nt
AIRCRAFT
go
reme na
l
u me WL 1190
as as
me ure
nal
BL 1968
me
go nt 3° ± 0.15
Dia LH
200 200
Plane of reference
Wing-Angle of setting LH
Datum point for ± 0.5°

98 ± 15
Figure 8: Adjustment Report, General Items (Metric Data)

wing sweep WL 1570
FS 2196
1° ± 0.2 A-Bolt B-Bolt
Datum point for
Plane of reference wing sweep
Wing-Angle of setting RH
DA 42 NG AMM
Rev. 5
Doc # 7.02.15
Rev. 5
Doc # 7.02.15
Wing
DA 42 NG AMM
Horizontal Stabilizer Reference Plane

Angle of Incidence Symmetry Floor LH Sweep Dihedral Angle of Incidence
Required angle [°] 1.0° ± 0.3° 0° ± 0.5° 0° ± 0.5° left right left right left right left right
Actual angle [°] Required movement [in] (3.86 ± 0.59) (16.93 ± 0.79)
Actual movement [in]
Measurement of dihedral with Datum point for Required angle [°] 1° ± 0.2° 5.5° ± 0.25° 3° ± 0.15°
wings supported (main bolts unloaded) wing dihedral Actual angle [°]
Datum point for Deviation-Max 0.25° 1.97 [in]
wing dihedral
Deviation-actual
16.94± 0.79
5.5° ± 0.25
Datum point for
.72
diagonal measurement
17
1° ± 0.3
Baggage-hold floor top-surface LH
H
tR Dia
men go
na
ure lm
as ea WL 46.85
AIRCRAFT
l me su
rem
na
BL 77.48
go en
tL 3° ± 0.15
Dia H
7.87 7.87
Plane of reference
Wing-Angle of setting LH
Datum point for ± 0.5°

3.86 ± 0.59
wing sweep WL 61.81

FS 86.46
1° ± 0.2 A-Bolt B-Bolt
06-00-00
Datum point for
Plane of reference wing sweep
Figure 9: Adjustment Report, General Items (Imperial Dimensions)

Wing-Angle of setting RH
Dimensions and Areas
22 Dec 2021
Page 13
AIRCRAFT
% Main Landing Gear Wheel Track and Camber Report A/C S/N: _____________________
% Date: _____________________
% (for test/adjustment procedure refer to Section 32-10
% Sign: _____________________
Paragraph 11)
% Check procedure Measured data
% (1) Perform check at empty weight (fuel tank empty).

%
%
% Set airplane MLG wheels on relocatable plates (2

% (2) steel plates 250 x 300 x 2 mm; use Aeroshell
% grease between steel plates to reduce friction)
% Use either a track/camber fixture or perform the

% (3)
% check manually
% Measure wheel track Limits
%
% (4) Track LH wheel 0° ± 0.5° δVSL= °
% ---------------------------------------
%
% (5) Track RH wheel 0° ± 0.5° δVSR= °
% ---------------------------------------
%
% Angle between LH and RH wheel δVS= °
% (6) 0° ± 1.0°
% (dvsl + dvsr) ---------------------------------------
%
% Measure wheel camber Limits
%
% max + 1.5°
% (7) Camber LH wheel yL= °
% min - 1.5°
% ---------------------------------------
%
% max + 1.5°
% (8) Camber RH wheel yR= °
% min - 1.5°
% ---------------------------------------
% Measure track width
%
% (9) Overall track width S= mm
% ---------------------------------------
Figure 10: Main Landing Gear Toe-In and Camber Report
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%
Wheel Track: δVS = 0° ± 1°
%
% δVSL = 0° ± 0.5° δVSR = 0° ± 0.5°
%
%
%
%
%
%
%
%
%
%
% Direction of Flight
%
%
%
0°
%
δ < 0° δ > 0° δ > 0° δ < 0°
% (-) (+) (+) (-)
% Wheel Camber: MLG loaded with empty weight.
% (View from the back)
%
%
%
γL = 0° + 1.5° γR = 0° + 1.5°
%
-1.5° 0° -1.5°
%
%
% S = 2894 mm
End of axle End of axle
% S gets measured to the ends of the axles
%
% γ > 0° γ < 0° γ < 0° γ > 0°
% (+) (-) (-) (+)
%
%
%
Figure 11: Main Landing Gear Track and Camber
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Lifting and Shoring
DA 42 NG AMM
AIRCRAFT General
CHAPTER 07
LIFTING AND SHORING - GENERAL
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AIRCRAFT
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AIRCRAFT General
TABLE OF CONTENTS
CHAPTER 07
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 07-10
Jacking
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Lifting the Airplane on Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 07-11
Hoisting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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CHAPTER 07
1. General
The DA 42 NG has no lifting points. You must use straps to lift the airplane. Two persons can lift the
outer wing, or the horizontal stabilizer, or any of the airplane control surfaces.
Section 07-10 tells you how to lift the airplane with jacks.
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Lifting and Shoring
DA 42 NG AMM
AIRCRAFT General
Section 07-10
Jacking
1. General
The DA 42 NG has three jacking points. There are two main jacking points under each stub-wing and
the tie-down hole in the lower fin makes the tail jacking point. For maintenance lift the fuselage with
three hydraulic jacks. Use a trestle with a special former to hold the front of the fuselage. Use standard
trestles under the wings at the position where the winglets connect to the wing.
Refer to Figure 1.
2. Lifting the Airplane on Jacks
A. Equipment
Item Quantity Part Number
Airplane jacks (1000 kg / 2200 lb minimum lifting 3 Commercial.

capacity).
Nose trestle. 1 Commercial.
Wing trestles. 2 Commercial.
Ballast (min. 50 kg / 110 lb). 1 Local Manufacture.
Belt. 1 Commercial.
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Wing Trestle Main Jack Nose Trestle Main Jack Wing Trestle
Tail Jacking Point
Nose Trestle Main Jacking Point Ballast Tail Jack

LH & RH
Figure 1: Lifting the Airplane on Jacks
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DA 42 NG AMM
AIRCRAFT General
B. Lifting the Airplane
Detail Steps/Work Items Key Items/References
CAUTION: IF THE AIRPLANE IS IN THE OPEN THEN ALIGN IT INTO THE WIND.
MAXIMUM WIND SPEED: 10 KM/H (6 KTS).
(1) Put chocks under the main wheels.
(2) Put the 2 jacks into position under the main Refer to Figure 1. The jacking plates
jacking points. Extend the jacks to engage with are bonded to the bottom surface of the
the jacking plates. stub wing, under of the forward main
spar.
(3) Put the jack into position under the tail jacking
point. Extend the jack until to engage with the
lower fin skid plate. Tie down the tail section by
use of a belt connected to the ballast.
(4) Extend all the jacks until the airplane wheels are You must operate all the jacks together
clear of the ground. to keep the airplane level.
(5) If necessary, level the airplane. Refer to Section 08-20.
CAUTION: DO NOT PUT TRESTLES UNDER THE MIDDLE OF THE WING. YOU
MUST ONLY PUT TRESTLES AT THE TIPS OF THE WINGS.
(6) Put the wing trestles in position under each wing, Refer to Figure 1.
at the tip.
(7) Put the nose trestle into position under the front At the front bulkhead.
fuselage.
CAUTION: YOU MUST USE THE NOSE TRESTLE. CG MOVEMENTS, E.G.

RETRACTION/EXTENSION OF THE LANDING GEAR, MAY
OVERBALANCE THE AIRPLANE. THE AIRPLANE CAN TILT
FORWARD.
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C. Lowering the Airplane
WARNING: MAKE SURE THAT THE AREA UNDER THE AIRPLANE IS CLEAR
BEFORE YOU LOWER THE AIRPLANE WITH THE JACKS.
(1) Remove the nose trestle from under the front

fuselage.
(2) Remove the wing trestles from under the wing

tips.
(3) Retract the jacks until the airplane wheels are on Retract the 3 jacks equally to keep the
the ground. airplane level at all times.
(4) Apply the parking brake. Put chocks under the

wheels.
(5) Retract the 3 jacks fully and move the jacks clear
of the airplane.
(6) Remove the belt and the ballast from the

fuselage.
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Lifting and Shoring
DA 42 NG AMM
AIRCRAFT General
Section 07-11
Hoisting
1. General
You do not need any lifting equipment to remove the wings and you do not need any lifting equipment
to remove the horizontal stabilizer.
Use a sling assembly similar to the sling assembly shown in Figure 1. The sling assembly must have
a lifting capacity of 2000 kg (4410 lb). If you remove any equipment (for example, an engine or landing
gear leg), you move the center of gravity of the airplane. If you move the center of gravity of the
airplane then you must change the lifting position of the lifting sling assembly. You can do this by
repositioning the sling straps or by repositioning the shackle on the lifting beam.
WARNING: DO NOT GO UNDER THE AIRPLANE WHEN IT IS HELD BY THE HOIST.

IF THE HOIST FAILS, YOU CAN BE INJURED.
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Sling Assembly
Shackle
Lifting
Beam
Rear Strap
Front Strap
Centre of Gravity
Figure 1: Hoisting the Airplane
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DA 42 NG AMM Leveling and Weighing
AIRCRAFT
CHAPTER 08
LEVELING AND WEIGHING
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TABLE OF CONTENTS
CHAPTER 08
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 08-10
Weighing
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Weighing with Mechanical Scales Under the Wheels . . . . . . . . . . . . . . . . . . . . . . . 4
Section 08-20
Leveling
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Make the Airplane Level with Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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CHAPTER 08
1. General
This Chapter tells you how to weigh the airplane. It also tells you how to level the airplane. Use the
procedures given in Section 08-10 to weigh the airplane and to calculate the airplane moment. Use
the procedures in Section 08-20 to level the airplane.
Note: In this Airplane Maintenance Manual masses are referred to as weights. The
authors accept that this is technically incorrect but have used the expression for
simplicity and convenience.
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Section 08-10
Weighing
1. General
Only operate the airplane within the permitted range of weight and center of gravity limits. This will give
good flight performance and good handling qualities. It is also necessary for safe operation of the
airplane.
If you make any changes to the airplane that may alter the weight (or the center of gravity), then you
must calculate the new weight of the airplane. You must also calculate the center of gravity.
Only an approved person can weigh the airplane. The national Airworthiness Authority of the country
where the airplane is registered gives approval for persons who can weigh the airplane. It also gives
the time limits for when the airplane must be weighted.
Use the Weighing Report when you do the weight and balance calculations (refer to Figure 3).
You can use mechanical scales or electronic weighing units to weigh the airplane. Electronic weighing
units give more accurate and consistent results. They are also easier to use. You must obey the
manufacturer's instructions for using the scales or weighing units.
The reference plane for the DA 42 NG is a transverse, vertical plane in front of the airplane. It is at right
angles to the horizontal reference line. The reference plane lies at 2196 mm (86.46 in) in front of the
stub-wing leading edge at the wing root rib.
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Spirit Level
Horizontal Part of
Baggage Compartment Frame
Figure 1: Level the Airplane Laterally for Weighing
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Reference Plane
Arm - Empty Weight XCG
2196 mm (86.46 in.)
X2
G2
X1LH Main Ramps
X1RH (Height of Main Scale+ Height of Block)
G1
Ramp same Height as Nose Scale Blocks to Level the Airplane
X1 = 2780 mm (109.45 in.)

= 925 mm (36.42 in.)
Legend:
X1 = Arm, Reference Plane to center line of main wheels.
X2 = Arm, Reference Plane to center line of nose wheel.
G1 = G1LH + G1RH = Net weight, main wheel scales LH and RH.
G2 = Net weight, Nose wheel scale.
G = G1LH + G1RH + G2 = Empty Weight.
XCG = Arm - Empty Weight center-of-gravity (calculated).
Figure 2: Weighing Dimensions for Mechanical Scales Under the Wheels
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2. Weighing with Mechanical Scales Under the Wheels
If you use mechanical scales to weigh the airplane, you must also use wooden blocks under the
wheels to level the airplane. You must obey the manufacturers instructions for using the scales.
A. Equipment
Mechanical scales (the scales used for the main 3 Commercial.

wheels must be the same).
Spirit level. 1 Commercial.
Plumb line. 1 Commercial.
Wooden blocks (various thicknesses). A/R Local Manufacture.
Ramps. 3 Local Manufacture.
Optional: airplane jacks 3 Commercial.

(1000 kg / 2200 lb. minimum lifting capacity).
Note: This procedure uses jacks because the main wheel scales need a number of
blocks to bring the airplane level.
Before you weigh the airplane do these items:
) Make sure that the airplane has all its equipment. The equipment must be in the location given
in the Airplane Inventory.
) Defuel the airplane to the unusable fuel level 7.57 liter (2 US gal). Refer to Section 12-10.
) Replenish the engine oils, hydraulic fluid and cooling fluid up to the maximum levels. Refer to
Section 12-10.
) Clean the airplane and dry it. Check that all the water drain holes are unobstructed. Refer to
Section 12-20.
) Remove all objects which are not part of the Airplane Inventory (for example tools, baggage,
etc.).
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B. Weighing Procedure with Mechanical Scales Under the Wheels
Note: Weigh the airplane in a closed room. This will avoid any wind caused weighing
errors.
(1) Make a copy of the Weighing Report form. Figure 3.
(2) Put the weighing scales in position on the floor

in front of each wheel.
(3) Zero the scales. Refer to the scale manufacturer’s

instructions.
(4) Close the canopy.
(5) Lift the airplane on jacks. Refer to Section 07-10.
(6) Put the flat part of the ramps under each wheel.
(7) Lower the airplane onto the ramps with the Refer to Section 07-10.
jacks. Remove the jacks.
(8) Put a wooden block on the scale in front of each The blocks should be of the same
main wheel. thickness. Figure 2.
(9) Push the airplane forward onto the scales. Make sure that the wheels are above
the center of the scales.
(10) Make the airplane level laterally: Refer to Figure 1.
S Put a spirit level on the horizontal surface of Behind the back seats.
the baggage compartment frame.
S If necessary, use additional thin blocks Push the airplane on and off the scales
between the scale and the main wheel on as necessary. Make sure that you do not
the low side to bring the spirit level touch the airplane when you read the
horizontal. spirit level.
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(11) Make the airplane level longitudinally: Refer to Figure 2.
S Place a spirit level on the top surface of the

front baggage compartment floor, left side.
S Put thin blocks between the nose wheel and

the scale to bring the spirit level horizontal.
S Or, if necessary, reduce the air pressure in

the nose wheel tire to bring the spirit level
horizontal.
(12) Remove the levelling equipment from the

airplane.
(13) Put the rear passenger seats in the upright

position.
(14) Close the passenger door.
(15) Read the value from the left main wheel scale.
Enter the value on the weighing form under
MAIN G1LH Gross.
(16) Read the value from the right main wheel scale.
MAIN G1RH Gross.
(17) Read the value from the nose wheel scale.

NOSE G2 Gross.
(18) Use the plumb line to mark the position of the Do this on each side.
reference plane on the floor:
S Hold the plumb line against the leading edge

of the wing where the wing joins the
stub-wing.
S Mark this position on the floor.
S Draw a straight line between the 2 points

you marked on the floor.
S Draw a second line 2196 mm (86.46 in)

forward of the first line.
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(19) Use the plumb line to mark the position of the

nose wheel center line on the floor.
(20) Use the plumb line to mark the position of each

main wheel center line on the floor.
(21) Lift the airplane off the scales with the jacks. Refer to Section 07-10.
(22) Read the weight of the wooden blocks on each

of the scales. Record the values in the column
headed TARE in the Weighing Report.
(23) Remove the scales and the ramps.
(24) Measure the distance X1LH. Record the value in

the Weighing Report.
(25) Measure the distance X1RH. Record the value in

(26) Measure the distance X2. Record the value in

(27) Refer to the calibration records for the weighing

scales. If necessary, correct the Gross and Tare
values of MAIN G1LH, MAIN G1RH, and NOSE G2.
(28) Subtract each Tare value from the related Gross

value. Record the result under Net in the
Weighing Report.
(29) Lower the airplane with the jacks.
(30) Calculate the Empty Weight, G, from the Net G = Net G1LH + Net G1RH + Net G2
values.
(31) Calculate the Empty Weight Moment, M. M = (G1LH * X1LH)+( G1RH * X1RH) +
(G2 * X2)
(32) Calculate the position of the Empty Weight XCG = M/G

Center-of-Gravity, XCG.
(33) Record the Empty Weight (G) and the Empty

Weight Moment (M) in the Airplane Flight
Manual.
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AIRCRAFT
WEIGHING REPORT
Model: DA 42 NG Serial Number:___________ Registration:_____________
Data with reference to the Type Certificate Data Sheet and the Airplane Flight Manual.
Reference Plane: Vertical plane 2196 mm (86.46 in) in front of the leading edge of wing at the root rib.
Horizontal reference line: Front baggage compartment floor, left side.
Equipment Inventory - dated:_______ Cause for Weighing:______________________________
Weight and Balance Calculations (Weighing at the wheels)
Weight Condition: Include brake fluid, hydraulic fluid, coolant, engine oil, unusable fuel main tanks
(7.57 liter/ 2 US gal) and unusable fuel auxiliary tanks (if installed; 5.0 liter/ 1.32 US gal).
Support Gross Tare Net Lever Arm
MAIN G1LH X 1LH = .... mm (..... in.)
MAIN G1RH X 1RH = .... mm (..... in.)
NOSE G2 X2 = ... mm (..... in.)
Empty Weight
Calculate the Empty Weight, G = MAIN G1LH + MAIN G1RH + NOSE G2. G=
Calculate the Empty Weight Moment, M=
M = (G1LH * X1LH)+( G1RH * X1RH) + (G2 * X2).
Calculate the Empty Weight Center-of-Gravity position, XCG = M/G. XCG =
Maximum permitted all-up-weight: VÄM 42-004 1900 kg (4189 lb).

Max. AUW. (OSB 42-068)
Maximum useful load = Max AUW - G.
Record the Empty Weight (G) and the Empty-Weight Moment (M) in the Airplane Flight Manual.
Place/Date Authorizing Stamp Authorizing Signature
Figure 3: Weighing Report for Mechanical Scales Under the Wheels
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Section 08-20
Leveling
1. General
These procedures tell you how to make the airplane level. See Section 07-10 for lifting the airplane
with jacks.
Make the airplane level with jacks unless you are weighing the airplane.
If you have to do an asymmetry test, use the jacks to make the airplane level. If you weigh the airplane,
change the airplane tire pressures or use blocks to make the airplane level (see Section 08-10).
2. Make the Airplane Level with Jacks
A. Equipment
Airplane jacks (1000 kg / 2200 lb minimum lifting 3 Commercial.

capacity).
Wing trestle. 2 Commercial.
Spirit level. 1 Commercial.
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Spirit Level
Horizontal Part of
Figure 1: Level the Airplane Laterally
Spirit Level on
the top surface
of the front baggage
compartment floor,
left side.
Figure 2: Level the Airplane Longitudinally
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AIRCRAFT
B. Level the Airplane with Jacks
Note: Level the airplane in a closed room.
(1) Fasten the ballast with the belt at the airplane. Refer to Figure 2.
(2) Lift the airplane on jacks. Refer to Section 07-10. Pay attention
not to lift the ballast.
(3) Make the airplane level laterally: Refer to Figure 1.
S Put a spirit level on the horizontal surface of Behind the back seats.
the baggage compartment frame.
S Adjust the main jacks to bring the sprit level

horizontal.
(4) Make the airplane level longitudinally: Refer to Figure 2.
S Place a spirit level on the top surface of the

front baggage compartment floor, left side.
S Adjust the tail jack to bring the spirit level

horizontal.
(5) Put trestles under each wing and the front Refer to Section 07-10, Figure 1.
fuselage.
(6) Remove the spirit level from the airplane.
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Towing and Taxiing
DA 42 NG AMM
AIRCRAFT General
CHAPTER 09
TOWING AND TAXIING - GENERAL
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AIRCRAFT General
TABLE OF CONTENTS
CHAPTER 09
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 09-10
Towing
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Towing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 09-20
Taxiing
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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AIRCRAFT General
CHAPTER 09
1. General
You can move the airplane on the ground by hand or by taxiing. Use the procedures in Section 09-10
and Section 09-20 to move the airplane safely. Section 09-10 tells you how to tow the airplane. Section
09-20 tells you how to taxi the airplane.
WARNING: YOU MUST NOT TAXI THE AIRPLANE UNLESS YOU HAVE BEEN
TRAINED TO TAXI AND HAVE BEEN AUTHORIZED BY YOUR
AIRWORTHINESS AUTHORITY.
CAUTION: YOU MUST NOT EXCEED THE WHEEL STEERING ANGLE LIMITS
WHEN TOWING THE AIRPLANE WITH A TOW VEHICLE. EXCEEDING
THE WHEEL STEERING ANGLE LIMITS WILL DAMAGE TO THE NOSE
GEAR LEG AND THE RUDDER CONTROL SYSTEM.
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AIRCRAFT General
Section 09-10
Towing
1. General
You can move the airplane by hand with or without using a steering or tow bar. You can push or pull
the DA 42 NG at the inner section of the propeller blades near the spinners. You can push the
DA 42 NG at the wing nose and at the rough upper surface of the center wing, inboard of the engine
nacelle. Nevertheless the use of a tow bar facilitates towing and is preferable to pulling or pushing.
You can move the airplane using a tow vehicle that is suitable in size and power. You must not exceed
the maximum wheel steering angle and starting and stopping of the movement must always be smooth
and slowly to avoid damaging the nose landing gear. A qualified person must sit in the cockpit for
immediate braking action in the event that the tow vehicle becomes uncoupled.
2. Towing Procedure
WARNING: DO NOT PUSH ON THE SPINNERS. IF YOU PUSH ON A SPINNER YOU

CAN DAMAGE THE SPINNER WHICH CAN CAUSE VIBRATION.
WARNING: DO NOT DAMAGE THE VORTEX GENERATORS WHEN YOU PUSH ON

THE CENTER WING.
CAUTION: NEVER USE FORCE ON THE PROPELLER TIPS OR ON THE

CONTROL SURFACES. YOU CAN DAMAGE THE PROPELLERS AND
THE CONTROL SURFACES.
CAUTION: NEVER APPLY WEIGHTS TO THE TAILPLANE TO LIFT THE NOSE

WHEEL. YOU CAN DAMAGE THE TAILPLANE.
CAUTION: NEVER TOW THE AIRPLANE IF THE WHEELS ARE BLOCKED BY

SNOW OR MUD. YOU CAN DAMAGE THE LANDING GEAR.
CAUTION: THE NOSE MAXIMUM WHEEL STEERING ANGLE IS 40º TO THE LEFT
AND RIGHT. IF YOU TURN THE WHEEL MORE THAN 40º YOU WILL
CAUSE DAMAGE TO THE NOSE GEAR.
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A. Movement by Hand
To move the airplane on ground, it can be pushed or pulled by hand on the inner section of the propeller
blades near the spinner or pushed at the wing nose and at the rough surface of the center wing, inboard
of the nacelles. Do not push on the spinners, as you can damage the spinner which may cause
vibration and damage to the engine. Do not use force on the propeller tips or on the airplane control
surfaces and do not push on the de-icing nozzles (if installed) on the propeller blade root, as you may
damage the propeller, the control surfaces or the de-icing nozzles.
It is recommended to use the steering bar or a tow bar which is available from the manufacturer to
assist steering and towing. The tow bar is engaged in the appropriate hole in the nosewheel as shown
in Figure 1.
Nose Landing Gear Leg
Max. 40°
Max. 40°
Tow Bar
Steering Bar
Figure 1: Steering Bar or Tow Bar Attachment
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B. Movement with a Tow Vehicle
When towing the airplane with a tow vehicle, a qualified person must sit in the cockpit ready for
immediate braking action, in the event that the tow vehicle becomes uncoupled. The movement of the
tow vehicle should always be started and stopped slowly to avoid shock loads on the nose landing gear.
The maximum steering angle of 40 degrees to either side must not be exceeded.
If the airplane must be pulled out of soft ground or deep snow, towing lines must be used. The towing
lines should be attached to the main landing gear struts as high as possible without interfering with the
brake lines. The ropes should be long enough to sufficiently clear the nose or tail. Make sure the wheels
are not blocked by snow or mud. A qualified person must sit in the cockpit to maintain control of the
airplane using the nose wheel steering and brakes.
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Section 09-20
Taxiing
1. General
The DA 42 NG can easily be taxied by using the nose wheel steering. To reduce the turn radius the
wheel brakes furthered by asymmetric power can be used.
WARNING: DO NOT TAXI THE AIRPLANE UNLESS YOU HAVE BEEN TRAINED TO
TAXI AND YOU HAVE BEEN AUTHORIZED.
CAUTION: THIS SECTION GIVES GENERAL DATA ON TAXIING ONLY. YOU MUST
USE THE DA 42 NG AIRPLANE FLIGHT MANUAL WHEN YOU TAXI THE
AIRPLANE.
(1) Make sure that the area around the airplane is For example: Ground equipment and
clear of objects. tools.
(2) Operate the parking brake.
(3) If necessary remove:
S The wheel chocks.
S The tow bar.
S The mooring ropes.
S Any other support equipment attached to

the airplane.
WARNING: MAKE SURE THAT THERE ARE NO PERSONS OR OBJECTS NEAR

THE AIRPLANE. THE AIRPLANE CAN INJURE PERSONS. OBJECTS
CAN CAUSE DAMAGE TO THE AIRPLANE.
(4) Start the engines. Refer to the DA 42 NG Airplane Flight

Manual.
(5) Release the parking brake.
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Rev. 5 09-20-00 22 Dec 2021
Towing and Taxiing
AIRCRAFT
ft)
0
(3
m
10
3
m
(1
0
ft)
3
m
(1
0
ft)
ft)
0
(1
m
3
Figure 1: The Safety Area for Taxiing the DA 42 NG Airplane
Page 2 Doc # 7.02.15

22 Dec 2021 09-20-00 Rev. 5
Towing and Taxiing
DA 42 NG AMM
AIRCRAFT General
WARNING: MAKE SURE THAT THE BRAKES OPERATE CORRECTLY WHEN

YOU TAXI THE AIRPLANE. IF THE BRAKES SHOULD FAIL, YOU
MUST BE ABLE TO STOP THE AIRPLANE BEFORE YOU HIT
PERSONS OR EQUIPMENT.
CAUTION: COMPLY WITH THE SAFETY AREA FOR TAXIING SHOWN IN

FIGURE 1.
CAUTION: TAKE CARE IF YOU TAXI ON UNEVEN GROUND. THE

PROPELLERS MUST NOT TOUCH THE GROUND. LOOSE STONES
AND GRAVEL CAN DAMAGE THE PROPELLERS. USE THE LOWEST
POSSIBLE RPM TO REDUCE THE RISK OF FOREIGN OBJECT
DAMAGE TO THE PROPELLERS.
(6) Taxi the airplane to the new position.
(7) Shut down the engines. Refer to the DA 42 NG Airplane Flight

Manual.
(8) Park the airplane. If necessary, moor the Refer to Chapter 10-00.
airplane.
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AIRCRAFT
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22 Dec 2021 09-20-00 Rev. 5
Parking, Mooring and
DA 42 NG AMM
AIRCRAFT
Storage
CHAPTER 10
PARKING, MOORING, STORAGE

AND RETURN TO SERVICE
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Storage AIRCRAFT
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DA 42 NG AMM
AIRCRAFT
Storage
TABLE OF CONTENTS
CHAPTER 10
PARKING, MOORING, STORAGE AND RETURN TO SERVICE
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 10-10
Parking and Storage
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section 10-20
Mooring
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 10-30
Return to Service
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Return to Service Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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DA 42 NG AMM
Storage AIRCRAFT
Page 2 Doc # 7.02.15

DA 42 NG AMM
AIRCRAFT
Storage
CHAPTER 10
PARKING, MOORING, STORAGE AND RETURN TO SERVICE
1. General
Always park or moor the DA 42 NG when it is not in use. Use the procedures given in Section 10-10
for parking the airplane. Use the procedures given in Section 10-20 to moor the airplane. If the airplane
is parked overnight we recommend that you moor the airplane. If strong winds are forecast, you must
always moor the airplane.
Refer to the AE Operation Manual, latest revision for detailed information about engine standstill and
storage procedures.
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Storage AIRCRAFT
Page 2 Doc # 7.02.15

22 Dec 2021 10-00-00 Rev. 5
DA 42 NG AMM
AIRCRAFT
Storage
Section 10-10
Parking and Storage
1. General
Use these procedures to protect the airplane when it is parked. Use the short term parking procedure
when the airplane will be parked for less than 5 days. Use the long term parking procedure when the
airplane will be parked for 5 to 30 days. Use the storage procedure when the airplane will be parked
for more than 30 days.
All pilots and all maintenance staff for the DA 42 NG must know the procedures in this Section.
CAUTION: MAKE SURE THAT THE AIRPLANE IS CORRECTLY MOORED AND

PROTECTED IF STRONG WINDS ARE FORECAST. STRONG WINDS
CAN CAUSE DAMAGE TO AN UNPROTECTED AIRPLANE.
A. Equipment
Wheel chocks. 4 Commercial.
Gust locks. 1 Commercial.
Pitot cover. 1 -
B. Short-Term Parking
(1) If necessary, taxi or tow the airplane to the Refer to Chapter 09.
parking position.
(2) Align the airplane into the wind (or forecast

wind).
CAUTION: MAKE SURE THAT THE NOSE WHEEL IS ALIGNED STRAIGHT

AHEAD WHEN THE AIRPLANE STOPS. THIS WILL PREVENT SIDE
LOADS WHICH CAN DAMAGE THE NOSE LANDING GEAR.
(3) If the wind is gusty (or the weather is stormy) Refer to Section 10-20.
moor the airplane.
(4) If there is packed snow or ice on the parking

area, spread sand under the wheels.
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Rev. 5 10-10-00 22 Dec 2021
DA 42 NG AMM
Storage AIRCRAFT
CAUTION: DO NOT APPLY THE PARKING BRAKE WHEN THE BRAKES ARE
OVER-HEATED. THE BRAKES CAN SEIZE ON.
(5) Set the parking brake ON. Pull the lever fully
aft, and push both the brake pedals at least two
times.
(6) Put chocks in front of and behind the main

wheels.
(7) RELEASE the parking brake. Lever fully forward.
(8) Set the airplane controls to neutral. Install the

control lock.
(9) Set the flaps to UP position. Fully up.
(10) Make sure that the passenger door and canopy

as well as the front baggage doors are closed
and locked.
CAUTION: DO NOT INSTALL THE PITOT COVER WHILE THE PITOT TUBE IS
HOT.
(11) Install Pitot cover on Pitot tube. Located on the lower surface of the LH
wing.
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DA 42 NG AMM
AIRCRAFT
Storage
C. Long-Term Parking
CAUTION: MAKE SURE THAT YOU DO THE LONG TERM PARKING PROCEDURE
WHEN YOU PARK THE AIRPLANE FOR A LONG TIME. IF YOU DO NOT
DO THE LONG TERM PARKING PROCEDURE CORRECTLY, THE
ENGINE CYLINDERS AND WHEEL BEARINGS CAN CORRODE. ALSO
THE TIRES CAN DEFORM.
(1) Do the procedure for short-term parking. Refer to Paragraph B.
(2) If the ice protection system is installed, then do

the following procedure:
S Fill the de-icing fluid tank to at least one Refer to Section 12-10.
quarter of its capacity.
S Close the canopy.
S Operate the windshield pumps of the ice To deaerate the system.

protection system several times.
S Operate the system on HIGH until evidence

of de-icing fluid on the porous panels is
noticed.
S If the de-icing fluid tank is completely empty, Refer to Section 12-10.

refill the de-icing fluid tank with approx.
2 liter (0.5 US gal) of de-icing fluid.
(3) If the airplane can be moved, remove the You can push or tow the airplane.
chocks, move the airplane to turn the wheels Make sure that a different part of the tire
3 or 4 revolutions. Put the chocks back. touches the ground when you stop.
Note: Do step 3 every day in cold weather and every 7 days in warm weather.
(4) For engine standstill period refer to the

AE Operation Manual, latest revision.
CAUTION: DO NOT INSTALL THE PITOT COVER WHILE THE PITOT TUBE IS
HOT.
(5) Install Pitot cover on Pitot tube. Located on the lower surface of the LH
wing.
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Rev. 5 10-10-00 22 Dec 2021
DA 42 NG AMM
Storage AIRCRAFT
(6) Install the gust lock:
S Move the rudder pedals fully rearward.
S Engage the control surfaces gust lock with

the pedals.
S Engage the stick; wrap straps around stick

once.
S Attach the locks and tighten the straps.
(7) Do a test for water contamination of the fuel. Refer to Section 12-10.
Note: Do step 6 after each rainy day to prevent water contamination due to leaky fuel
tank caps.
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22 Dec 2021 10-10-00 Rev. 5
DA 42 NG AMM
AIRCRAFT
Storage
2. Storage
If the airplane is parked (or not operated) for more than 30 days, you have to do this storage
procedure.
A. Equipment and Material
Tire protector spray. A/R Commercial.
B. Preparation
(1) If possible, ventilate the airplane in a dry

atmosphere.
(2) Do the procedure for the long-term parking. Refer to Paragraph 1.
(3) For engine standstill period and storage refer to

(4) Close all engine openings airproof.
(5) Disconnect the airplane main battery. Refer to Section 24-31.
(6) Completely fill the fuel tanks with fuel. Refer to Section 12-10.
(7) Wipe the tires with a dry cloth. Apply tire Obey the tire protector manufacturers
protector spray. instructions.
(8) Lubricate the airplane. Refer to Section 12-20.
(9) Deactivate the ELT.
(10) Remove loose equipment from the airplane.
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Rev. 5 10-10-00 22 Dec 2021
DA 42 NG AMM
Storage AIRCRAFT
C. Monthly Routine Check
Do these steps each month while the airplane is stored.
(1) Remove all plugs from the engine openings.
(2) Tighten the v-ribbed belt. Refer to AE Maintenance Manual, latest

revision.
(3) Engine ground run:
S Connect the main battery or connect the

airplane to ground power.
S Start up both engines for at least Refer to AFM Chapter 4A.

20 minutes.
S Disconnect the main battery or disconnect

the airplane from ground power.
CAUTION: The engine must not be started after v-ribbed belt tension relieve.
(4) Relieve v-ribbed belt tension. Refer to AE Maintenance Manual, latest

revision.
(5) Close all engine openings air proof.
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AIRCRAFT
Storage
Section 10-20
Mooring
1. General
CAUTION: IF THE AIRPLANE MUST BE STORED OUTSIDE FOR A LONG TIME, IT

HAS TO BE MOORED. STRONG WINDS OR GUSTS CAN CAUSE
DAMAGE TO AN AIRPLANE WHICH IS NOT MOORED.
IT IS RECOMMENDED TO MOOR THE AIRPLANE FOR OVERNIGHT
PARKING TOO. INSTALL THE GUST LOCK TO PREVENT DAMAGE TO
THE CONTROL SURFACES.
2. Mooring
A. Equipment
Rope (nylon preferred or hemp). A/R Commercial.
B. Mooring Procedure
(1) Park the airplane. Refer to Section 10-10.
(2) Make sure that the flaps are set to UP. Fully up.
CAUTION: MOOR THE AIRPLANE AT THE MOORING POINTS ONLY.
CAUTION: WHEN USING HEMP ROPES, DO NOT MAKE THEM TIGHT. IF THE
ROPES GET WET THEY WILL TIGHTEN AND MAY DAMAGE THE
AIRPLANE. THIS IS MOST IMPORTANT WHEN YOU ARE USING
SECURE GROUND ANCHOR POINTS.
(3) Attach a rope to each mooring point and to the

ground anchor point.
Do not make the ropes too tight.
(4) Remove all items from the area that may cause
damage to the airplane.
(5) If snow is forecast you must put a trestle under

the lower fin.
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Rev. 5 10-20-00 22 Dec 2021
DA 42 NG AMM
Storage AIRCRAFT
Wing Tie-Down Point Wing Tie-Down Point
Mooring Ring
Rear Tie-Down Point
Figure 1: Location of Mooring Points on the Airplane
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DA 42 NG AMM
AIRCRAFT
Storage
Section 10-30
Return to Service
1. General
Do this procedure when the airplane has been parked (or stored) for more than 5 days.
2. Return to Service Procedure
A. Storage Time Less Than One Year
(1) If necessary, install loose equipment which was

removed for storage.
(2) If the battery has been removed: Refer to Section 24-31.
S Install the airplane main battery.
(3) Do the test for water contamination of the fuel. Refer to Section 12-10.
(4) Do the test for correct air pressure in each tire. Refer to Section 12-10.
If necessary, inflate the tires.
(5) Check the strut extension of each gear damper. Sliding bare piston should be visible.
If necessary, charge the damper assemblies of Refer to Sections 32-10 and 32-20.
main and nose landing gear.
(6) Check Pitot system and canopy for

contamination/dirt.
(7) Open all engine openings.
(8) Install the v-ribbed belt according to the

AE Maintenance Manual, latest revision.
(9) Change the engine oil to approved engine oil. Refer to Airplane Flight Manual, latest
revision.
(10) Check oil and coolant level. Refer to Section 12-10.
(11) Perform an engine ground run according to the

(12) Reactivate the ELT.
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Rev. 5 10-30-00 22 Dec 2021
DA 42 NG AMM
Storage AIRCRAFT
(13) Remove the gust lock:
S Loosen the straps and detach the locks.
S Disengage the stick from the straps.
S Disengage the pedals from the gust lock.
S Move the rudder pedals into position.
B. Storage Time One Year and More
(1) Contact the engine manufacturer Austro Engine

GmbH.
(2) If necessary, install loose equipment which was

removed for storage.
(3) If the battery has been removed: Refer to Section 24-31.
S Install the airplane main battery.
(4) Remove the gust lock:
S Loosen the straps and detach the locks.
S Disengage the stick from the straps.
S Disengage the pedals from the gust lock.
S Move the rudder pedals into position.
(5) Do a 200 hour maintenance check. Refer to Section 05-10.
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DA 42 NG AMM Placards and Markings
AIRCRAFT
CHAPTER 11
PLACARDS AND MARKINGS
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Placards and Markings DA 42 NG AMM
AIRCRAFT
Page 2
22 Dec 2021 11-TITLE Doc # 7.02.15
Rev. 5
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 11
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Replace Plastic Foil Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 11-20
Exterior Placards and Markings
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Replace the Safety Walk Adhesive Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 11-30
Interior Placards and Markings
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Replace a Placard Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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AIRCRAFT
CHAPTER 11
1. General
Placards are used for identification and indication. They show the function, operation and operating
limitations of systems and equipment.
Note: Placards must not be removed, exchanged or altered unless approved by the
national Airworthiness Authority.
This Chapter shows you the location of these placards and markings:
) Exterior placards.
) Exterior markings.
) Interior placards.
Self-adhesive foil is used for all the placards except for the aircraft identification plate and the
instrument panel labels. The aircraft identification plate is made from metal and the instrument panel
with integrated lighting is made from composite plates.
2. Replace Plastic Foil Placards
A. Material
Solvent. A/R Commercial.
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Rev. 5 11-00-00 22 Dec 2021
AIRCRAFT
B. Replace a Placard
Use this procedure for both internal and external foil placards.
(1) Remove the old placard: Do not over-heat the composite

structure.
S Warm the placard with a hot air blower.
S Lift one corner of the placard.
S Carefully pull the placard off.
WARNING: DO NOT GET SOLVENT ON YOUR SKIN. DO NOT BREATHE

SOLVENT VAPOR. SOLVENT CAN CAUSE DISEASE OR ILLNESS.
(2) Clean the area where the new placard will go. Use a commercial solvent. There must
be no grease or dirt on the surface.
Obey the solvent manufacturer’s
instructions.
(3) Remove the protective backing from the new

placard.
(4) Put the new placard into the correct position. Refer to the related Figure in this
Make the placard smooth with a clean cloth. Chapter.
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22 Dec 2021 11-00-00 Rev. 5
AIRCRAFT
Section 11-20
Exterior Placards and Markings
1. General
Figure 1 shows the exterior placards for the DA 42 NG airplane.
If OÄM 42-187 is installed the safety walk is a coated safety walk instead of safety walk with adhesive
strips. Refer to Section 51-20 for coated safety walk repair procedures.
Figure 1: Exterior Placards
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Rev. 5 11-20-00 22 Dec 2021
AIRCRAFT
LH and RH
LH and RH
Diamond
AIRCRAFT
LH and RH
LH and RH
LH and RH
LH and RH
LH and RH
Figure 2: Design Example for Exterior Markings
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22 Dec 2021 11-20-00 Rev. 5
AIRCRAFT
1. General
This Section tells you how to replace safety walk adhesive strips.
2. Replace the Safety Walk Adhesive Strips
A. Equipment
Safety walk template. 1 D64-1127-10-52.
Roller. 1 Commercial.
Heat gun. 1 Commercial.
B. Material
Socomore Dienstone DLS Satwipes. as required. 29003-C86-C10.
Acetone. as required. N000 148.
C. Replacement Procedure

(1) Remove the safety walk adhesive strips:
S Use a heat gun to warm up the safety Do not exceed 60° C (140°F).
walk adhesive strips.
S Start removing the safety walk adhesive

strips by lifting one corner.
S Carefully pull the safety walk adhesive

strips off.
WARNING: WHEN HANDLING CHEMICALS ALWAYS OBSERVE HEALTH AND

SAFETY REGULATIONS GIVEN BY THE MANUFACTURER OF THE
CHEMICALS.
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AIRCRAFT

(2) Remove the adhesives layer of the safety
walk adhesive strips from surface:
S Use fresh acetone or Socomore®

cleaning cloth (P/N: 29003-C86-C10) to
remove the adhesive layer. Do not use
cleaning or polishing agents which
contain silicon.
(3) Use water to remove dirt from the surface. If Refer to Section 12-30.
necessary, add a mild cleaning agent.
(4) Use a commercial solvent to remove grease

from the surface. The surface must be
totally clean from grease or dirt.
(5) Place the safety walk template on the center Refer to Figure 3.
wing.
(6) Make sure that the template orientation is

parallel to flight direction.
(7) Remove the protective layer from the safety

walk adhesive strips.
(8) Place the safety walk adhesive strips into

the slots of the safety walk template.
(9) Use a roller to flatten and paste on the

safety walk adhesive strips.
(10) Place the ‘No Step’ placard (front) and the Refer to Figure 3.
‘Foot Step’ placard (rear) according to the
safety walk template.
(11) Use a clean cloth to flatten the ‘No Step’

placard and the ‘Foot Step’ placard.
(12) Remove the safety walk template.
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22 Dec 2021 11-20-00 Rev. 5
AIRCRAFT
SAFETY WALK TEMPLATE

D64-1127-10-52
Place nose of Place nose of
Safety Walk Template Safety Walk Template
on fuselage wall on fuselage wall
LEADING EDGE
TRAILING EDGE
No Step
Place triangular
marker to trailing
edge
Foot Step
Figure 3: Safety Walk Template Positioning
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AIRCRAFT
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22 Dec 2021 11-20-00 Rev. 5
AIRCRAFT
Section 11-30
Interior Placards and Markings
1. General
Figures 1 and 2 show the interior placards and markings in the cockpit. Figures 3 and 4 show the
instrument panel placard panels.
2. Description
The DA 42 NG has self adhesive foil placards for the cockpit interior. The instrument panel has placard
panels which are attached to the instrument panel with screws. The placard panels have integral
lighting which is controlled by a combined ON/OFF dimmer switch. The dimmer switch is mounted on
the top left of the instrument panel. Refer to Section 33-10 for more data about the dimmer switch and
refer to Section 31-10 for more data about the inverter for the placard panels.
There are 8 placard panels and you can replace each of the placard panels.
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Rev. 5 11-30-00 22 Dec 2021
AIRCRAFT
(On underside of canopy)

%
% (Inside door behind handle) (If OÄM 42-207 is installed)
COCKPIT BAGGAGE BAGGAGE STANDARD BAGGAGE SHORT BAGGAGE
%
COMPARTMENT EXTENSION COMPARTMENT EXTENSION
MAX. 45 kg [100 lb] MAX. 18 kg [40 lb] MAX 30 kg [66 lb] MAX 15 kg [33 lb]
ARM: 3 89 m [153 1"] ARM: 4.54 m [178.7"] ARM: 3.65 m [143.7 in] ARM: 3.97 m [156.3 in]
If OÄM 42-067 or
% OÄM 42-259 is installed
during
MAX BAGGAGE TOTAL (COCKPIT BAGGAGE
%
TAKE-OFF & LANDING
COMPARTMENT & EXTENSION): 45 kg [100 lb]
SET SEAT BACKRESTS
CAUTION: OBSERVE WEIGHT AND BALANCE LIMITATIONS CAUT ION: OBSERVE WEIGHT AND BALANCE LIMITATIONS
UPRIGHT
SEE AIRPLANE FLIGHT MANUAL CHAPTER 6 SEE AIRPLANE FLIGHT MANUAL CHAPTER 6
parallel to this
position line
%
%
ELT
LOCATED
Hydraulic Fluid
Optional
% TABLET MOUNT:
AeroShell Fluid 41
AMG-10
CAUTION: Mixing of different fluid-types is not permitted!
% - SIZE MAX: 255mm BY 200mm (10.03" BY 7.87")

- WEIGHT MAX: 1,1kg (2.43lb)
Refer to AMM for refilling or fluid change
- INTERCONNECTING ARM LENGTH MAX: 76.2mm (3")
%
%
%
%
%
%
during
TAKE-OFF & LANDING
SET SEAT BACKRESTS
UPRIGHT
parallel to this
position line
If OÄM 42-067 or
% Optional OÄM 42-259 is installed
% PEDAL SLIDE
SWITCH
KEY-HANGER
%
Limitations for GFC 700 Autopilot System:
GROUND USE ONLY
DE-ICING FLUID Autopilot / Yaw Damper DISC during take-off and
landing.
Minimum altitude for autopilot operation:
Max . 3 1.6 l iters (8.3 US g al)
%
Use able 30 liters (7.9 US gal) Do not use AP during single engine operation. Cruise, Climb, Descent and Maneuvering: 800 feet AGL
Refer to AF
M for approved fluids Maximum speed for autopilot operation is 180 KIAS. Approach: 200 feet AGL
Minimum speed for autopilot operation is 90 KIAS. Departure: 200 feet AGL
If MÄM 42-1134 is installed

% PAINTING SCHEME
%
STD. PAINT SCHEME (See D64-5 111-0 1-00 )
UPPER:
LOWER:
NOSE:
% CUSTOMISED PARTS:
% Alternate Static
OPEN
% Or
CLOSED
If Alternate Static is open
Emergency Window and
Cockpit Vent must be closed
PAINTING SCHEME
% PAINT SCHEME MAIN COLORS

UPPER:
LOWER:
%
NOSE:
This airplane may only be operated in accordance with the Airplane
Flight Manual in the "Normal" category. Provided that national
CUSTOMISED PARTS / ADDITIONAL COLORS: operational requirements are met and the appropriate equipment is
installed and operational, this airplane is approved for the following
% Max Baggage:
kinds of operation: day VFR, night VFR, IFR and flight into known or
forecast icing conditions. All aerobatics manouvers including spinning
are prohibited. For further operational limitations refer to the Airplane
NOTE: ALL COLORS IN ACCORDANCE WITH AMM SECT. 51-20
30 kg [66 lb] Flight Manual.
%
Operating manouvering speed:
V o=122 KIAS (above 1800 kg / 3968 lb)
V o=119 KIAS (above 1700 kg / 3748 lb to 1800 kg / 3968 lb)
V o=112 KIAS (above 1700 kg / 3748 lb)
LH & RH
%
No engine start
%
No take-off below Diesel Fuel Class
below
OXYGEN -5°C (+23°F) +5°C (+41°F)
Diesel Fuel of unknown class or
DO NOT SMOKE! unknown fuel blend
% DO NOT TRANSPORT F LAMMABLE F LUIDS, OILS AND
GREASES IN T HE NOSE BAGGAGE COMPARTMENT! -10°C (+14°F) -5°C (+23°F) Diesel Fuel Class C
-15°C (+5°F) -10°C (+14°F) Diesel Fuel Class D, E or F

% Optional
If OÄM 42-251 is installed
%
Figure 1: Interior Placards and Markings
Page 2 Doc # 7.02.15

22 Dec 2021 11-30-00 Rev. 5
AIRCRAFT
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
Figure 2: Interior Placards - Instrument and Control Panels
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NO SMOKING LH MAIN BUS

COM1 GPS/NAV1 XPDR ENG INST
DE IC E
XFER PUMP
PITOT DE-ICE
TAXI/MAP FLOOD
ACL OXY
GEAR WRN
PFD ADC AHRS ELEV LIMIT GEAR
RH MAIN BUS
LH ENGINE RH ENGINE
VOTER ECU VOTER
A ECU A TEST AUTO A
U U
T T AVIONICS BUS
O O
ECU B ECU B
ALTERNATOR
ON
LH RH
OFF
LH ENG ECU BUS LH RH RH ENG ECU BUS
LH ECU BUS RH ECU BUS
If MÄM 42-403 is installed
AVIONICS BUS
If OÄM 42-119 or
OÄM 42-213 is installed
Figure 3: Placard Panels - Sheet 1
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If OÄM 42-270 is installed
Figure 4: Placard Panels - Sheet 2
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The placards shown in Figures 5 thru 8 are installed only if the optional oxygen system is installed
(OÄM 42-055 is incorporated):
Figure 5: Placard on the Refill Unit, on the LH Side of the Nose Baggage Compartment
Figure 6: Placard on Each Outlet Manifold Figure 7: Placard on the PUSH/PULL Knob
Figure 8: Placard on the LH/RH Oxygen Compartment Cover
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If OÄM 42-193 is carried out the following placard is mounted next to the compressor:
NOTE
Contains fluorinated greenhouse gas

covered by the Kyoto Protocol.
1,1,1,2 - Tetrafluoroethane
Figure 9: RACC Compressor Placard
All maintenance and replenishment which requires to open and depressurize the refrigerant circuit
must be carried out by authorized personnel according to national and international regulations for
refrigerant systems.
If OÄM 42-193 is carried out the following placard is mounted next to the switch for the map reading
light:
Figure 10: Map Reading Light Placard
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1. General
This Section tells you how to replace a placard panel. You cannot repair a placard panel.
2. Replace a Placard Panel
Use this procedure for all of the placard panels.
(1) Disconnect the airplane main battery and ECU Refer to Section 24-31.
backup batteries.
(2) Remove the instrument panel cover. Refer to Section 25-10.
(3) Disconnect the electrical cables form the If necessary, at the inline connector.
placard panel that you will replace.
(4) Replace the placard panel:
S Remove the screws that attach the placard Make sure that you remove all of the
panel to the instrument panel. screws!
S Move the placard panel clear of the

instrument panel.
S Move the new placard panel into position on Make sure that you route the electrical
the instrument panel. cables correctly.
S Install the screws that attach the placard

panel to the instrument panel.
S Connect the electrical cables for the placard At the inline connector.
panel.
(5) Install the instrument panel cover. Refer to Section 25-10.
(6) Connect the airplane main battery and the ECU Refer to Section 24-31.
backup batteries.
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(7) Do a test for the correct operation of the placard

panel lights:
S Set the ELECT. MASTER to ON.
S Rotate the INSTRUMENT dimmer switch The placard lights must come on.
fully clockwise.
S Rotate the INSTRUMENT dimmer switch a The placard lights must dim.
small amount counter-clockwise.
S Rotate the INSTRUMENT dimmer switch The placard lights must go out.
fully counter-clockwise.
S Set the ELECT. MASTER to OFF.
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DA 42 NG AMM Servicing - General
AIRCRAFT
CHAPTER 12
SERVICING - GENERAL
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Servicing - General DA 42 NG AMM
AIRCRAFT
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TABLE OF CONTENTS
CHAPTER 12
SERVICING
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 12-10
Replenishment
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Refueling/Defueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Fuel Contamination Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Engine Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6. Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7. Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8. Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9. Ice Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
10. Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
11. Oxygen System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Section 12-20
Scheduled Servicing
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Section 12-30
Unscheduled Servicing
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Exterior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Canopy and Transparency Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Interior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5. Engine Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6. Snow and Ice Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7. Conservation of Exterior Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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CHAPTER 12
SERVICING
1. General
This Chapter gives the servicing tasks which apply to the whole airplane:
) Section 12-10. Replenishment procedures for various systems.
) Section 12-20. Lubrication data.
) Section 12-30. Cleaning and snow and ice removal.
The procedures for preventive and corrective maintenance of systems are given in the related Chapter
of this manual. Refer to Chapter 05 for the time limits and servicing schedules.
Note: The designation of "left" and "right" as well as of "forward" and "afterwards" is
based on the airplane's direction of flight.
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Section 12-10
Replenishment
1. General
Use the procedures in this Section to replenish the fluid systems of the airplane.
Figure 1 shows the location of the servicing points.
2. Fuel System
A. Main Fuel Tanks
There are three interconnected fuel tanks in each wing holding the fuel for the DA 42 NG. The fuel
capacity is 26 US gal (98.4 liter) per wing. The tanks are located in the wing outboard of the engine
nacelles, between the main spars.
Each wing has a filler cap located on the top surface of the wing. The filler cap connects to the
outboard end of the outer fuel tanks. A fuel tank drain is located on the lower surface of each wing.
The drain connects to the inboard end of the inner fuel tank.
B. Auxiliary Fuel Tanks (Optional Equipment)
The auxiliary fuel tanks consist of a single fuel chamber in each engine nacelle. The auxiliary fuel
tanks are installed in the rear section of the engine nacelles, above the wing main spars. The
additional fuel capacity is 13.7 US gal (52 liter) per side. The total fuel capacity (main fuel tanks and
auxiliary fuel tanks) is 39.7 US gal (150 liter) per side.
Each auxiliary tank has a filler cap located on the top surface of the nacelle. The filler cap connects
to the forward end of the auxiliary tanks. A fuel tank drain is located at the rear of each auxiliary
tank.
WARNING: DO NOT ALLOW FIRE, SPARKS OR HEAT NEAR FUEL. FUEL BURNS
VIOLENTLY AND CAN CAUSE INJURY TO PERSONS AND DAMAGE
TO THE AIRPLANE.
WARNING: DO NOT GET FUEL ON YOUR SKIN. FUEL CAN CAUSE SKIN DISEASE.
WARNING: CONNECT THE AIRPLANE AND THE FUEL SUPPLY VEHICLE TO

ELECTRICAL GROUND BEFORE REFUELING. IF YOU DO NOT
GROUND THE AIRPLANE, STATIC ELECTRICITY CAN CAUSE FIRE
DURING REFUELING.
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WARNING: MAKE SURE THAT A SUITABLE FIRE EXTINGUISHER IS AVAILABLE

AT ALL TIMES DURING REFUELING/DEFUELING.
WARNING: TURN OFF ALL GROUND EQUIPMENT IN THE REFUELING AREA.
WARNING: DO NOT OPERATE ELECTRICAL SWITCHES IN THE AIRPLANE

DURING REFUELING.
WARNING: REFUELING WITH PERSONS ON BOARD IS PROHIBITED.
CAUTION: USE ONLY THE FUEL TYPES GIVEN IN CHAPTER 2 OF THE

AIRPLANE FLIGHT MANUAL.
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Fuel
Hydraulic Fluid
Fuel Brake Fluid
(on Co-Pilot's
Brake Pedals)
Fuel
Fuel
Nitrogen & Oil

Tire Air
Tire Air (LH & RH)
Nitrogen & Oil
(LH & RH)
Coolant
Gear Oil
Engine Oil
Figure 1: Replenishment Points
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3. Refueling/Defueling
A. Refueling
(1) Shut down the engines.
(2) ENGINE MASTER OFF.
(3) All occupants leave the airplane.
(4) Ground the airplane electrically. At the refueling connection.
(5) Ground the refueling vehicle electrically.
(6) Remove the fuel filler cap.
(7) Refuel the airplane.
(8) Install the fuel filler cap. Make sure that the filler cap is locked.
(9) Do steps 4 thru 6 for the other wing.
(10) Do steps 6 thru 8 for the auxiliary tanks, if Filler caps are located on the outboard
installed (OÄM 42-056). side of the engine nacelles.
(11) Remove the ground cable from the airplane.
(12) Remove the ground cable from the refueling

vehicle.
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B. Defueling
Detail Items/Work Steps Key Items/References
(1) Ground the airplane electrically. At the refueling connection.
(2) Put a suitable container below the drain valve Make sure that you have enough
for the wing that you will defuel. containers to hold all the fuel. Each wing
can hold approximately 26 US gal
(100 liter) fuel.
(3) Open the drain valve.
(4) When the fuel stops draining, close the drain Make sure that the drain valve is seated
valve. correctly.
(5) Do steps 2 thru 4 for the auxiliary fuel tank, if Each auxiliary tank can hold
installed (OÄM 42-056). approximately 13.7 US gal (52 liter) fuel.
(6) If necessary, do steps 2 thru 4 for the other

wing.
(7) Remove the ground cable from the airplane. At the refueling ground connection.
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4. Fuel Contamination Test
A. Equipment
Glass container. 1 Commercial.
B. Fuel Contamination Test Procedure
(1) Put the glass container under the fuel tank drain
valve that you will take the fuel from.
(2) Open the drain valve.
(3) When the fuel container is half full, close the Make sure that the drain valve is seated
drain valve. correctly.
(4) Let the fuel in the glass container stand for

1 minute.
(5) Examine the fuel: If you find any contamination you must
do the test again. If you still find
S It must be clear (JET A1).
contamination after 3 tests, you must
S Look specifically for small drops of water in drain the related fuel tank. Flush the
the bottom of the glass container. tank (use fuel) and fill it with clean fuel.
S Look for small particles of solid material.
(6) Perform steps 1 thru 5 for the other wing.
(7) Drain the nacelle tanks.
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5. Engine Oil System
WARNING: ENGINE OPERATION WITH NO OIL (OR VERY LOW OIL LEVEL) WILL
CAUSE ENGINE MALFUNCTION OR DAMAGE.
The engines installed in the DA 42 NG have a wet sump oil system. The engine oil sump can hold
7 liter (7.4 US qt). You must only use engine oil specified by the engine manufacturer.
The oil filler is located on the left side of the engine (Figure 2). There is an access hole implemented
in the top LH engine cowling. The oil filler has a dip-stick attached.
A marginal oil consumption is normal. Measure the oil quantity before each flight (or engine ground
run-up). If necessary, replenish the oil system.
A. Replenish the Oil System
Detail Steps / Work Items Key Items / References
(1) Open the access panel located at the upper left

cowling.
CAUTION: USE ONLY THE CORRECT ENGINE OILS. REFER TO THE AE

MAINTENANCE MANUAL, LATEST REVISION FOR THE CORRECT
OIL SPECIFICATIONS AND CHAPTER 2 OF THE AFM. IF YOU DO
NOT USE THE CORRECT ENGINE OIL, THE ENGINE CAN BE
DAMAGED.
For oil system replenishment procedures refer to AE Maintenance Manual, latest revision.
(2) Close the access panel located at the upper left

cowling.
B. Change the Engine Oil
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Figure 2 : Engine Oil Filler/Dip-Stick
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6. Gearbox Oil
WARNING: ENGINE OPERATION WITH NO GEARBOX OIL (OR VERY LOW OIL
LEVEL) WILL CAUSE ENGINE MALFUNCTION OR FAILURE.
Refer to the AE Maintenance Manual, latest revision for proper gearbox oil level.
A. Replenish the Gearbox Oil System
CAUTION: IF THE GEARBOX OIL LEVEL IS LOW THE REASON MUST BE

DETERMINED AND THE PROBLEM MUST BE CORRECTED BY
AUTHORIZED PERSONNEL.
(1) Remove the engine top cowling.
For gearbox oil system replenishment procedures refer to AE Maintenance Manual, latest revision.
(2) Install the top engine cowlings.
B. Change the Gearbox Oil
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To Thermostat Filler Cap
Expansion Tank
Coolant Bypass Hose
Pressure
Regulating
Valve
Figure 3: Engine Coolant Expansion Tank / Filler Cap
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To Thermostat Filler Cap
Silicate Pouch
Cartridge
Max. Coolant Level Marking Plate
Expansion Tank
Coolant Bypass Hose
Pressure
Relief Valve
Coolant Level
Sensor
Figure 4: Engine Coolant Expansion Tank / Filler Cap (if MÄM 42-852 is installed)
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7. Engine Coolant
WARNING: DO NOT REMOVE THE EXPANSION TANK FILLER CAP WHEN THE
ENGINE IS HOT. THE TANK IS PRESSURIZED WITH HOT COOLANT.
HOT COOLANT CAN CAUSE INJURY TO PERSONS.
WARNING: DURING NORMAL OPERATION THE AE E4 ENGINE SHOULD NOT

CONSUME COOLANT. ANY COOLANT LOSS MUST BE INVESTIGATED
BEFORE FURTHER OPERATION OF THE ENGINE. OPERATING THE
ENGINE WITH A FAULTY COOLING SYSTEM CAN DAMAGE THE
ENGINE
The DA 42 NG engines use liquid coolant to cool the engine and supply heating to the flight cabin. The
coolant is circulated around the engine in an integral water jacket. When the coolant is at normal
engine operating temperature a thermostatic valve directs the coolant to flow through a heat
exchanger. The thermostatic valve controls the flow of coolant through the heat exchanger in order to
control the temperature of the coolant.
A coolant expansion tank is located on the left side of the engine (Figure 3 and 4). The expansion tank
has a filler cap, a pressure relief valve, a silicate pouch and a coolant level sensor. Use the procedures
in this Paragraph to replenish the coolant system when the system has been drained for maintenance
or system repair.
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A. Replenish the Engine Coolant
(1) Remove the top engine cowling.
WARNING: DO NOT REMOVE THE EXPANSION TANK FILLER CAP WHEN THE
ENGINE IS HOT. THE TANK IS PRESSURIZED WITH HOT COOLANT.
HOT COOLANT CAN CAUSE INJURY TO PERSONS.
(2) Carefully remove the filler cap from the coolant

expansion tank.
CAUTION: USE ONLY THE CORRECT COOLANT. REFER TO CHAPTER 2 OF
THE AIRPLANE FLIGHT MANUAL FOR THE CORRECT COOLANT
SPECIFICATIONS. IF YOU DO NOT USE THE CORRECT COOLANT,
THE ENGINE CAN BE DAMAGED.
(3) If MÄM 42-852 is NOT installed:
Add coolant until the fluid level is at the bottom

of the tank filler tab.
Add coolant until the fluid level is at the “max.

coolant level marking” in the filler neck.
(4) Install the filler cap.
S Install the filler cap. Torque refer to Section 20-70.
Check O-ring for deformation, apply

EZ TURN.
S Install safety lock wire to secure filler cap. Wire diameter 0.8 mm (0.032 in).
(5) Install the engine cowlings.
Note: When the coolant system has been drained for maintenance/repair air may get
trapped in the system. The following steps are to remove any air trapped in the
system and give a correct fluid level in the expansion tank.
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(6) Do an engine ground run until the engine Refer to Section 71-00.
reaches normal operating temperature. Then
shut-down the engine.
(7) Repeat steps 1 thru 6 until the coolant level

remains constant at the correct level.
B. Fill and Bleed an Engine Cooling System
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8. Brake System
The brake fluid reservoirs are located on the brake master cylinders on the co-pilot's side. You get
access in the cockpit below the instrument panel.
WARNING: DO NOT GET BRAKE FLUID ON YOUR SKIN OR IN YOUR MOUTH.

BRAKE FLUID IS TOXIC AND CAN CAUSE INTERNAL INJURY.
CAUTION: REMOVED SPILLED BRAKE FLUID IMMEDIATELY. BRAKE FLUID CAN

CAUSE DAMAGE TO PAINT AND OTHER MATERIALS.
A. Fill the Brake System Reservoirs
(1) Clean the top of the brake fluid reservoir and

filler cap.
(2) Remove the filler cap.
(3) Fill the reservoir to the correct level. Use only MIL-PRF-5606H hydraulic
fluid.
12 to 25 mm (0.5 to 1 in) below the top

of the filler hole.
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9. Ice Protection System
% The ice protection system is optional equipment (OÄM 42-053 carried out). The deicing fluid tank is
installed in the nose compartment of the airplane, on the RH side. It has a capacity of 30 liter
(7.9 US gal).
The filler is located in the fuselage nose on the right side and is accessible via the nose baggage
compartment.
A. Fill the Deicing Fluid Tank
(1) Open the right nose baggage compartment.
(2) Clean the filler cap.
(3) Remove the filler cap.
(4) Fill the de-icing fluid tank. Refer to the AFM for approved deicing
fluids.
(6) Close the right nose baggage compartment.
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10. Tires
The DA 42 NG uses these tires:
Main tires: 15x6.0-6; 6 PR, TT, 160 mph, Flight Special II, Goodyear
Only if MÄM 42-659 is installed:
15x6.0-6; 6 PR, TT, 160 mph, Flight Special II / Flight Custom III, Goodyear
Nose tire: 5.00-5; 10 PR, TT, 120 mph, Flight Special II, Goodyear
A. Examine the Tires and Measure the Pressure
(1) Examine the tires. Look specially for: Move the airplane as necessary so that
each part of each tire can be seen.
S Cuts and friction damage.
S Correct alignment of the slippage markers. If the slippage markers do not align,
remove the wheel for shop
maintenance.
(2) Measure the tire pressure. If necessary, inflate Main tire: 4.7 bar (68 PSI).
the tires to the correct pressure.
Nose tire: 6.0 bar (87 PSI).
6.1 bar (88 PSI).
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11. Oxygen System
The continuous flow oxygen system is optional equipment (OÄM 42-055 incorporated). The oxygen
cylinder is installed in its own vented compartment in the nose baggage compartment. Its capacity is
10.7 liter (650 cu.in.) at 128 bar (1850 PSI). The filling unit is also installed in the oxygen compartment
accessible via a cover on the LH side of the nose baggage compartment.
WARNING: OXYGEN STRONGLY SUPPORTS - RISK FOR FIRE AND EXPLOSION.

SMOKING STRICTLY PROHIBITED. AVOID FLAMES, SPARKS AND
OTHER SOURCES OF IGNITION. AVOID CONTACT WITH FLAMMABLE
MATERIALS (E.G., OIL OR GREASE). SERIOUS PERSONAL INJURY
AND/OR DAMAGE TO EQUIPMENT MAY RESULT.
CAUTION: OIL, GREASE OR OTHER LUBRICATIONS IN CONTACT WITH

OXYGEN CREATE A SERIOUS HAZARD. SUCH CONTACT MUST BE
AVOIDED WHEN HANDLING WITH ANY PART OF THE OXYGEN
SYSTEM.
A. Filling the Oxygen Cylinder
(1) Open both nose baggage compartment doors.
(2) Remove all loose items from the baggage

compartment.
(3) Check baggage compartment for oil or oil

residue.
(4) Check deicing fluid tank: must be closed and

clean.
(5) Open the cover of the oxygen filling unit on the

LH side of the oxygen compartment.
(6) Check pressure gauges by comparing the

pressure indication of the filling block with the
pressure indication of the gauge installed on the
RH side of the instrument panel.
(7) Remove the filling port protection nut and check

the filling valve for dust.
(8) Connect the oxygen filling station outlet port to Do not use oxygen with a lower purity
the filling valve. grade than prescribed by
MIL-PRF-27210.
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(9) Slightly open the valve of the oxygen filling The oxygen cylinder is limited to a
station and check oxygen flow. pressure of 128 bar (1850 PSI).
Refilling of a fully depleted cylinder will

take approximately 3.5 minutes.
(10) Close the valve of the oxygen filling station

when a pressure of 128 bar (1850 PSI) is
reached.
(11) Disconnect the filling station outlet port from the

filling valve.
(12) Reinstall the filling valve protection nut.
(13) Check pressure gauges by comparing pressure

indication of the filling block with pressure
indication of the gauge installed on the RH side
of the instrument panel.
(14) Close the cover of the oxygen filling unit.
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Section 12-20
Scheduled Servicing
1. General
This Section gives lubrication data. It tells you where components are located. It gives a list of
approved lubricants. It also gives components which MUST NOT be lubricated.
Most systems and components have maintenance-free bearings. These can be sealed ball/roller
bearings or Teflon bushes. These bearings MUST NOT be lubricated. Table 1 shows the bearings
which MUST NOT be lubricated.
Table 1 - Items Which MUST NOT Be Lubricated
Rudder pedal sled. DO NOT LUBRICATE
Flap rod-end bearings. DO NOT LUBRICATE
Aileron rod-end bearings. DO NOT LUBRICATE
Elevator rod-end bearings. DO NOT LUBRICATE
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2. Lubrication Schedule
Table 2 shows the lubrication schedule. Clean each lubrication point before lubrication.
See Figures 1 and 2 for the location of the lubrication points listed on the left side of the table. The
center column shows the type of lubricant. The right column shows the lubrication interval.
Table 2 - Lubrication Schedule
Location Type of Lubricant Interval
No. See Figure 1 and 2 1 2 3 4 5 6 7 (Hours)
see Notes
(1), (2)
(1) Brake pedal pivot shaft interior ! 1000
(2) Rudder cable S-tubes ! 200
(3) Flap actuator extension rod ! 200
(4) Passenger door safety hook button (red) ! 100
(5) Upper rudder pivot bearing ! 200
(6) Nose wheel bearing (see notes 3, 5, and 6) ! ! 200
(7) Wing main bolts ! 2000
(8) Stick support pivot pins ! 1000
(9) Battery terminals ! 1000
(10) B-bolts ! 2000
(11) B-bolt spherical bearings ! 2000
(12) A-bolts ! 2000
(13) A-bolt spherical bearings ! 2000
(14) Brake pedal pivot ! 200
(15) Flap actuator universal pivot block ! 1000
(16) Brake caliper locating pins ! 1000
(17) Torque link bearings ! 100
(18) Main wheel bearings (see notes 3, 5, and 6) ! ! 200
(19) Cable eyes on rudder ! 200
(20) Landing gear actuator bearings ! 100
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Notes:
(1) Lubricate at the time shown or at every disassembly / assembly.
(2) Lubricate more frequently in severe climates or operating conditions.
(3) Lubricate more frequently when the ice protection system (optional equipment) is frequently
operated.
(4) Lubricate at the time shown and at Annual Inspection.
(5) Do not grease on the threads. It will reduce the friction of the lock-nut.
CAUTION: DO NOT MIX AVIATION WHEEL BEARING GREASES WITH EACH

OTHER. IF USING OTHER APPROVED GREASES, COMPLETE
REMOVAL OF CONTAINED GREASE AND BEARING CLEANING IS
REQUIRED. REPLACEMENT OF PREVIOUSLY LUBRICATED FELT
GREASE SEALS IS ALSO REQUIRED.
(6) The wheel manufacturer lubricates the main wheel bearings with Mobil Aviation Grease SHC 100
Type 1 grease is completely compatible with the wheel bearings.
(7) On airplanes registered in the USA, lubricate the wheel bearings at every annual / 100 hour
inspection (see FAR 43, Appendix D).
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Table 3 - Lubricant Specifications
Specification Product Manufacturer
TYPE 1
MIL-G-3545 (obsolete) AeroShell Grease 5 Shell Oil Company
Grease CIATIM 201, RUSMA LLC Company

GOST 6267-74
Grease CIATIM 221, RUSMA LLC Company

GOST 9433-80
Mobil Aviation Grease Exxon Mobil Oil Corp.

SHC 100
TYPE 2
MIL-L-7870 Royco 363 Royal Lubricants Co. Inc.
Brayco 363 Bray Oil Co.
Warm climates only LPS 2 LPS
TYPE 3
Greaseless Lubricant LPS 1 LPS
TYPE 4
VV-P-236 (petrolatum) Royco 1 Royal Lubricants Co. Inc.
DC 4 Dow Corning
TYPE 5
MIL-C-16173 (Grade 2) LPS 3 LPS
TYPE 6
MIL-A-907 Loctite Antiseize 767 Loctite

- Multi-Purpose Lubricant DRI SLIDE
- LPS Force 842 LPS
- Lubriplate X-357 Lubriplate
- Loctite 8191 Loctite
- Anti-Friction Spray MoS2 WEICON GmbH
TYPE 7
MIL-PRF-81322, Grade 2 or Aeroshell Grease 22 Shell Oil Company
DOD-G-24508 A Mobil Aviation Grease Exxon Mobil Oil Corp.

SHC 100
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AIRCRAFT
1
2
1
2
3 5
14 15
20
17
16
6
8
18
Figure 1: Lubrication Points Sheet 1
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19
11 & 13
10 & 12
Figure 2: Lubrication Points Sheet 2
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Section 12-30
Unscheduled Servicing
1. General
This Section tells you how to clean the airplane. It also tells you how to remove snow and ice from the
airplane.
2. Exterior Cleaning
The outer surfaces of the DA 42 NG must be kept clean to maintain the good performance
characteristics of the airplane. The leading edge of the wings are specially important.
Protect all control surface bearings and other lubricated components before cleaning the airplane.
Use large quantities of water to clean the airplane. If necessary, add a mild cleaning agent to the
water. Remove excess dirt or dead insects immediately after flight. Dried on dirt and dead insects are
very difficult to remove.
CAUTION: DO NOT USE CLEANING OR POLISHING AGENTS WHICH CONTAIN

SILICON. IF THE AIRPLANE NEEDS REPAIR AT SOME TIME, SILICON
CAN PREVENT REPAIR MATERIALS FROM BONDING CORRECTLY.
Approximately once a year, apply a silicone-free automotive polish to the outer surface of the airplane.
3. Canopy and Transparency Cleaning
CAUTION: DO NOT RUB THE CANOPY OR TRANSPARENCIES WHILE THEY ARE

DRY. DO NOT USE DIRTY CLOTHS OR SPONGES. THE ACRYLIC
TRANSPARENCIES SCRATCH VERY EASILY WITH THE SMALLEST
PARTICLES OF DUST OR DIRT.
Clean the canopy and transparencies with large quantities of clean water. Use clean sponges and
good chamois leather that you should not use for any other purpose.
Polish dull or scratched areas using a special acrylic cleaner. Remove scratches with special
transparency polishing systems (e.g. Micro-Mesh).
4. Interior Cleaning
Clean the interior of the airplane cabin with a flame-proof vacuum cleaner.
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AIRCRAFT
5. Engine Cleaning
Use a cold cleaning agent (e.g. Berner Cold Cleaner No.13618.0 or refer to the AE Maintenance
Manual).
CAUTION: DO NOT CLEAN THE ENGINE WHILE THE ENGINE IS HOT.
CAUTION: DO NOT USE HIGHLY FLAMMABLE OR CORROSIVE CLEANING

AGENTS TO CLEAN THE ENGINE.
CAUTION: DO NOT LET THE CLEANING AGENT GET INTO ELECTRICAL

COMPONENTS AND ENGINE INTAKES.
CAUTION: DO NOT START THE ENGINE UNTIL ALL OF THE CLEANING AGENT
HAS EVAPORATED.
Protect all electrical components and cables. Use polythene bags to seal intakes and other areas that
you want to keep dry. After washing you can dry the engine using compressed air (< 8 bar (118 PSI).)
6. Snow and Ice Removal
Remove snow and ice as soon as possible to prevent water from the melting snow or ice re-freezing
and causing damage.
CAUTION: DO NOT USE SHARP OBJECTS TO REMOVE SNOW OR ICE. YOU

CAN DAMAGE THE AIRPLANE STRUCTURE.
Use soft brushes to remove snow from the surfaces.
Put the airplane in a heated hangar to remove ice or spray de-icing fluid onto ice-covered surfaces
using a suitable spray bottle. For approved de-icing fluids refer to AFM, Section 8.7.
Use a soft piece of cloth to wipe the airplane dry.
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7. Conservation of Exterior Parts
This Section tells you which exterior parts are protected with an anti-corrosion coating, when and how
a new anti-corrosion coating must be applied.
A. Anti-Corrosion Coating Check
Check the protected exterior parts (refer to the Anti-Corrosion Checklist and Figures 1 through 15)
for a film of the anti-corrosion coating. If the film is scratched or the part shows signs of corrosion,
you must replace the anti-corrosion coating (refer to Paragraphs B and C of this Section).
B. Remove the Anti-Corrosion Coating
CAUTION: YOU MUST USE THE APPROVED ANTI-CORROSION COATING

CLEANING AGENTS IN ORDER TO PREVENT DAMAGE TO OTHER
PARTS OF THE AIRPLANE.
Approved anti-corrosion coating cleaning agents are:
) Ardrox® AV 980
) Diestone DLS
Remove the anti-corrosion coating:
) Read the product datasheet carefully.
) Cover the airplane parts and surfaces in your working area, which are not subject to the
cleaning.
) Apply the anti-corrosion cleaning agent to the parts.
) Use a cloth to remove the remains.
) Repeat until the surface is clean and dry.
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C. Apply the Anti-Corrosion Coating
CAUTION: YOU MUST USE THE APPROVED ANTI-CORROSION COATINGS IN

ORDER TO PREVENT DAMAGE TO OTHER PARTS OF THE
AIRPLANE.
Approved anti-corrosion coatings are:
) Ardrox® AV 30 (color: red; recommended for not visible parts)
) Socopac 65H (color: red; recommended for not visible parts)
) Cor - Ban 35 (color: transparent; recommended for visible parts)
Apply the anti-corrosion coating:
) Read the product datasheet carefully.
) Cover the airplane parts and surfaces in your working area, which are not subject to the
anti-corrosion coating.
) Apply the anti-corrosion agent to the parts. Make sure the surface is covered with a thin film
of the anti-corrosion coating.
) The anti-corrosion coating needs 3 hours to dry.
) Remove the covers from the airplane.
D. Anti-Corrosion Coating Checklist
Refer to the figure numbers in the following table to identify the parts, where anti-corrosion coatings
must be applied.
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Anti-Corrosion Coating Checklist
Figure Part / Location Initials
FLAPS LH/RH
1 Control rod eye end fitting
1 Ball joint bolt and nut
AILERONS LH/RH
2 Control rod eye end fitting
2 Ball joint bolt and nut
MAIN LANDING GEAR LH/RH
3, 5 Tension spring
3, 5 Forward pivot bearing, bolt head and nut
3, 5 Aft pivot bearing, bolt head and nut
3, 5 Tension spring
3, 5 Latch operating arm, bolt heads and nuts (2)
3, 5 Driver plate and folding stay bracket
4 Main landing gear axle, bolt heads and nuts (4)
4 Main landing gear leg assy / trailing arm oversize bolt head and nut
4 Damper upper bolt head and nut
4 Damper lower bolt head and nut
6 Main landing gear bay, door hinges (2), bolt heads (6) and nuts (6)
6 Main landing gear bay nuts (5)
ELEVATOR, ELEVATOR CONTROLS AND ELEVATOR TRIM SYSTEM
7, 8 Elevator push rod, upper eye end fitting
7, 8 Elevator upper eye end fitting, bolt head and nut
7, 8 Elevator trim bolt heads (8) and nuts (8)
7, 8 Elevator trim actuating lever attaching bolt head and nut
9 Elevator push eye end fitting, bolt head and nut
9 Elevator bellcrank, bolt heads (3) and nuts (3)
9 Elevator centering springs (2) and mountings (3)
Page 5
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Anti-Corrosion Coating Checklist
Figure Part / Location Initials
RUDDER
10 Rudder pedestal, nuts (4)
10 Rudder friction damper coupling and bolt heads (2)
10 Rudder plate, bolt heads (3) and nuts (3)
11 Rudder upper bearing
NOSE LANDING GEAR
12 Centering unit guidance plate and bolt heads (3)
12 Nose wheel fork bolt heads (4)
12 Torque links bolt heads (5) and nuts (5)
13 Tension spring
13 Tension spring mounting bolt heads (2) and nuts (2)
13 Folding stay latching mechanism
13 Folding stay latch operating arm: lower ball joint, bolt head and nut
14 Actuator eye end fitting
14 Mounting bracket bolt heads (5)
15 Nose landing gear bracket and bolt heads LH (4), RH (4)
15 Door rod upper eye end fitting LH, RH
15 Door hinges LH (4) , RH (4)
FUSELAGE
16 Foot step screws LH (4), RH (4)
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AIRCRAFT
LH Shown, RH Similar
Control Rod, Flaps LH & RH
Anti-corrosion coating according to

Section 12-30 of this AMM
Figure 1: Anti-Corrosion Coating - Control Rod Flaps LH/RH
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Control Rod, Ailerons LH & RH

Figure 2: Anti-Corrosion Coating - Control Rod Ailerons LH/RH
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Keep Switch free of Preventives
Coating with Preventives according to

Reverse Side
Figure 3: Anti-Corrosion Coating - Main Landing Gear LH/RH (1)
Page 9
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Keep Caliper, Brake Disc and

Tyre free of Preventives
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Apply Preventives on joints of this part

not visible on this drawing
Page 11
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Apply Preventives on all Door Hinges

and related Fasteners from both sides

Figure 6: Anti-Corrosion Coating - Main Landing Gear Bay LH/RH
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AIRCRAFT


Keep Elevator Trim System

free of Preventives
Keep Elevator Trim System free of Preventives
Figure 7: Anti-Corrosion Coating - Elevator and Elevator Trim System (1)
Page 13
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Coating with Preventives according

to Section 12-30 of this AMM
Figure 8: Anti-Corrosion Coating - Elevator and Elevator Trim System (2)
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Preventives to be applied on joints not visible as well
Figure 9: Anti-Corrosion Coating - Elevator Controls
Page 15
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Keep Spring & Rods free of Preventives
Coating with Preventives

according to Section 12-30
of this AMM
Apply Preventives on complete

surface of Pedestal
Keep Rudder Trim Damper Rod,

Friction Damper, Bowden Cable
& Rudder Springs free of Preventives
Figure 10: Anti-Corrosion Coating - Rudder Pedestal
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Apply Coating with Preventives

on both sides of the Bearing
Figure 11: Anti-Corrosion Coating - Rudder
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Keep Tyre free of Preventives
Figure 12: Anti-Corrosion Coating - Nose Landing Gear (1)
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Keep Switch free of

Preventives
Page 19
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AIRCRAFT
Apply Preventives on Joints of

this part not visible as well
LH Shown, RH Opposite
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AIRCRAFT

Section 12-30-00 of this AMM
Apply Preventives on joints

of this part not visible
in this picture as well
Apply Preventives on joints

Nose Landing Gear Door of this part not visible
View from Below in this picture as well
Apply Preventives to both

sides of all Door Hinges
Apply Preventives to both

sides of all Door Hinges
(LH Shown, RH Opposite)
Page 21
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Anti-corrosion coating according to Section 12-30 of this AMM
Figure 16: Anti-Corrosion Coating - Foot Step Screws
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DA 42 NG AMM Standard Practices
AIRCRAFT
CHAPTER 20
STANDARD PRACTICES
Doc # 7.02.15 Page 1

Standard Practices DA 42 NG AMM
AIRCRAFT
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TABLE OF CONTENTS
CHAPTER 20
STANDARD PRACTICES
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 20-10
Standard Practices - Airframe
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Bolt and Nut Types Used in the Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Standard Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Special Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Torque Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section 20-30
Standard Practices - Electrical
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Thread Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Repair and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 20-70
Standard Practices - Engines
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Special Torque Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Installation and Tightening Torques of Worm Drive Clamps . . . . . . . . . . . . . . . . . 4
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Section 20-90
Standard Practices - Center Wing
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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AIRCRAFT
CHAPTER 20
STANDARD PRACTICES
1. General
This Chapter gives you the standard practices for the DA 42 NG airplane. Use industry standard
practice where no specific practice is given.
This Chapter has the following Sections:
) Section 20-10. Standard Practices - Airframe.
) Section 20-30. Standard Practices - Electrical.
) Section 20-70. Standard Practices - Engines.
) Section 20-90. Standard Practices - Center Wing.
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AIRCRAFT
Section 20-10
Standard Practices - Airframe
1. General
This Section gives you data about the fasteners (bolts/screws/nuts) used in the DA 42 NG airplane and
their related torque values. This Section tells you the procedures used to tighten the fasteners.
Note: Use the standard torque values listed on the subsequent pages of this section
where no specific values are given.
Note: Composite structures can have a different thickness for the same component or
assembly. You must always make sure that you use the correct length of fastener.
The length of fastener given in the Illustrated Parts Catalogue may NOT be correct
for all components or assemblies.
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2. Bolt and Nut Types Used in the Airplane
The DA 42 NG airplane uses these bolts:
- DIN bolts.
- LN bolts.
- AN bolts.
The minimum strength for the bolts is DIN specification 8.8. Letters and numbers on the head of the
bolt identify the bolt type. The surface treatment also identifies the bolt.
A. DIN Bolt
Bolt Head Identification
OEV Trade Mark
Surface Treatment - Galvanized
10.9 Strength Category
B. LN Bolts
P Letter (P, H, R)
Surface Treatment - Galvanized and chromated yellow
9037 LN Standard
C. AN Bolts
P Letter
(Also Adjacent)
X Cross
Surface Treatment - Galvanized or chromated yellow
The DA 42 NG uses these types of standard nuts: DIN934, DIN 985, AN 364, AN 365, LN 9338,
LN 9348, MS21042, MS21044.
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3. Standard Torque Values
A. AN Fine Threads
Bolt Size Torque (Nm) Torque (lbf.ft.)
10 - 32 1.6 1.2
1/4 - 28 6.2 4.6
5/16 - 24 13.6 10
3/8 - 24 20.7 15.3
7/16 - 20 37.7 27.8
1/2 - 20 54.2 40
9/16 - 18 90.4 66.7
5/8 - 18 124.3 91.7

B. AN Coarse Thread Series
Bolt Size Torque (Nm) Torque (lbf.ft.)
10 - 24 1.6 1.2
1/4 -20 5.7 4.2
5/16 - 18 10.2 7.5
3/8 - 16 20.9 15.4
7/16 - 14 28.9 21.3
1/2 - 13 54.2 40
9/16 - 12 79 58.3
5/8 - 11 101.6 75
C. DIN and LN Specifications
Metric Thread Torque (Nm) Torque (lbf.ft.)
M4 1.8 1.3
M5 3.6 2.7
M6 6.4 4.7
M8 16 11.8
M10 32 23.6
M12 60 44.3
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4. Special Torque Values
Part Torque (Nm) Torque (lbf.ft.)
Bolts attaching the engine mount to the firewall. 40 29.5
Bolts attaching the engine mounting arms to the engine 20 ± 2* 14.75 ± 1.48
(if MÄM 42-600 is installed).
Front LH / RH shock mounts to engine mounting arms. 85* 62.7
Rear LH / RH shock mounts to engine mounts. 28 ± 2.8 20.64 ± 2.06
Propeller to engine nuts. 85 - 90 62.7 - 66.4
Propeller governor nut. 28 20.7
Intercooler clamp. 5 3.7
V-clamp turbo charger. 5.0 ± 0.5 3.7 ± 0.4
V-clamp turbo charger (if MÄM 42-963/a is installed). 5.5 ± 0.5 4.0 ± 0.4
Cabin air heat exchanger clamp. 5 3.7
Fuel filter drain connection. 22 16.2
Fuel drain valve. 1-3 0.74 - 2.21
% Hydraulic pump motor electric connection bolt. 9 - 11 6.6 - 8.1
Bolts attaching the main landing gear brake back plates Refer to Cleveland/Parker Maintenance
to the caliper. Manual, latest revision or placard on
brake cylinder assy.
Main landing gear axles (all bolts M 8). 16* 11.8*
Main landing gear axles (all bolts M 12). 60* 44.3*
Trailing arm main landing gear attachment bolts M 12. 30* 22.1*
Upper main landing gear damper attachment bolt M 12. 48* 35.4*
Horizontal stabilizer attachment bolts. 45* 33.2*

*) Values including friction.
5. Torque Measurement
For self-locking nuts, add the torque value of the locking device (friction or brake torque) to the value
in the table. Read the friction value from the torque wrench before the nut seats.
Where a bolt is tightened from the bolt-head, add the value of the shaft friction (the friction of the bolt
in the attached part) to the value in the table. Read the fiction value from the torque wrench before the
bolt seats.
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Section 20-30
Standard Practices - Electrical
1. General
This Section gives you the standard practices for the electrical system. Modern airplanes reliability
depends on proper function of the electric and electronic systems to a greater extent than previous
certified airplanes. Maintenance carried out must be of good workmanship strictly considering the
guidelines of AC 43-13.1B. Any time you work on the engine harness refer to AE Maintenance Manual,
Doc. No. E4.08.04, latest revision.
The satisfactory performance of a modern airplane, like the DA 42 NG, depends to a great extent, on
reliability of its electrical systems. Improperly or carelessly maintained wiring can be a source of
potential danger, and many malfunctions and failures of an electrical system can be traced to this
cause. The continued proper performance of the electrical systems depends on the knowledge of the
personal who do the inspection and repair.
It is therefore important that maintenance is carried out in accordance with the best available
techniques and properly trained maintenance personal, in order to eliminate possible failures.
2. Thread Locking
Many electrical terminals are locked with electrical varnish or lacquer. If you release a terminal that has
been thread locked with lacquer or varnish then use Loctite 222 or equivalent to lock the thread when
you re-assemble the terminal.
3. Repair and Maintenance
Repair and maintenance of the electrical system wiring, not covered in a separate document (e.g.
Service Bulletin, Work Instruction) is limited to the extent of:
) Replacement of wires and cables.
) Replacement of ring terminals.
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A. Crimp Tools
Following crimp tools are commonly used for crimp contacts in the DA 42 NG. Refer to the
equipment manufacturer for more details of the tools and their use.
) Tyco, P/N 69478-1
) Tyco CERTI-LOK, P/N 169400
) Tyco SUPER CHAMP FT, P/N 720781-3
) Tyco CERTI-CRIMP, P/N 91523-1
) Tyco CERTI-CRIMP, P/N 91512-1
) Commercial, M22520/1-01
B. Wires and Cables
(1) Wires
For the purpose of electric and electronic installation, an insulated wire consists of a metal
conductor covered with a dielectric or insulating material. Wires used in the airplane contain
stranded conductors for flexibility. The insulation may consist of several materials and layers to
provide:
) Dielectric insulation
) Thermal protection
) Abrasion resistance
) Moisture resistance
) Fluid resistance
Approved wires for the DA 42 NG:
) M22759/16
) M22759/34
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(2) Cables
The term “cable”, may refer to any of the following:
) Two conductors twisted together (twisted pair).
) A single center conductor with a metallic braided outer conductor (coaxial cable).
) Two or more insulated conductors contained in a common covering (multi conductor

cable).
) One or more insulated conductors with an overall shield (shielded cable).
Approved cables for the DA 42 NG are:
) M27500
) M17/60-RG142
) M17/128-RG400
(3) Wire Marking
Locating a specific wire within a large wiring loom would be extremely difficult without individual
identification of each wire, or cable. To simplify maintenance, each interconnecting wire and
cable installed in the airplane is marked with a combination of numbers and letters. If a wire or
cable must be replaced, the wire must be marked according to the wiring diagrams in
Chapter 92.
C. Testing
After a wire, cable or ring terminal has been replaced, testing must be done as listed below:
) Visual inspection of the crimp connection (all leads within the crimp, insulation not crimped
etc.).
) Check for continuity between the two ends of the conductor.
) Check for NO continuity between the conductor and aircraft electrical ground.
) The crimp contact is not damaged of bend.
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AIRCRAFT
Section 20-70
Standard Practices - Engines
1. General
This Section gives you data about the fasteners used on the AE E4-B engines installed in the
DA 42 NG airplane. It also gives you the procedures for tightening the fasteners.
Refer to the AE Maintenance Manual, latest revision for more data.
2. Torque Values
Use the torque values given in tables 1 thru 4 for standard fasteners on the engine and use the torque
values given in table 5 for the components listed.
3. Special Torque Procedures
When you use self-locking nuts, add the safety torque (friction torque or braking torque) to the table
values. Set this value on the dial of the torque meter before you tighten the nut.
If a bolt has an additional torque due to shaft friction, add this torque value to the table value. Set this
calculated value on the dial of the torque meter before you tighten the bolt.
Lubricate threads unless shown differently.
CAUTION: YOU MUST ADD THE SAFETY TORQUE (OR THE FRICTION TORQUE)
TO THE FOLLOWING VALUES FOR SELF-LOCKING NUTS (OR BOLTS
WITH SHAFT FRICTION).
Table 1 - Standard Torque Values for Engine Bolts and Nuts
INCH THREAD TORQUE (Nm) TORQUE (lbf.ft.)
1/4 11 8
5/16 23 17
3/8 41 30
7/16 68 50
1/2 102 75
9/16 149 110
5/8 203 150
3/4 366 270
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Table 2 - Standard Torque Values for Engine Pipe Plugs
TAPER THREAD TORQUE (Nm) TORQUE (lbf.ft.)
1/16 - 27 NPT 4.5 3.3
1/8 - 27 NPT 4.5 3.3
1/4 - 18 NPT 9.5 7
3/8 - 18 NPT 12.3 9
1/2 - 14 NPT 18 13.3
3/4 - 14 NPT 26 19
Table 3 - Standard Torque Values for Engine Crush-Type Asbestos Gaskets
THREAD PITCH ANGLE OF TURN
THREADS PER INCH ALUMINUM ASBESTOS COPPER ASBESTOS
8 135° 67°
10 135° 67°
12 180° 90°
14 180° 90°
16 270° 135°
18 270° 135°
20 270° 135°
24 360° 180°
28 360° 180°
Note: Install all crush type gaskets (except the self-centering type) with the continuous
surface against the flange of the plug or against the part which you will tighten
against the gasket. Turn the part until the surfaces which you must seal, touch the
gasket. Then tighten to the angle of turn shown for the thread size as given in
Table 3.
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Table 4 - Standard Torque Values for Engine Flexible Hose (or Tube) Connections
TUBE SIZE THREAD TORQUE (Nm) TORQUE (lbf.ft.)
(-4) 1/4 7/16 - 20 11 - 16 7 -11
(-6) 3/8 9/16 - 18 17 - 22 11 - 16
(-10) 5/8 7/8 - 14 41 - 48 30 - 36
Table 5 - Special Torque Values for the Engine
ITEM THREAD TORQUE (Nm) TORQUE (lbf.ft.)
Engine oil filter - 25 18.5
Gearbox distance bolts

(if MÄM 42-600 is 28 ± 3 20.6 ± 2.2
installed)
Coolant silicate pouch

- 32.5 ± 2.5 24.0 ± 1.8
cartridge
Coolant tank filler cap

-
(if MÄM 42-852 is 12-15 8.85 - 11.06
installed)
Pressure relief valve - 12-15 8.85 - 11.06
Loctite 243
Coolant level sensor 25-30 18.44 - 22.13
O-Ring
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4. Installation and Tightening Torques of Worm Drive Clamps
The Figures and tables show the proper installation and the tightening torques of worm drive clamps.
A. Single Worm Drive Clamp
CAUTION: DO NOT PLACE A WORM DRIVE CLAMP ON A TUBE BEAD. THIS CAN
DAMAGE THE HOSE AND MAY (IN CASE OF ENGINE CHARGE AIR
INSTALLATION) CAUSE LOSS OF ENGINE POWER.
Worm Drive Clamp
Aluminium
Tube Bead
Silicon Hose Aluminium Tube
Figure 1: Installation with Single Worm Drive Clamp
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B. Two Worm Drive Clamps
(1) Axial Placement
CAUTION: DO NOT PLACE A WORM DRIVE CLAMP ON A TUBE BEAD. THIS CAN
DAMAGE THE HOSE AND MAY (IN CASE OF ENGINE CHARGE AIR
INSTALLATION) CAUSE LOSS OF ENGINE POWER.
Worm Drive Clamps
Aluminium
Tube Bead
Figure 2: Installation with Two Worm Drive Clamps and Single Bead (Axial Placement)
Worm Drive Clamps
Aluminium
Tube Beads
Figure 3: Installation with Two Worm Drive Clamps Two Beads (Axial Placement)
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Expansion Bellows
Maximum Insertion
Aluminium
Tube Beads
Spring Steel Aluminium Tube

Support Ring
Silicon Hose Worm Drive Clamps
Figure 4: Installation with two Worm Drive Clamps, Two Beads (Axial Placement)
and a Hose with flexible Bellows (if MÄM 42-1004 is installed)
(2) Radial Placement
Minimum 4 mm
Minimum 2 mm
Minimum 90°
Connection Tube Silicon Tube

Hose Clamps
Figure 5: Installation with Two Worm Drive Clamps (Radial Placement)
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C. Tightening Torques for Worm Drive Clamps
CAUTION: WORM DRIVE CLAMPS MUST BE TIGHTENED ACCORDING TO THE

TABLE BELOW. OVER-TIGHTENING A WORM DRIVE CLAMP CAN
DAMAGE THE HOSE AND MAY (IN CASE OF ENGINE INSTALLATIONS)
CAUSE LOSS OF ENGINE POWER.
CAUTION: FOR WORM DRIVE CLAMP INSTALLATION THE ENGINE MUST BE

COLD. INSTALLATION ON A HOT ENGINE CAN CAUSE DAMAGE TO
THE HOSE AND MAY (IN CASE OF ENGINE INSTALLATIONS) CAUSE
LOSS OF ENGINE POWER.
CAUTION: DO NOT RE-TIGHTEN A WORM DRIVE CLAMP ON A SILICONE HOSE

PERFORMING AN AIRPLANE INSPECTION UNLESS IT IS LOOSE.
REFER TO THE TABLE BELOW FOR THE CORRECT TIGHTENING
TORQUES OF WORM DRIVE CLAMPS.
(1) Tightening Torques for Clamp Widths Below 12 mm (0.47 in)
Clamp Diameter Torque (Nm) Torque (lbf.ft.)
8-12 2.5 ± 0.5 1.8 ± 0.4
10-160 3.0 ± 0.5 2.2 ± 0.4
(2) Tightening Torques for Clamp Widths of 12 mm (0.47 in) and Higher
Clamp Diameter Torque (Nm) Torque (lbf.ft.)
8-160 5.0 ± 0.5 3.7 ± 0.4
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Section 20-90
Standard Practices - Center Wing
1. General
This Section shows the typical installation in the center wing section. The installation details of
electrical cables, hoses and Bowden cables may change with optional equipment installed and serial
number development. The following figures show typical installation positions for the components.
2. Description
The Figures show the key points of the routing. The cables and hoses may be removed for
maintenance and repair work. Make sure to install components according to the previous setting.
Note: A minimum clearance of 5 mm (0.2 in) is required between electrical cables or

hoses and moving parts, if jamming may occur.
Note: A minimum clearance of 2 mm (0.08 in) is required between electrical cables or

hoses and moving parts, if chafing may occur.
Note: It might be helpful to document the actual installation in the center wing section with
some photographs.
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Figure 1: Routing in Center Wing - Overview
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Figure 2: Routing in Center Wing - Detail 1
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Line Section Rudder Cable
Do not connect the Line Section

with the Rudder Cable
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Trouble-Shooting
1. General
The table below lists defects you could have in the aileron control system. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair given
in the Repair column.
Trouble Possible Cause Repair
Clearance less than 5 mm Electrical cables, hoses and Position and fix the electrical
(0.2 in) if jamming may occur. Bowden cables position. cables, hoses and Bowden
cables properly.
Clearance less than 2 mm Electrical cables, hoses and Position and fix the electrical
(0.08 in) if chafing may occur. Bowden cables position. cables, hoses and Bowden
cables properly.
Hoses pinched. Cable tie tightened with undue Replace the cable tie.
force.
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1. General
For maintenance of the components refer to the related Chapters of this AMM.
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DA 42 NG AMM Heating and Ventilation
AIRCRAFT
CHAPTER 21
HEATING AND VENTILATION
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TABLE OF CONTENTS
CHAPTER 21
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 21-20
Air Distribution
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Replace a Heater Control Valve Forward Inner Control Cable . . . . . . . . . . . . . . 201
3. Replace a Heater Control Valve Control Cable (if MÄM 42-739 is installed) . . . 209
4. Test/Adjust a Heater Valve Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Section 21-40
Heating
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Heat Exchanger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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Section 21-50
Cooling (OÄM 42-193/c or earlier installed)
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Trouble Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Remove/ Install the Central Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
3. RACC - System Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
4. Remove/Install Parts of the Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 209
Section 21-51
Cooling (OÄM 42-193/d or later installed)
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Trouble Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Remove/ Install the Central Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
3. RACC - System Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
4. Remove/Install Parts of the Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 209
Section 21-60
Temperature Control
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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CHAPTER 21
1. General
This Chapter tells you about the air conditioning system for the DA 42 NG. It gives you a description
of the system and operation. It also provides information on trouble-shooting and tells you how to
remove and install the main components of the air conditioning system.
If OÄM 42-193 is carried out, a recirculating air - cabin cooling (RACC) system is installed. Refer to
Section 21-50 (if OÄM 42-193/c or earlier is installed) or Section 21-51 (if OÄM 42-193/d or later is
installed) for more details about the RACC system.
Note: Refer to Section 20-90 before starting maintenance work in the center wing area.
2. Description and Operation
The DA 42 NG has two separate systems for heating and one ventilating/cooling system for the cabin
area. Figure 1 shows the schematic for the heating and ventilating/cooling systems.
Refer to Section 21-20 for more data about the air conditioning distribution system. Refer to Section
21-40 for more data about the heating system and refer to Section 21-60 for more data about the
temperature control system.
A. Cabin Heating and Canopy Defrosting
A heat exchanger in each engine nacelle provides the warm air for cabin heating. Hot cooling liquid
from the engine cooling system flows through the matrix of the heat exchanger. Ambient air flows
from an air inlet in the engine nacelle through the heat exchanger. The air flows from the heat
exchanger through a control valve to the airplane cabin. The heated air is then used for cabin
heating and windscreen defrosting. Levers in the central control console of the cockpit connect to
the control valves with Bowden cables and control the flow of heated air.
The warm air from the left engine installation supplies the canopy defrosting system and the warm
air from the right engine installation supplies the cabin heating.
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B. Cabin Ventilation/Cooling
Ambient air flows through a NACA duct at the lower surface of the right-side wing center-section.
In flight, ambient air flows through this NACA duct into the cabin ventilation/cooling system via
flexible hoses. The flow of air into the forward cockpit is controlled by outlets located in each side
of the instrument panel. The flow of air to the rear passenger area is controlled by air outlets
located in the cockpit instrument panel and the rear-cabin overhead-panel. The volume and
direction of the air flowing from the outlets can be controlled at the outlets.
Refer to Section 21-50 for more details about the RACC system (if OÄM 42-193/c or earlier is
installed).
Refer to Section 21-51 for more details about the RACC system (if OÄM 42-193/d or later is
installed).
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Figure 1: Air Conditioning Schematic Diagram
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Heater Heater
Radiator Valve
NACA Air Inlet

To Floor Element
Cabin Air
Cockpit Ventilation, Instrument Panel
Control, RH
Heater Control Levers
Bowden Cable, RH
Cabin Air Control,
Rear Floor, RH
Defrost Cabin Air Controls, Rear
(Overhead Panel Mounted)
Bowden Cable, LH
Cabin Air Control,

Cockpit Ventilation, Rear Floor, LH
Instrument Panel Cabin Air
Control, LH
Heater Valve
Heater
Radiator
Figure 2: Air Conditioning Schematic Diagram (if MÄM 42-739 is installed)
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Section 21-20
Air Distribution
1. General
The DA 42 NG has a heating and a ventilation system. The ventilation system uses ambient air to
ventilate the cabin. Warm air for windscreen defrosting and cabin heating is provided by heat-
exchangers located in the engine nacelles. This Section tells you about the air distribution system of
the DA 42 NG. Refer to Section 21-40 for data about the air heating system and refer to Section 21-60
for data about the temperature control system.
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Figure 1: Ventilation Air Distribution System Schematic Description and Operation
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A. Ventilation
Figure 1 shows the ventilation air distribution system. In normal flight ambient air flows through a
NACA duct on the lower surface of the right-side center wing section. The air flows through sealed
compartments in the center wing section to the fuselage. At the fuselage the airflow is divided.
Some of the air is directed into an integral GRP duct that directs the air to the two air outlets on the
J-panel and to the two air outlets in the rear passenger compartment overhead panel. The
remaining air flows through flexible hoses to air outlets located at each side of the instrument panel.
The airflow is controlled by rotating the nozzles of the air outlets.
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Figure 2: Cabin Heating and Defrost Air Distribution System Schematic
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Heater
Valve
Heater
Radiator
Heater Control Levers
Bowden Cable, RH
Defrost
Bowden Cable, LH
Cockpit Ventilation,
Instrument Panel
Heater
Radiator
Heater Valve
Figure 3: Cabin Heating and Defrost Air Distribution System Schematic

(if MÄM 42-739 is installed)
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B. Heating and Defrosting
Figure 2 and 3 shows the schematic drawing for the cabin heating and defrost air distribution
system. Air enters the heating and defrosting systems through inlet ducts located at the right lower
side of each engine nacelle. The left engine supplies warm air to the canopy defrosting system and
the right engine supplies warm air to the cabin heating system. The warm air supply system is
similar for both engines.
Ambient air flows through the inlet duct in the engine nacelle into a carbon fiber composite (CFC)
shroud and is directed through the heat exchanger. When the engine is running, hot coolant flows
from the engine through the core of the heat exchanger and back to the engine. The temperature
of the air increases as it passes through the matrix of the heat exchanger. The heated air then flows
through flexible hoses from the heat exchanger shroud to a heater valve mounted on the engine
firewall.
Each heater valve has an internal flap that can be moved from an open position to a bypass
position. If a valve is set to the open position the heated air flows into the related heating or
defrosting system. If the valve is set to the bypass position the heated air flows out of the valve into
the engine compartment.
Two control levers located in the cockpit center console control the position of the flaps in the
heater valves via Bowden cables. The left lever (DEFROST) controls the left engine heater valve.
The right lever (CABIN) controls the right engine heater valve. If MÄM 42-739 is NOT installed, a
forward Bowden cable from each control lever attaches to the left and right relay levers located
under the pilots’ seats. Two aft Bowden cables connect the relay levers to the left and right heater
valves. If MÄM 42-739 is installed, a forward Bowden cable from each control lever attaches to the
left and right heater valves.
Moving the DEFROST to the open position allows heated air to flow through the heater valve into
a flexible hose. A flexible hose connects the heater valve to the cockpit defrosting system. The
flexible hose passes through the leading edge of the left-side central wing section into the fuselage.
At the fuselage the hose connects to a splitter which causes the air flow to be divided. Two smaller-
diameter flexible hoses connect the outlets of the splitter to the left and right side canopy defrosting
ducts. The volume of heated air flowing through the defrosting system is controlled by the position
of the DEFROST control lever in the center console.
Moving the CABIN lever from the closed position allows heated air to flow through the heater valve
into a flexible hose. The flexible hose connects the heater valve to the cockpit heating system in
the fuselage. The warm air flows from the flexible hoses into the area of the passengers’ and the
pilots' foot-wells. The volume of heated air flowing through the cabin heating system is controlled
by the position of the CABIN control lever in the center console.
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Trouble-Shooting
1. General
This table tells you how to trouble-shoot the air conditioning distribution system. Refer to Section 21-40
for trouble-shooting data for the air heating system and see Section 21-60 for trouble-shooting data
for the temperature control system.
If you find the trouble in column 1 do the repair given in column 3.
No air flows from the cabin Fresh air outlets closed. Open the fresh air outlets.
fresh air outlets. Section 21-20 Paragraph 2A.
NACA air inlet duct blocked. Make sure the inlet duct is not
blocked.
Flexible hose(s) between the Examine the flexible hoses,

air inlet ducts and the fresh air repair or replace the hoses as
inlet blocked or damaged. required.
No warm air flows through the The DEFROST control lever in Make sure that the DEFROST
cockpit defrosting system the cockpit center console set control lever (left lever) is set to
outlets. to OFF. ON.
Left engine heater valve Adjust the left engine heater

control cable(s) out of valve control cable(s).
adjustment.
Left engine heater valve Replace the left engine heater

control cable(s) broken. valve control cable(s).
Flexible hose(s) between the Examine the flexible hoses,

left engine heater control valve repair or replace the hoses as
and the de-frosting ducts required.
damaged or broken.
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No warm air flows through the The CABIN lever in the cockpit Make sure that the CABIN
cockpit heating system outlets. center console set to OFF. control lever (right lever) is set
to ON.
The right engine heater valve Adjust the right engine heater
control cable(s) out of valve control cable(s). Refer to
adjustment. Section 21-20.
Right engine heater valve Replace the right engine

forward/aft control cable(s) heater valve forward/aft control
broken. cable(s). Refer to Section
21-20.
Flexible hose(s) between the

right engine heater control Examine the flexible hoses,
valve and the fuselage repair or replace the hoses as
damaged or broken. required.
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1. General
This Section tells you how to replace a heater valve control cable. It also tells you how to adjust a
heater valve. Refer to Section 21-60 for more data about engine heater valves.
2. Replace a Heater Control Valve Forward Inner Control Cable
Use these procedures for both the left and right heater valves.
A. Replace a Heater Control Valve Forward Inner Control Cable

IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
TURNS IT CAN CAUSE INJURY TO PERSONS.
(1) Make sure that the related engine is safe:
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to 0%.
(2) Remove the engine cowlings from the related Refer to Section 71-10.
engine.
(3) Remove the pilot’s/co-pilot’s seat as necessary. Pilot’s seat for DEFROST cables,
co-pilot’s seat for CABIN cables.
(4) Disconnect the forward cable at the relay lever: Refer to Figures 4 and 5.
S Loosen the screw that attaches the swivel

fitting to the control lever and cable.
S Pull the cable clear of the swivel fitting.
S Move the swivel fitting clear of the relay Retain the swivel fitting.
lever.
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Figure 4: LH Heater Valve Control Cables
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(5) Remove the cover plate from the CABIN and

DEFROST control levers in the center console:
S Remove the 4 screws that attach the

cover plate to the center console.
S Slide the cover plate clear of the control

levers.
(6) Disconnect the control cable from the related

control lever:
S Move the related control lever to the OFF For access.

position.

fitting to the control lever.
(7) Move the broken control cable clear of the cable Remove and retain the swivel fitting
outer sheath. from the broken cable.
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Figure 5: RH Heater Valve Control Cables
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(8) Install the new inner control cable:
S Move the new cable into position in the From the cockpit control lever.
outer sheath.
S Connect the control cable to the related

heater valve flap lever:
S Make sure that the heater valve is in the

fully closed/bypass position.
S Move the swivel fitting into position in the

flap lever.
S Pass the cable through the swivel fitting.
S Tighten the swivel fitting screw.
S Connect the control cable to the relay lever

under the pilot’s/co-pilot’s seat:
S Move the control lever to a position 3 mm

(0.1 in) clear of the OFF position.

relay lever.
S Pass the control cable through the swivel

fitting.
(9) Do a test for the correct operation of the related Refer to Paragraph 4.
heater valve. If necessary, adjust the heater
valve cable.
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(10) Install the DEFROST/CABIN control-lever cover

at the center console:
S Move the cover into position at the center

console.
S Install the 4 screws that attach the cover to

the center console.
S Tighten the 4 screws.
S Make sure that both control levers move

freely through the full range of movement.
(11) Install the engine cowlings that you removed in Refer to Section 71-10. Make sure that
step 2. there is no servicing equipment left in
the engine nacelle.
(12) Install the pilot’s/co-pilot’s seat that you Refer to Section 25-10.
removed.
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B. Replace a Heater Control Valve Aft Cable

INJURY TO PERSONS.
engine.
co-pilot’s seat for CABIN cables. Refer
to Section 25-10.
(4) Disconnect the aft cable at the relay lever: Figures 4 and 5.

fitting to the control lever and cable.
lever.
(5) Disconnect the cable at the heater valve Figures 4 and 5.

operating lever:

fitting to the operating lever and cable.
lever.
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S Move the new cable into position in the From the relay lever.
outer sheath.



flap lever.

S Move the control lever at the center

console to a position 3 mm (0.1 in) clear of
the OFF position.

relay lever.

fitting.
valve cable.
(8) Install the engine cowlings that you removed. Refer to Section 71-10.
(9) Install the pilot’s/co-pilot’s seat as necessary. Refer to Section 25-10.
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3. Replace a Heater Control Valve Control Cable (if MÄM 42-739 is installed)
A. Replace a Heater Control Valve Control Cable

INJURY TO PERSONS.
engine.
co-pilot’s seat for CABIN cables.
(4) Disconnect the cable at the heater valve Refer to Figures 6 and 7.
operating lever:

fitting to the operating lever and cable.
S Pull the cable clear of the swivel fitting. Retain the swivel fitting.
S Move the swivel fitting clear of the operating

lever.
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(5) Remove the cover plate from the CABIN and

DEFROST control levers in the center console:
S Remove the 4 screws that attach the

cover plate to the center console.
S Slide the cover plate clear of the control

levers.
(6) Disconnect the control cable from the related

control lever:
S Move the related control lever to the OFF For access.

position.

fitting to the control lever.
(7) Move the broken control cable clear of the cable Remove and retain the swivel fitting
outer sheath. from the broken cable.
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S Move the new cable into position in the From the cockpit control lever.
outer sheath.



flap lever.

S Move the control lever to a position 3 mm

(0.1 in) clear of the OFF position.

relay lever.

fitting.
valve cable.
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(10) Install the DEFROST/CABIN control-lever cover

at the center console:
S Move the cover into position at the center

console.

the center console.
S Tighten the 4 screws.
S Make sure that both control levers move

freely through the full range of movement.
the engine nacelle.
(12) Install the pilot’s/co-pilot’s seat that you Refer to Section 25-10.
removed.
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Control Levers
in Center Console
Defrost
Lever, LH
Defrost Lever
Swivel Fitting
Bowden Cable, LH
Locking Nuts
LH Defrost Valve
(in Engine Nacelle)
Typical Swivel Fitting Detail
Swivel
Fitting
Figure 6: LH Heater Valve Control Cables (if MÄM 42-739 is installed)
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Bowden Cable, RH
RH Heater Valve
(in Engine Nacelle)
Locking Nuts
Swivel Fitting
Control Levers Typical Swivel Fitting Detail

in Center Console
Heater
Lever, RH
Heater Lever
Swivel Fitting
Figure 7: RH Heater Valve Control Cables (if MÄM 42-739 is installed)
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4. Test/Adjust a Heater Valve Control Cable

INJURY TO PERSONS.
(2) Remove the engine cowlings for the heater Refer to Section 71-10.
valve control cable that you will test/adjust.
(3) Test the operation of the heater valve: There must be ‘bounce’ of about 3 mm
(0.1 in) between the bottom of the lever
and the cockpit stop.
S Set the related control lever in the cockpit to
the OFF position.
S Make sure that the flap of the heater valve

fully closes off the outlet from the heater
valve to the engine firewall.
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(4) If necessary, adjust the control cable in the

swivel fitting to give the correct bounce:
S Set the related heater valve control lever to

ON.
S Loosen the screw in the swivel fitting and

move the flap a small distance towards the
closed/bypass position.
S Tighten the screw in the swivel fitting.
(5) Repeat steps 3 and 4 as necessary to get the It may also be necessary to adjust the
correct adjustment. cables at the relay lever under the
pilot’s/co-pilot’s seats.
the engine nacelle.
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Section 21-40
Heating
1. General
The DA 42 NG has separate heating supplies for the windscreen defrosting and the cabin heating
systems. The left engine supplies warm air for the defrost system. The right engine supplies warm air
for the cabin heating system. This Section tells you about the engine heat exchangers. Refer to
Section 21-20 for data about the air distribution systems and Section 21-60 for data about the
temperature control systems.
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Figure 1: Heating System
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The heated air from the left engine is used for windscreen defrosting and the heated air from the right
engine is used for cabin heating. Both the left and right engine air heating systems are similar. The left
engine system is used in this description.
With the engine running, or when the airplane is in flight, ambient air is forced into a duct on the lower
right side of the engine cowling. The duct connects to a carbon fiber composite (CFC) shroud which
houses a heat exchanger. Hot coolant from the engine liquid cooling system flows through the core
of the heat exchanger. The coolant is taken from upstream of the engine cooling system thermostatic
valve. The temperature of the ambient air is raised as it flows through the matrix of the heat exchanger.
A flexible hose connects the outlet of the CFC shroud to the heater valve.
The heater valve is mounted on the engine firewall and has one air inlet and two air outlets. An internal
flap divides the air flow from the inlet between the two outlets. In the OFF or bypass position, the flap
covers the outlet to the airplane heating system and provides the firewall seal. In the this position all
the air from the heat exchanger is vented into the engine nacelle and then overboard with the normal
flow of air through the engine nacelle. As the flap moves from the OFF or bypass position some air can
flow through the heater valve into the airplane heating system. When the flap is in the fully ON or open
position the flap seals the outlet into the engine nacelle and all the air flows into the airplane heating
system.
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Trouble-Shooting
1. General
This table tells you how to trouble-shoot the air conditioning heating system. Refer to Section 21-20
for trouble-shooting data for the air distribution system and see Section 21-60 for trouble-shooting data
for the temperature control system.
The air flowing through the The left engine is not at normal Allow the engine to warm-up to
windscreen defrosting vents is running temperature. normal operating temperature.
cold or not warm enough.
Air trapped in the left engine Bleed the heat exchanger and
heat exchanger or heat heat exchanger supply system.
exchanger coolant supply.
Left engine heat exchanger Replace the heat exchanger.

matrix blocked or damaged.
The air flowing through the The right engine is not at Allow the engine to warm-up to
cabin heating vents is cold or normal running temperature. normal operating temperature.
not warm enough.
Air trapped in the right engine Bleed the heat exchanger and
heat exchanger or heat heat exchanger supply system.
exchanger coolant supply.
Right engine heat exchanger Replace the heat exchanger.

matrix blocked or damaged.
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1. General
The Maintenance Practices in this Section tell you how to replace a heat exchanger and how to bleed
the heat exchanger coolant system. Refer to Section 75-00 for more data about the engine liquid
cooling system.
2. Remove/Install a Heat Exchanger Assembly
Use this procedure for both the left engine and right engine heat exchanger assembly.
A. Remove a Heat Exchanger Assembly

INJURY TO PERSONS.
(3) Remove the engine cowlings from the engine Refer to Section 71-10.
that you will remove the heat exchanger.
WARNING: IF THE COOLANT SYSTEM IS HOT IT MAY BE PRESSURIZED. IF

YOU BREAK INTO A PRESSURIZED SYSTEM YOU MAY SPILL HOT
COOLANT. HOT COOLANT CAN CAUSE INJURY TO PERSONS.
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Airbox
Bolt
Washer
Bolt
Washer
Washer
Bolt
Engine Mounting Frame
Figure 2: Heat Exchanger Installation 1
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Part of Engine
Part of Engine
Worm Drive Clamps

Worm Drive
Clamps Engine Mounting Frame
Water Hose Nut

Water Hose Washer
P-Clamp
Airbox Washer
Worm Drive
Clamps P-Clamp
Bolt
Heater Radiator
Worm Drive Clamps
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(4) Relieve any over pressure from the coolant

system:
S Turn the cap of the coolant tank a small Refer to Section 75-00.
distance to release the pressure.
S When the pressure has fully released, close

the cap again tightly.
(5) Remove the flexible hose that connects the heat Refer to Figure 3.
exchanger outlet to the heater valve:
S Remove the worm drive clamp.
S Remove the flexible hose.
(6) Remove the flexible hoses that connect the heat Make sure that the system is not
exchanger to the engine cooling system: pressurized.
S Remove the worm drive clamp from the heat At the heat exchanger.
exchanger coolant supply connection.
S Remove the worm drive clamp from the heat At the heat exchange.
exchanger coolant return connection.
S Remove both the flexible hoses from the Use a suitable container to catch spilt
heat exchanger. coolant.
(7) Remove the heat exchanger and shroud

assembly from the airplane:
S Remove the nuts, washers and bolts that

attach the heat exchanger assembly to the
mounting bracket.
S Move the heat exchanger assembly clear of

the airplane and drain the contents of the
heat exchanger into a suitable container.
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B. Install a Heat Exchanger Assembly
(1) If necessary, remove the shroud from the heat

exchanger that you removed and install it on to
the heat exchanger that you will install:

attach the shroud to the heat exchanger.
S Move the shroud clear of the heat

exchanger.
S Move the heat exchanger shroud into

position onto the heat exchanger that you
will install.
S Install the bolts, washers and nuts that

attach the heat exchanger shroud to the
heat exchanger.
(2) Install the heat exchanger assembly:
S Move the heat exchanger assembly into

position in the engine mount.

attach the heat exchanger assembly to the
mounting bracket.
S Tighten the bolts.
(3) Install the flexible hoses that connect the

coolant supply and return to the heat
exchanger:
S Move the supply hose into position on the Make sure that the hose is located
heat exchanger supply pipe. correctly.
S Move the return hose into position on the Make sure that the hose is located
heat exchanger return pipe. correctly.
S Install the worm drive clamps onto the hoses

and tighten the clamps.
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(4) Install the flexible hose that connects the heat

exchanger outlet to the heater valve:
S Move the flexible hose into position at the Make sure that the hose is correctly
connector on the heat exchanger shroud. located on the outlet.
S Install the worm drive clamp and tighten the

worm drive clamp.
(5) Replenish the coolant supply and then bleed the Refer to Chapter 75-00.
engine liquid cooling system.
(6) Install the engine cowlings that you removed in Refer to Section 71-10.
Paragraph 1A, step 2.
(7) Do an engine ground test of the related engine Refer to the DA 42 NG Airplane Flight
and make sure that: Manual.
S The cooling system operates correctly.
S That there are no leaks.
(8) If necessary, replenish the liquid cooling Refer to Section 12-10.

system.
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Section 21-50
Cooling (OÄM 42-193/c or earlier installed)
1. General
If OÄM 42-193/c or earlier is installed, a recirculating air - cabin cooling (RACC) system is installed.
The RACC system is an independent subsystem of the airplane and is electrically powered. It consists
of the central unit (installed aft of baggage compartment) and a control panel (in the cabin, LH
sidewall).
2. Description
A. Central Unit
The central unit operates with a refrigerant R134a vapor cycle cooling circuit. The system requires
electrical power (28 V DC, max. 65 A) for operation, which is provided by an additional alternator.
The central unit is subdivided into the following components:
) Compressor assembly (part of refrigerant circuit).
) Condenser assembly (part of refrigerant circuit).
) Evaporator assembly (part of refrigerant circuit).
) Condenser fan.
) Evaporator radial fan.
) Cabin radial fan.
) Electrical control system.
Refer to Figure 1 for a system schematic of the RACC system.
Note: The refrigerant vapor cooling system is a hermetically sealed and

pressurized circuit and contains the refrigerant R134a.
WARNING: ALL MAINTENANCE AND REPLENISHMENT WHICH REQUIRES TO

OPEN AND DEPRESSURIZE THE REFRIGERANT CIRCUIT MUST BE
CARRIED OUT BY AUTHORIZED PERSONNEL ACCORDING TO
NATIONAL AND INTERNATIONAL REGULATIONS FOR REFRIGERANT
SYSTEMS.
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Figure 1: RACC System Schematic
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B. Control Panel
The control panel is situated on the LH sidewall in the cabin. It is electrically connected to the
RACC controller and provides all necessary elements to control the center unit. An integrated
display shows the preset air temperature.
Refer to Figure 2 for details about the RACC control panel.
Figure 2: RACC Control Panel
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3. Operation
If electrical power is provided to the RACC system, the blue LED on the control panel flashes.
The control panel of the RACC system on the LH sidewall allows the crew to control the fan speed and
the cabin temperature. A two digit display shows the preset cabin air temperature in °F. A push-button
is used to set the RACC system to ON (if the RACC system is already running, the display is
illuminated if the push-button is pressed) and set to OFF (if pressed and held for approximately one
second).
During power-up the software version of the control panel is displayed.
The central unit is located aft of the baggage compartment. The RACC controller is located on top of
the central unit and controls the refrigerant circuit valves and the compressor with respect to the
control panel settings. With the control panel set to ON and a temperature preset lower than the
current cabin air temperature, the refrigerant cooling circuit is activated. An electrically powered
compressor takes the low-pressure low-temperature refrigerant gas and compresses it to a high-
temperature gas. A pressure switch on the compressor assembly regulates the compressor discharge
pressure. The hot refrigerant gas is cooled down in the condenser and condenses to a high pressure
liquid. An axial condenser fan forces outside air through the condenser coils and vents the thus heated
air overboard. The filter / drier / collector bottle removes moisture from the refrigerant and stores the
refrigerant. The expansion valve controls the amount of refrigerant liquid flowing to the evaporator. The
refrigerant boils in the evaporator and turns back into a low-pressure low-temperature gas while
cooling the coils of the evaporator. Two radial cabin fans force cabin air through the cooling coils and
thus remove heat from the cabin air. The cool cabin air cannot hold the moisture and water
condensates on the evaporator cooling coils. The condensate is collected under the evaporator and
is drained overboard. The refrigerant gas returns to the compressor.
A cooling fan vents air through the RH air outlet on top of the fuselage and ensures ventilation of the
rear fuselage.
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Trouble Shooting
1. General
The table below lists the defects you could have with the control panel in the center console. If you
have the trouble detailed in the Trouble column read across to the Possible Cause column. Then do
the repair given in the Repair column.


SYSTEMS.
Blue LED on control panel RACC circuit breaker open. Set.

does not illuminate.
Additional alternator defective. Check RACC power supply of
the airplane.
Central unit does not power Control panel defective. Replace.

up.
Electrical control unit defective. Replace.
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Insufficient cooling. Air inlet filter contaminated. Clean or replace filter.
Electrical power source Check ground power source

insufficient. respective RACC power supply
of airplane.
Hot air outlet on LH fuselage Remove blockage.

blocked.
Leak in refrigerant circuit. Perform a leak test.
Repair leak.
Charge the system.
Condenser faulty. Check condenser coils for dirt

accumulation and remove dirt.
Expansion valve faulty. Replace expansion valve.
Compressor faulty. Replace compressor.
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1. Remove/ Install the Central Unit
If OÄM 42-324 is installed:
WARNING: WHEN REMOVING A SEAT FROM THE AIRCRAFT, VERIFY THAT THE
AMSAFE SEATBELT AIRBAG SYSTEM RESTRAINT IS NOT BUCKLED
AND DISCONNECT CABLE INTERFACE ASSY. FROM THE END-
RELEASE BUCKLE ASSEMBLY CONNECTOR BEFORE REMOVAL OF
THE SEAT. AN ELECTRICALLY CONNECTED AMSAFE SEATBELT
AIRBAG RESTRAINT SYSTEM AND BUCKLED SEAT BELT MAY
RESULT IN DAMAGE TO THE EQUIPMENT OR DEPLOYMENT OF THE
SYSTEM. REFER TO AMSAFE MAINTENANCE DOCUMENTATION.
A. Remove the Central Unit
(1) Remove the passenger seats. Refer to Section 25-10.
% (2) If OÄM 42-324 is NOT installed OR OÄM 42-334 Refer to 25-10.

% is installed:
%
% Remove the seatbelt pulleys of the passenger
% seats.
% If OÄM 42-324 is installed AND OÄM 42-334 is

% NOT installed:
% Refer to AmSafe Maintenance Documentation.
(3) Unplug the electrical connection of the cabin fan:
S Open the baggage tray.
S Unplug the electrical connector on the rear

wall of the short baggage extension.
(4) Remove the short baggage extension. Refer to Section 25-10.
(5) Remove the air ducts from the RACC central unit.
(6) Remove the metal air duct tube from the LH air
outlet.
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(7) Unplug the electrical connections from the RACC

central unit to:
S 3 connectors at the RACC central unit.
S 3 heavy cables (under the passenger seats

and at the lightning protection system).
(8) Remove the four bolts which connect the

mounting panel of the RACC central unit to the
mounting panel supports.
(9) Slide the RACC central unit forward.
(10) Lift the RACC central unit clear of the airplane.
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Figure 3: RACC Central Unit Installation
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B. Install the Central Unit
(1) Lift the RACC central unit into the airplane.
(2) Slide the RACC central unit backward. Make sure

to position the mounting panel on the mounting
panel supports in the fuselage.
(3) Install the 4 screws which connect the mounting

panel of the RACC central unit to the mounting
panel supports.
(4) Connect the RACC central unit electrically to:
S 3 electrical connectors of the RACC unit.
S 3 heavy cables (under the passenger seats Verify correct connection.

and at the lightning protection system). Refer to Section 92-00.
(5) Install the metal air duct tube to the RH air outlet.
(6) Install the air ducts on the RACC central unit.
(7) Install the short baggage extension. Refer to Section 25-10.
(8) Connect the cabin fan electrically:
S Open the baggage tray.
S Plug in the electrical connector on the rear

wall of the short baggage extension.
% (9) If OÄM 42-324 is NOT installed OR OÄM 42-334 Refer to Section 25-10.
% is installed:
%
% Install the seatbelt pulleys of the passenger
% seats.

% NOT installed:
(10) Install the passenger seats. Refer to Section 25-10.
(11) Perform a cooling test of the RACC system.
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Figure 4: Central Unit - Front and LH Side
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Figure 5: Central Unit - Back and RH Side
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2. Remove/Install the Control Panel
A. Remove the Control Panel
(1) Remove the console from the LH sidewall. Refer to Section 25-10.
(2) Unplug the electrical connectors of the control

panel.
(3) Unclip the RACC control panel from the LH

sidewall.
B. Install the Control Panel
(1) Move the RACC control panel in position on the

console on the LH sidewall.
(2) Push the control panel into the console until the
clips hold the panel in place on the console.
(3) Connect the electrical connectors to the control

panel.
(4) Install the console. Refer to Section 25-10.
(5) Perform a RACC - System Test. Refer to Paragraph 3.
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3. RACC - System Test Procedure
(1) Perform an engine ground test. Refer to Section 71-00.
(2) Set the LH engine to idle power

(700 - 800 RPM).
(3) Set the AUX POWER switch to ON. The blue LED on the RACC control
panel must flash.
(4) Push the ON/OFF button on the RACC control The preset temperature display on the
panel once to switch the RACC system ON. RACC control panel must illuminate.
(5) Push the Preset Temperature DOWN button

until the preset temperature shows ‘LO’.
(6) Verify that the cabin outlet air temperature is

significantly lower than the cabin air temperature.
(7) Set the cabin air preset temperature to a Use the preset temperature UP and
convenient temperature level. DOWN buttons on the control panel.
(8) Push the ON/OFF button on the RACC control

panel for approximately 1 second to switch the
RACC system to OFF.
(9) Set the AUX POWER switch to OFF.
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4. Remove/Install Parts of the Refrigerant Circuit


SYSTEMS.
Before you do any maintenance on parts of the refrigerant circuit you must remove the central unit from
the airplane. Refer to Paragraph 1.
Make sure to obey the regulations for handling the refrigerant.
A. Discharge/Charge the Refrigerant Circuit
(1) Equipment
One of the following automated discharge and charging stations or equivalent must be used:
Silco CS 199. 1 Commercial.
(2) Discharge the Refrigerant Circuit
(1) Remove the central unit from the airplane. Refer to Paragraph 1.
(2) Connect the RACC system to the discharge / Follow the instructions of the
charging station. discharge/charging station.
(3) Discharge the refrigerant. Follow the instructions of the

discharge/charging station.
(4) Print the protocol of the discharge/charging station Follow the instructions of the
and add it to the RACC system documentation. discharge/charging station.
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(3) Charge the Refrigerant Circuit
(1) Make sure that all connectors of the refrigerant

circuit are tight.
(2) Charge the refrigerant circuit: Follow the instructions of the

S Use R 134a: 0.45 kg (0.99 lb).
S Use Reniso Triton Oil: SE 55, 0.019 liter

(0.02 quart).
(3) Print the protocol of the discharge/charging Follow the instructions of the
station and add it to the RACC system discharge/charging station.
documentation.
(4) Disconnect the RACC system from the Follow the instructions of the
discharge/charging station. discharge/charging station.
(5) Install the RACC central unit in the airplane. Refer to Paragraph 1.
(6) Perform a RACC system test. Refer to Paragraph 3.
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B. Remove/Install the Compressor
(1) Remove the Compressor
(1) Discharge the refrigerant circuit. Refer to Paragraph 4A (2).
(2) Unplug the electrical connectors from the

compressor.
(3) Loosen the hose connections of the refrigerant Use caps to plug the hose connectors.
circuit on the compressor.
(4) Remove the three screws which attach the

compressor to the RACC mounting panel.
(5) Move the compressor clear of the central unit.
(2) Install the Compressor
(1) Position the compressor on the RACC mounting

panel.
(2) Use the three screws to attach the compressor to

the RACC mounting panel.
(3) Connect the refrigerant circuit hoses to the Remove the caps from the hose
compressor. connectors. Use new O-rings.
(4) Connect the electrical connectors to the

compressor.
(5) Charge the refrigerant circuit. Refer to Paragraph 4A (3).
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C. Remove/Install the Filter/Drier Assembly
(1) Remove the Filter/Drier Assembly
(2) Remove the electrical connectors from the

pressure sensor.
circuit on the filter/drier assembly.
(4) Remove the two screws which attach the

filter/drier assembly to the central unit.
(5) Move the filter/drier assembly clear of the central

unit.
(2) Install the Filter/Drier Assembly
(1) Position the filter/drier assembly on the RACC

mounting panel.
(2) Use the two screws to attach the filter/drier

assembly to the central unit.
filter/drier assembly. connectors. Use new O-rings.
(4) Connect the electrical connectors to the pressure

sensor.
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D. Remove/Install the Expansion Valve
(1) Remove the Expansion Valve
circuit to the expansion valve.
(3) Open the pressure line fittings which connect the

expansion valve to the evaporator.
(4) Move the expansion valve clear of the central unit.
(2) Install the Expansion Valve
(1) Position the expansion valve on the central unit.
(2) Attach the expansion valve to the evaporator with Use new O-rings.
the pressure line fittings.
expansion valve. connectors.
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Section 21-51
Cooling (OÄM 42-193/d or later installed)
1. General
If OÄM 42-193/d or later is installed, an improved recirculating air - cabin cooling (RACC) system is
installed. The RACC system is an independent subsystem of the airplane and is electrically powered.
It consists of the central unit (installed aft of baggage compartment) and a control panel (in the cabin,
center console).
2. Description
A. Central Unit
The central unit operates with a refrigerant R134a vapor cycle cooling circuit. The system requires
electrical power (28 V DC, max. 65 A) for operation, which is provided by an additional alternator.
The central unit is subdivided into the following components:
) Compressor assembly (part of refrigerant circuit).
) Condenser assembly (part of refrigerant circuit).
) Evaporator assembly (part of refrigerant circuit).
) Condenser radial fan.
) Evaporator radial fan.
) Electrical control system.
Refer to Figure 1 for a system schematic of the RACC system.
Note: The refrigerant vapor cooling system is a hermetically sealed and pressurized
circuit and contains the refrigerant R134a.

SYSTEMS.
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AIRPLANE
CABIN
Evaporator Fan
(Radial)
Vents (x6)
Compressor Cold Air

Evaporator Duct
Compartment
Deventilation
via Tail Spar
Condenser
Expansion Valve
Receiver/Drier
Condenser Fan
(Radial)
Compartment Exhaust
Ventilation (1 x Ø150mm) Refrigerant Circuit
(1 x Ø100mm)
Air Flow
Figure 1: RACC System Schematic (OÄM 42-193/d or later is installed)
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B. Control Panel
The control panel is situated on the center console in the cabin. It is electrically connected to the
RACC controller and provides all necessary elements to control the center unit. An integrated
display shows the preset air temperature.
Refer to Figure 2 for details about the RACC control panel.
Cabin Cabin Temperature

Temperature UP
ON/OFF
Cabin Fan
Speed UP
Fresh
Air LED
Cabin Fan Power Status Cabin Temperature

Speed DOWN LED DOWN
Figure 2: RACC Control Panel (if OÄM 42-193/d or later is installed)
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3. Operation
If electrical power is provided to the RACC system, the power status LED on the control panel flashes.
The control panel of the RACC system in the center console allows the crew to control the fan speed
and the cabin temperature. A two digit display shows the preset cabin air temperature in °C.
A push-button is used to set the RACC system to ON (if short depressed; display is illuminated) and
OFF (if pressed and held for approximately one second).
During power-up the software version of the control panel is displayed.
The central unit is located aft of the baggage compartment. The RACC controller is located below the
condenser unit and controls the refrigerant circuit valves and the compressor with respect to the
control panel settings. With the control panel set to ON and a temperature preset lower than the
current cabin air temperature, the refrigerant cooling circuit is activated. An electrically powered
compressor takes the low-pressure low-temperature refrigerant gas and compresses it to a high-
temperature gas. A pressure switch on the compressor assembly regulates the compressor discharge
pressure. The hot refrigerant gas is cooled down in the condenser and condenses to a high pressure
liquid. A radial condenser fan forces outside air through the condenser coils and vents the thus heated
air overboard. The drier / receiver bottle separates moisture from liquid and filters contaminations from
refrigerant. The expansion valve controls the amount of refrigerant liquid flowing to the evaporator. The
refrigerant boils in the evaporator and turns back into a low-pressure low-temperature gas while
cooling the coils of the evaporator. A radial evaporator fan forces cabin air through the cooling coils
and thus remove heat from the cabin air. The cool cabin air cannot hold the moisture and water
condensates on the evaporator cooling coils. The condensate is collected under the evaporator and
is drained overboard. The refrigerant gas returns to the compressor.
An inlet including a drip tray and an air filter enables ambient air to enter the RACC compartment
ensuring sufficient compartment ventilation.
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Trouble Shooting
1. General
The Power Status LED on RACC circuit breaker open. Set.

control panel does not
illuminate. Additional alternator defective. Check RACC power supply of
the airplane.
Central unit does not power Control panel defective. Replace.

up.
Electrical control unit defective. Replace.
Insufficient cooling. Hot air outlet on fuselage Remove blockage.

bottom blocked.
Leak in refrigerant circuit. Perform a leak test.

Repair leak.
Charge the system.
Condenser faulty. Check condenser coils for dirt

accumulation and remove dirt.
Expansion valve faulty. Replace expansion valve.
Compressor faulty. Replace compressor.
Electrical power source Check ground power source

insufficient. respective RACC power supply
of airplane.
Filter/dryer assembly Replace filter/dryer assembly

inoperative.
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1. Remove/ Install the Central Unit
A. Remove the Central Unit
% is installed:
%
% Remove the seatbelt pulleys of the passenger
% seats.

% NOT installed:
(3) Remove the short baggage extension. Refer to Section 25-10.
(4) Remove the flexible air hoses from the RACC

central unit:
S Flexible cold air hose.
S Flexible hot air hose.
(5) Remove the hot exhaust air duct from the RACC
central unit.
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(6) Unplug the electrical connections from the RACC

central unit to:
S 2 heavy connectors at the RACC central unit

terminal board (LH).
S 1 plug coming from the RACC control panel.
(7) Remove the drain hoses from the RACC central

unit:
S Drip tray drain hose.
S Evaporator drain hose.
(8) Remove the drip tray.
(9) Remove the four bolts which connect the base

plate of the RACC central unit to the RACC
brackets on the LH and RH side of airplane.
(10) Slide the RACC central unit forward.
(11) Lift the RACC central unit clear of the airplane.
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RACC Compartment Ventilation Inlet

(Drip Tray incl. Filter behind)
Overhead Cold Air Duct Flexible Cold Air Hose
C-Profile
RACC Central Unit
Drain Hoses
Hot Exhaust Air Duct
Hot Exhaust Air Outlet
Flexible Hot Air Hose
Figure 3: RACC Central Unit Installation (if OÄM 42-193/d or later is installed)
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B. Install the Central Unit
(1) Lift the RACC central unit into the airplane.
(2) Slide the RACC central unit backward. Make sure

to position the baseplate of the RACC central unit
above the RACC brackets and trailing edge of
the baseplate inside the C-profile.
(3) Install four bolts which connect the baseplate of

the RACC central unit to the RACC brackets on
LH and RH side of airplane.
(4) Install the drip tray.
(5) Install the drain hoses to the RACC central unit:
S Drip tray drain hose.
S Evaporator drain hose.
(6) Connect the electric cables to the RACC central

unit to:
S 2 heavy connectors of the RACC central unit

terminal board (LH).
S 1 plug coming from control panel.
(7) Install the hot exhaust air duct to the RACC

central unit.
(8) Install the flexible air hoses to the RACC central

unit:
S Flexible cold air hose.
S Flexible hot air hose.
(9) Install the short baggage extension. Refer to Section 25-10.
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% is installed:
% Install the seatbelt pulleys of the passenger

% seats.

% NOT installed:
% Refer to AmSafe Maintenance Documentation
(12) Perform a cooling test of the RACC system.
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Cabin Cold Air Out

Condenser
Evaporator
Evaporator Fan
Condenser Fan
Electric Fan with

Control Box behind
Figure 4: Central Unit - Front and LH Side (if OÄM 42-193/d or later is installed)
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Expansion Valve
Evaporator Cover
Drier / Receiver Bottle
Compressor
Figure 5: Central Unit Back and RH Side (if OÄM 42-193/d or later is installed)
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2. Remove/Install the Control Panel
A. Remove the Control Panel
(1) Remove the center console. Refer to Section 25-10.
(2) Unplug the electrical connectors of the control

panel.
(3) Unclip the RACC control panel from the center

console.
B. Install the Control Panel
(1) Move the RACC control panel in position on the

center console.
(2) Push the center console into the center console

until the clips hold the panel in place on the
center console.
(3) Connect the electrical connectors to the control

panel.
(4) Install the center console. Refer to Section 25-10.
(5) Perform a RACC-system test. Refer to Paragraph 3.
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3. RACC - System Test Procedure
(1) Perform an engine ground test. Refer to Section 71-00.
(2) Set the engine to 1000 to 1200 RPM. The test procedure may be alternatively
performed with power supplied by
engine or GPU.
(3) Set the AUX POWER switch to ON. The Power Status LED on the RACC
control panel must flash.
(4) Push the ON/OFF button on the RACC control The preset temperature display on the
panel once to switch the RACC system ON. RACC control panel must illuminate.
(5) Push the Preset Temperature DOWN button

until the preset temperature shows ‘LO’ and
switch the cabin fan speed to the highest stage
(“3") .
(6) Verify that the cabin air temperature at outlet is

significantly lower than the outside air
temperature. Perform test at ambient
temperature of 20 - 30°C and relative humidity of
20 - 90 %. The cabin air temperature at outlet
must be 8 - 15°C less than the ambient
temperature.
(7) Set the cabin air preset temperature to a Use the preset temperature UP and
convenient temperature level. DOWN buttons on the control panel.
(8) Push the ON/OFF button on the RACC control

panel for approximately 1 second to switch the
RACC system to OFF.
(9) Set the AUX POWER switch to OFF.
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4. Remove/Install Parts of the Refrigerant Circuit
Note: The refrigerant vapor cooling system is a hermetically sealed and pressurized
circuit and contains the refrigerant R134a.

SYSTEMS.
Before you do any maintenance on parts of the refrigerant circuit you must remove the central unit from
the airplane. Refer to Paragraph 1.
Make sure to obey the regulations for handling the refrigerant.
If the refrigerant circuit is open for more than 30 min and the filter /dryer assy is not sealed, Diamond
Aircraft recommends to replace the filter/dryer assy by a new one.
A. Discharge/Charge the Refrigerant Circuit
(1) Equipment
One of the following automated discharge and charging stations or equivalent may be used:
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(2) Discharge the Refrigerant Circuit
(1) Remove the central unit from the airplane. Refer to Paragraph 1.
(2) Connect the RACC system to the Follow the instructions of the
(3) Discharge the refrigerant. Follow the instructions of the

(4) Print the protocol of the discharge/charging station Follow the instructions of the
and add it to the RACC system documentation. discharge/charging station.
(3) Charge the Refrigerant Circuit
(1) Make sure that all connectors of the refrigerant

circuit are tight.
(2) Charge the refrigerant circuit with R134a Follow the instructions of the
(500 g ± 25 g if OÄM 42-193/d and subsequent or discharge/charging station.
450 g ± 25 g if OÄM42-193/c and earlier is
installed) and add 15 ccm ± 5 ccm of oil (type
PVE 68 cSt acc. to ISO 68).
If refrigerant circuit and compressor was
completely discharged add a total of 290 ccm of
oil instead of the amount described above.
(3) Perform a Leakage Test if not automatically Refer to Paragraph 4.

performed by the discharge/charging station.
(4) Print the protocol of the discharge/charging Follow the instructions of the
station and add it to the RACC system discharge/charging station.
documentation.
(5) Disconnect the RACC system from the Follow the instructions of the
(6) Install the RACC central unit in the airplane. Refer to Paragraph 1.
(7) Perform a RACC System test. Refer to Paragraph 3.
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(4) Leakage Test of the Refrigerant Circuit
After every discharge/charge of the refrigerant system it must be checked for leakages.
Most of the charging stations run automatically a leakage check before charging the air
condition system. If the applied service station was equipped with this function, but does not
automatically perform a test, engage manually the check before charging the air condition
system.
If leakage in the air condition system was detected or the air condition unit lost more than
150 g per year of refrigerant, then one of the below described checks must be performed:
(1) Use a detection spray or soapy water at the

suspicious areas and watch for bubbles and
foam.
If a leak is detected, repair the leakage.
To order spare parts contact DAI.
(2) Use an electronic leak detector suitable to detect

the R134a refrigerant with a minimum leakage
detection sensitivity of 5 g per year.
If a leak is detected, repair the leakage.
To order spare parts contact DAI.
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B. Remove/Install the Compressor
(1) Remove the Compressor
(1) Discharge the refrigerant circuit. Refer to Paragraph 4A(2).
(2) Unplug the electrical connectors from the

compressor.
circuit on the compressor.
(4) Remove the three screws which attach the

compressor to the RACC mounting panel.
(5) Move the compressor clear of the central unit.
(2) Install the Compressor
(1) Position the compressor on the RACC mounting

panel.
(2) Use the three screws to attach the compressor to

the RACC mounting panel.
compressor. connectors and replace O-rings of
circuit-hoses.
(4) Connect the electrical connectors to the

compressor.
(5) Charge the refrigerant circuit. Refer to Paragraph 4A(3).
(6) Perform a leakage check. Refer to Paragraph 4A(4).
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C. Remove/Install the Filter/Dryer Assembly
(1) Remove the Filter/Dryer Assembly
(2) Remove the electrical connectors from the

pressure sensor.
circuit on the filler/drier assembly.
(4) Remove the two screws which attach the

filler/drier assembly to the central unit.
(5) Move the filter/drier assembly clear of the central

unit.
(2) Install the Filter/Dryer Assembly
(1) Position the filter/drier assembly on the RACC

mounting panel.
(2) Use the two screws to attach the filter/drier

assembly to the central unit.
filter/drier assembly. connectors and replace O-rings of
circuit-hoses.
(4) Connect the electrical connectors to the pressure

sensor.
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D. Remove/Install Parts of the Refrigerant Circuit
(1) Remove the Expansion Valve
(2) Open latches of evaporator cover and remove

cover.
(3) Remove evaporator from fixing cover.
(4) Loosen the hose connections of the refrigerant Note and mark the correct position of
circuit to the expansion valve and remove refrigerant hoses evaporator fixing plate
associated evaporator fixing plate. on the expansion valve.
(5) Remove two bolts from the expansion valve and Note and mark correct position of the
the second evaporator fixing plate first and then expansion valve.
remove the expansion valve from the evaporator.
(6) Move the expansion valve clear of the central unit.
(2) Install the Expansion Valve
(1) Position the expansion valve on the evaporator. Use new O-rings on evaporator-hoses.
(2) Install the associated expansion valve fixing plate Check for correct position.
with two bolts.
(3) Connect the refrigerant circuit hoses and the Use new O-rings on refrigerant-hoses
second evaporator fixing plate to the expansion and check for correct position.
valve.
(4) Install the evaporator inside fixing cover.
(5) Install the evaporator cover and close the cover

latches.
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Section 21-60
Temperature Control
1. General
The DA 42 NG has separate heating supplies for the windscreen defrosting and the cabin heating
systems. The left engine supplies warm air for the defrost system. The right engine supplies warm air
for the cabin heating system. This Section tells you about the engine heater valves. Refer to Section
21-20 for data about the air distribution systems and Section 21-40 for data about the heating systems.
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Figure 1: Heater Valve Assembly
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The heater valves are similar for the left and the right engine. Figure 1 shows the left engine heater
valve installation. An insulated flexible hose connects the outlet of the heat exchanger to the inlet of
the heater valve.
The heater valve has two outlets. One outlet supplies air to the airplane heating/defrost system. The
other outlet directs the heated air into the engine compartment. An internal flap in the heater valve can
be set to close the outlet to the airplane heating system and allow all the warm air to flow into the
engine nacelle. Or it can be set to close the outlet to the engine nacelle and allow all the heated air to
flow to the airplane heating/defrost system. Or it can be set to any position between these positions
to regulate the flow of air to the airplane heating/defrost systems. The amount of warm air flowing into
the related system controls the operating temperature of the system.
The position of the flap in the heater valve is controlled by a control lever in the cockpit center console.
The DEFROST control lever controls the left engine heater valve and the CABIN control lever controls
the right engine heater valve.
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Trouble-Shooting
1. General
This table tells you how to trouble-shoot the air conditioning temperature control. Refer to Section
21-20 for troubleshooting data for the air distribution system and see Section 21-40 for trouble-
shooting data for the heating system. If you find the trouble in column 1 do the repair given in
column 3.
There is no control of the The related heater valve is Replace the heater valve.
temperature of the DEFROST inoperative.
or CABIN heating systems.
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1. General
The Maintenance Practices in this Section tell you how to replace an engine heater valve.
2. Remove/Install a Heater Valve
Use this procedure for both the left and right heater valve.
A. Remove a Heater Valve

INJURY TO PERSONS.
(2) Remove the engine cowlings from the engine Refer to Section 71-10.
that you will remove the heater valve.
(3) Remove the flexible hose that attaches the

heater valve to the heat exchanger:
S Remove the worm-drive-clamp that holds

the hose to the valve inlet.
S Remove the hose from the valve inlet.
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(4) Disconnect the heater valve control cable from

the heater valve flap lever:
S Loosen the swivel fitting screw.
S Remove the cable from the swivel fitting.
S Remove and retain the swivel fitting from the

flap lever.
(5) Remove the flexible hose that attaches the

heater valve to the airplane system:
S Remove the access panel from the under Refer to Section 52-40.
the rear of the engine nacelle.
S Remove the worm drive clamp that holds

the hose to the valve outlet.
S Remove the hose from the valve outlet.
(6) Remove the heater valve assembly:
S Remove the 2 nuts, washers and bolts that

attach the heater valve to the engine
firewall.
S Move the heater valve clear of the engine

nacelle.
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Figure 2: Heater Valve Installation
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B. Install a Heater Valve Assembly
(1) Move the heater valve assembly into position at

the related engine nacelle.
(2) Install the heater valve assembly:
S Hold the heater valve assembly in position.
S Install the 2 bolts, washers and nuts that

attach the heater valve assembly to the
firewall.
(3) Connect the flexible hose that attaches the

heater valve assembly to the airplane system:
S Move the worm drive clamp into position on

the flexible hose.
S Move the flexible hose into position on the

heater valve assembly.
S Tighten the worm drive clamp.
(4) Connect the heater valve control cable to the

S Move the swivel fitting into position on the

flap lever.
S Move the cable into position through the

swivel fitting.
S Move the related heater valve control lever

to the OFF position and then move it
0.3 mm (0.1 in) towards the ON position.
S Make sure that the heater valve flap is in the The flap must completely seal the heater
closed/bypass position. valve outlet to the airplane system.
S Tighten the screw of the swivel fitting.
(5) Test and if necessary adjust the heater valve Refer to Section 21-20 Paragraph 3.
control cable.
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(6) Install the flexible hose that connects the heater

valve assembly to the heat exchanger:
S Move the worm drive clamp into position on

the flexible hose.
S Connect the flexible hose to the heater valve

assembly inlet.
S Tighten the worm drive clamp.
(7) Install the engine cowlings that you removed at Refer to Section 71-10.
Paragraph 2A, step 2.
(8) Do an engine ground test and do a functional Refer to the DA 42 NG Airplane Flight
test of the related cabin heating/defrost system. Manual.
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CHAPTER 22
AUTO FLIGHT
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TABLE OF CONTENTS
CHAPTER 22
AUTO FLIGHT
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 22-10
Autopilot
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Roll Servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Roll Servo Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Remove/Install the Pitch Servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5. Remove/Install the Pitch Servo Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6. Remove/Install the Pitch Trim Servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
7. Remove/Install the Pitch Trim Servo Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
8. Remove/Install the Yaw Servo and the Yaw Servo Clutch . . . . . . . . . . . . . . . . . 211
9. Adjust the Bridle Cable Tension of the Roll and Pitch Servos . . . . . . . . . . . . . . 216
10. Adjust the Bridle Cable Tension of the Yaw Servo . . . . . . . . . . . . . . . . . . . . . . . 217
11. Adjust/Check the Servo Clutch Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
12. Mechanical Check of the Autopilot System (if OÄM 42-210 (GSM 86 Servo
Mounts) is not installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
13. Mechanical Check of the Autopilot System (if OÄM 42-210 (GSM 86 Servo
Mounts) is installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
14. Slip Clutch Override Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
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CHAPTER 22
AUTO FLIGHT
1. General
This Chapter tells you about the auto flight (autopilot) system that is installed in the DA 42 NG airplane.
This Chapter tells you about the components of the GFC 700 system installed in the airplane. This
Chapter does not tell you about the workshop maintenance of the equipment. For more data about the
equipment you must refer to the equipment manufacturer’s manuals.
Refer to Section 22-10 for more data about the autopilot system installed the DA 42 NG airplane.
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Section 22-10
Autopilot
1. General
This Section tells you about the GFC 700 autopilot system that is installed in the DA 42 NG.
2. Description
The GFC 700 autopilot system is a digital flight control system that provides roll, pitch, pitch trim, and
yaw steering with altitude control. The system has the following components (refer to Figure 1):
) Flight director (integral part of the Garmin G1000 system).
) GSA 81 roll servo.
) GSA 81 pitch servo.
) GSA 81 pitch trim servo.
) GSA 80 yaw servo.
The GFC 700 autopilot system is controlled via the MFD of the Garmin G1000 integrated cockpit
system (ICS).
The GFC 700 roll axis features includes wing leveler, heading select, and VOR/LOC intercept and
tracking. The GFC 700 is also coupled to the ICS for navigation information. Attitude information is
derived from the AHRS.
Pitch axis features include vertical speed, flight level change, glideslope and altitude hold along with
the optional altitude preselect. Pitch information is derived from AHRS and GDC. Internal monitors
keep constant track of the GFC 700's status and provide for automatic shutdown of the autopilot or trim
system in the event of a malfunction.
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%
PFD MFD
% Reversionary
GDU GDU
Switch
% 10XX 10XX
%
% GMU 44
%
%
GRS 7X
%
%
% GDC 7X
%
%
%
%
% GIA 6XW GMA GIA 6XW
1347/1360
%
%
% GSA 81
% Roll Servo
%
GSA 81
%
Pitch Servo
%
% GSA 81
% Pitch Trim Servo
% GSA 80
% Yaw Servo
%
%
% G1000 LRU
%
% Digital Communication
%
Discrete I/O
%
Figure 1: GFC 700 Autopilot Schematic Diagram
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A. GFC 700 Flight Control
For details about operation and the indications concerning GFC 700 functions refer to Garmin
DA 42 NG Pilot's Guide, latest revision.
B. GSA 81 Roll Servo
The roll servo is located behind the rear main bulkhead on the right side. It is mounted on a
mounting plate which is made from sheet aluminum. Two aluminum clamps connect a bridle cable
to the aileron push-rod.
C. GSA 81 Pitch Servo
The pitch servo is located aft of the baggage compartment frame. It is mounted on a mounting plate
which is made from sheet aluminum. Two aluminum clamps connect a bridle cable to the elevator
push-rod.
D. GSA 81 Pitch Trim Servo
The pitch trim servo is located under the co-pilot's seat. It is mounted on a mounting plate which
is made from sheet aluminum and mounting bracket which is made from GFRP. Servo movement
is transmitted to the trim wheel through a chain gear on the servo, a cardan shaft, and a chain gear
next to the trim wheel on the right side.
E. GSA 80 Yaw Servo
The yaw servo is located under the passenger seats. It is mounted on a mounting rack made from
stainless steel and a mounting bracket made from CFRP. A braided cable is connected to the two
turnbuckles of the rudder control cables.
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Figure 2: Roll Servo Installation
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1. General
These Maintenance Practices tell you how to install the components of the autopilot system. They also
tell you how to test and adjust the autopilot system.
2. Remove/Install the Roll Servo
A. Remove the Roll Servo
(2) Disconnect the connector from the servo.
(3) Remove the mounting screws (2 or 4) which Hold the servo.

attach the servo to the clutch.
(4) Remove the servo clear of the airplane.
B. Install the Roll Servo
(1) Put the servo in place on the clutch.
(2) Install the mounting screws (2 or 4) which attach Refer to Figure 2.

the servo to the mounting plate and clutch.
(3) Connect the connector to the servo.
(4) Do a test of the autopilot system:
S Set ELECT. MASTER switch to ON.
S Set AV. MASTER switch to ON.
S Observe self-test of the flight control If no error message appears, then the
computer. system is operative.
S Set AV. MASTER switch to OFF.
S Set ELECT. MASTER switch to OFF.
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3. Remove/Install the Roll Servo Clutch
A. Equipment
Cable tension gauge. 1 Commercial.
B. Remove the Roll Servo Clutch
(1) Remove the roll servo. Refer to Paragraph 2.
(2) Release the clamps which connect the bridle

cable to the aileron push-rod.
(3) Remove the cable guard.
(4) Remove the 4 screws which attach the clutch to Hold the clutch.
the mounting plate.
(5) Remove the clutch clear of the airplane.
C. Install the Roll Servo Clutch
(1) Remove the pilot's seat or the co-pilot's seat. Refer to Section 25-10. To give access
for the rigging pin.
(2) Put the clutch in place on the mounting plate.
(3) Install the 4 screws which attach the clutch to

the mounting plate.
(4) Center the aileron control system with a rigging Refer to Section 27-10.
pin at one control stick.
(5) Center the capstan. The recess for the ball in the middle of
the bridle cable must be in the
uppermost position.
(6) Install bridle cable to capstan. The ball in the middle of the bridle cable
must engage in the recess on the
capstan. Wrap bridle cable around
capstan 1.5 turns to each side.
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(7) Connect the ends of the bridle cable to the Tighten clamps lightly to allow
aileron push-rod with the clamps. adjustment (see next step).
(8) Using a small plastic hammer, move the clamps Adjust tension to 156 ± 9 N (35 ± 2 lbf).
along the push-rod to adjust the bridle cable Measure cable tension with cable tension
tension. gauge.
(9) Tighten the clamps.
(10) Install the cable guard.
(11) Remove the rigging pin from the control stick.
(12) Install the front seat which was removed. Refer to Section 25-10.
(13) Install the roll servo. Refer to Paragraph 2.
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4. Remove/Install the Pitch Servo
A. Remove the Pitch Servo
(1) Remove the trim/cover from the front face of the

baggage compartment and remove the lower
access panel from the baggage compartment
insert.

B. Install the Pitch Servo
(2) Install the mounting screws (2 or 4) which attach

the servo to the clutch.
S Set ELECT. MASTER to OFF.
(5) Install the baggage compartment lower access

panel and install the trim/cover to the front face
of the baggage compartment.
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Figure 3: Pitch Servo Installation
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5. Remove/Install the Pitch Servo Clutch
A. Equipment
B. Remove the Pitch Servo Clutch
(1) Remove the pitch servo. Refer to Paragraph 4.
(2) Release the clamps which connect the bridle

cable to the elevator push-rod.
(3) Remove the cable guard.
(4) Remove the 4 screws which attach the clutch to Hold the clutch.
the mounting plate.
(5) Remove the clutch clear of the airplane.
C. Install the Pitch Servo Clutch
(1) Put the clutch in place on the mounting plate.
(2) Install the 4 screws which attach the clutch to

the mounting plate.
(3) Center the elevator control system with a rigging Refer to Section 27-30.
pin at one control stick.
(4) Center the capstan. The recess for the ball in the middle of
the bridle cable must be in the under
most position.
(5) Install bridle cable to capstan. The ball in the middle of the bridle cable
must engage in the recess on the
capstan. Wrap bridle cable around
capstan 1.5 turns to each side.
(6) Connect the ends of the bridle cable to the Tighten clamps lightly to allow
elevator push-rod with the clamps. adjustment (see next step).
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(7) Using a small plastic hammer, move the clamps Adjust tension to 156 ± 9 N (35 ± 2 lbf).
along the push-rod to adjust the bridle cable Measure cable tension with cable
tension. tension gauge.
(8) Tighten the clamps.
(9) Install the cable guard.
(10) Remove the rigging pin from the control stick.
(11) Install the front seat which was removed. Refer to Section 25-10.
(12) Install the pitch servo. Refer to Paragraph 4.
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Figure 4: Pitch Trim Servo Installation
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6. Remove/Install the Pitch Trim Servo
A. Remove the Pitch Trim Servo
(1) Remove the co-pilot's seat. Refer to Section 25-10.

B. Install the Pitch Trim Servo
(2) Install the mounting screws (2 or 4) which attach

the servo to the clutch.
(5) Install the co-pilot's seat. Refer to Section 25-10.
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7. Remove/Install the Pitch Trim Servo Clutch
A. Remove the Pitch Trim Servo Clutch
CAUTION: DO NOT APPLY STRONG FORCES TO THE CARDAN SHAFT. THE

UPPER CARDAN JOINT CONNECTS TO A PART WHICH IS WEAK
BY DESIGN TO GIVE OCCUPANT PROTECTION IN AN
EMERGENCY LANDING.
(1) Remove the pitch trim servo. Refer to Paragraph 6.
(2) Remove the screws which hold the cap to the

capstan.
(3) Remove the cap from the capstan.
(4) Release chain tension with chain adjuster. On the chain gear next to the servo.
(5) Remove the chain from the chain gear.
(6) Remove the 4 screws which attach the clutch Hold the clutch and the chain adjuster.
and the chain adjuster to the mounting plate.
B. Install the Pitch Trim Servo Clutch
(1) Put the clutch and the chain adjuster in place on

the mounting plate.
(2) Install the 4 screws which attach the clutch and

the chain adjuster to the mounting plate.
(3) Install the chain to the chain gear.
(4) Put the cap in place on the capstan.
(5) Install the screws which hold the cap to the

capstan.
(6) Install the pitch trim servo. Refer to Paragraph 6.
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8. Remove/Install the Yaw Servo and the Yaw Servo Clutch
A. Equipment
B. Remove the Yaw Servo and the Yaw Servo Clutch
(3) Remove 4 screws which attach the rudder cable

support.
(4) Remove 7 screws which attach the yaw servo Hold the assembly.
mounting cradle to the airplane.
(5) Remove the bridle cable.
(6) Remove the yaw servo, the yaw servo clutch

and the mounting cradle from the airplane.
(7) Remove the 4 screws witch attach the servo to Hold the clutch, servo and cradle.
the clutch and the mounting cradle.
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Figure 5: Yaw Servo Installation
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C. Install the Yaw Servo, the Yaw Servo Clutch and Bridle Cable
(1) Adjust/check the servo clutch torques. Refer to Paragraph 11.
(2) Install the GM 85/86 servo mount and GSA 80

servo into the yaw damper frame assy with
8 screws.
(3) Install the yaw damper cable onto the capstan. Refer to Figure 6.
(4) Temporarily fix the cable on the servo frame

with tape.
(5) Install the cable guard kit (GSM 85 only) or the

capstan standoff kit (GSM 85 and GSM 86)
onto the servo mount and secure with
Loctite 243 or equivalent.
(6) Install the yaw damper tension plate on the

yaw damper frame.
(7) Put the rudder cable support in place (if

installed).
(8) Pre fit the yaw damper frame assy into the
airplane. Install but do not tighten the mounting
screws to allow axial movement.
Install the tension screw located on the front of

the yaw damper.
Check before crimping:
S Rudder in neutral position.
S Capstan ball cut-out in center up position.
Crimp thimble eye on the cables according to

AC 43.13-1B if necessary.
(9) Adjust the bridle cable tension. Refer to Paragraph 10.
(10) Connect the electrical connection of the yaw

servo. Fix the harness with cable ties.
(11) Install all clamps and fix the hydraulic lines to

the yaw damper frame. Fix the TKS lines with
cable ties (if installed).
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(12) Check all flight controls in working area for

minium 3 mm (0.12 in) clearance.
(13) Check if rudder is in neutral position and the

capstan ball cut-out is in center up position.
(14) Do an inspection of the adjusted controls. If

necessary for the Airworthiness Authority do a
second inspection of the controls.
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Figure 6: Yaw Damper Cable Installation
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9. Adjust the Bridle Cable Tension of the Roll and Pitch Servos
A. Equipment
B. Adjustment Procedure
(1) Loosen the bolts in the clamps which connect Do not remove the bolts. Loosen just
the bridle cable to the push-rod. enough so that the next step can be
done.
(2) Using a small plastic hammer, move the clamps Adjust tension to 156 ± 9 N (35 ± 2 lbf.)
along the push-rod to adjust the bridle cable for the pitch and roll servos.
tension.
Measure cable tension with cable
tension gauge.
(3) Tighten the bolts in the clamps which connect

the bridle cable to the push-rod.
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10. Adjust the Bridle Cable Tension of the Yaw Servo
A. Equipment
(1) Check tension of rudder cables. Refer to Section 27-20.
(2) Connect the yaw damper thimble eye to the

rudder cable turnbuckle with the carabiner.
Secure screwed connection on carabiner using

Loctite 243 or equivalent.
Remove the cable fixing tape.
CAUTION: DO NOT USE THE YAW SERVO ADJUSTMENT SCREW TO ADJUST

CABLE TENSION. MOVE THE SERVO UNIT WITH GENTLE
STROKES AND SECURE POSITION VIA THE ADJUSTMENT SCREW
INSTEAD.
CAUTION: DO NOT BEND THE FRAME ASSY DURING ADJUSTMENT.
(3) Check and adjust the yaw damper cable

tension:
S Pull the yaw damper cable centrally

between the pulley and the cable eye with
the spring scale with a force of 3 kg (6.6 lbf)
and adjust cable tension to obtain a
deflection of 5 mm to 10 mm ( 0.2 in to
0.39 in)
(4) Tighten the 6 screws mounting the yaw damper

frame to the airplane.
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(5) Fix carabiners and bridle cable eye-ends to

thimble eyes with cable ties.
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11. Adjust/Check the Servo Clutch Torques
A. Equipment
Garmin slip clutch adjustment fixture. 1 T10-00110-01.
(1) Remove the clutch from the airplane. Refer to this Section.
(2) Clean the servo output gears.
(3) Install the clutch assembly on the slip clutch test Refer to the equipment manufacturers'
stand. documentation.
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(4) If OÄM 42-210 (GSM 86 servo mounts) is not Refer to the equipment manufacturers'
installed: documentation.
Measure clockwise (CW) and counter-clockwise
The correct clutch torques are:
(CCW) clutch torque, adjust if necessary.
Roll servo 5.08 ± 0.68 Nm
(45 ± 6 lbf.in.)
Pitch servo 6.21 ± 0.79 Nm
(55 ± 7 lbf.in.)
Pitch trim servo 5.08 ± 0.68 Nm
(45 ± 6 lbf.in.)
Yaw servo 9.04 ± 1.13 Nm
(80 ± 10 lbf.in.)
Refer to the equipment manufacturers'

If OÄM 42-210 (GSM 86 servo mounts) is
documentation.
installed:
Measure clockwise (CW) and counter-clockwise The correct clutch torques are:
(CCW) clutch torque, replace if necessary. Roll servo 5.08 ± 0.68 Nm
(45 ± 6 lbf.in.)
Pitch servo 6.89 ± 1.01 Nm
(61 ± 9 lbf.in.)
Pitch trim servo 5.08 ± 0.68 Nm
(45 ± 6 lbf.in.)
Yaw servo 10.17 ± 1.47 Nm
(90 ± 13 lbf.in.)
(5) Remove the clutch assembly from the slip clutch

test stand.
(6) Apply grease to the servo output gears.
(7) Install the clutch to the airplane. Refer to this Section.
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12. Mechanical Check of the Autopilot System (if OÄM 42-210 (GSM 86 Servo Mounts) is not
installed)
Do this check at the intervals given in Section 05-10.
(1) Check bridle cable tension for the roll servo, Refer to this Section.
adjust if necessary.
(2) Check bridle cable tension for the pitch servo, Refer to this Section.
(3) Check the clutch torque settings for the roll Refer to this Section.
servo, adjust if necessary.
(4) Check the clutch torque settings for the pitch Refer to this Section.
(5) Check the clutch torque settings for the pitch Refer to this Section.
trim servo, adjust if necessary.
(6) Check the clutch torque settings for the yaw Refer to this Section.
(7) Check the bridle cable tension for the yaw Refer to this Section.
13. Mechanical Check of the Autopilot System (if OÄM 42-210 (GSM 86 Servo Mounts) is
installed)
Do this check at the intervals given in Section 05-10.
(1) Check bridle cable tension for the roll servo, Refer to this Section.
(2) Check bridle cable tension for the pitch servo, Refer to this Section.
(3) Check the bridle cable tension for the yaw Refer to this Section.
(4) Perform a slip clutch override procedure. Refer to this Section.
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14. Slip Clutch Override Procedure
(2) With the autopilot disengaged, check freedom

of control movement in all control axes,
including pitch trim.
(3) Power up the Garmin G1000 in Configuration Refer to G1000 System Maintenance
Mode. Manual, latest revision.
(4) Navigate to the second of the GFC pages.
(5) Engage the pitch servo:

S Select the ENG CLCH soft-key.
S Set the DRIVE SERVO speed to zero.
S Select the DRV SRVO soft-key.
(6) Manually override the servo actuator slip clutch The control should move with some
by moving the control stick forward and back resistance through its range of motion.
through its range of motion.
(7) Verify the servo motor does not turn by viewing The motor of the servo actuator should
the SPEED in the SERVO DATA area of the remain stationary.
screen.
(8) Disengage the pitch servo:

S Select the STP SRVO soft-key.
S Select the DIS CLCH soft-key. Verify freedom of movement of the pitch
axis.
(9) Repeat steps 5 to 8 for each axis including pitch

trim.
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DA 42 NG AMM Communications
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CHAPTER 23
COMMUNICATIONS
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Communications
DA 42 NG AMM
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Page 2
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TABLE OF CONTENTS
CHAPTER 23
COMMUNICATIONS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 23-10
Speech Communication
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a COM VHF Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install a PTT Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Section 23-15
Satellite Transceiver System (if OÄM 42-213 is carried out)
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the GSR 56 Satellite Transceiver . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Iridium Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Test of the GSR 56 Satellite Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
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DA 42 NG AMM
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Section 23-50
Audio Integration
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
% 2. Remove/Install the GMA 1347/1360 Audio Control Panel . . . . . . . . . . . . . . . . . 201
Section 23-60
Static Discharging
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Replace a Static Discharge Wick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
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CHAPTER 23
COMMUNICATIONS
1. General
This Chapter tells you about the communications system in the DA 42 NG airplane. It tells you about
the intercom system which lets the pilots and passengers talk to each other. It also tells you about the
radio system which lets the pilots talk to the ground and other airplane.
This Chapter does not tell you about the communications equipment. Refer to the equipment
manufacturers’ manual for data about the equipment. Refer to Chapter 92 for the wiring diagrams.
2. Description
The DA 42 NG communication system has these components:
% ) GMA 1347/1360 audio panel.
% ) NAV/COM transceivers (integral with the Garmin GIA 6X W integrated avionics units).
) COM VHF antennas.
) NAV antenna (integral with the horizontal stabilizer), or if OÄM 42-112 is carried out externally
on the vertical stabilizer.
) Push-to-talk (PTT) switches. A PTT switch is located in each of the pilot's control sticks.
) Headset sockets. Headset sockets are located on the back of the center console for both the
pilots and the passengers.
) Cabin speaker. A cabin speaker is mounted in the roof of the cockpit.
) GSR 56 satellite transceiver (if OÄM 42-213 is carried out).
) Iridium antenna (if OÄM 42-213 is carried out).
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Section 23-10
Speech Communication
1. General
This Section tells you about the speech communication system in the DA 42 NG. It does not tell you
about the speech communication equipment. Refer to the equipment manufacturers’ manuals for more
data about the equipment.
Figure 1 shows the main components of speech communication system.
RH Passenger Headset VOR Antenna

Speaker
Co-Pilot’s Headset
COM #2 Antenna
COM #1 Antenna
Audio Panel
LH Passenger Headset
Pilot’s Headset
Figure 1: Speech Communication System Main Components
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DA 42 NG AMM
AIRCRAFT
Active Frequency Stand-by Frequency COM Volume Control

(COM 1) (COM 1) Automatic Squelch
° 121.500 122.650 COM1 VOL PUSH

SQ
122.650 118.750 COM2 Frequency Transfer Key/
COM
EMERG
Emergency Frequency
Active Frequency COM Selector Knob
6
(COM 2)
PUSH
1-2
CRS BARO
Stand-by Frequency
(COM 2)
PUSH
Figure 2: Garmin 1000 Primary Flight Display Panel
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2. Description
The DA 42 NG has dual VHF radio communications transceivers (COM 1 and COM 2) which are
% integral with the GIA 6X W integrated avionics units. The No.1 GIA 6X W and No. 2 GIA 6X W units
are remotely located in the aft fuselage avionics rack. The COM 1 antenna is located on the upper
surface of the fuselage, aft of the cockpit. The COM 2 antenna is located on the lower surface of the
fuselage, aft of the cockpit. Refer to Section 31-40 for more data about the Garmin 1000 ICS.
Figure 2 shows the Garmin 1000 primary flight display (PFD). The speech communication system is
integral with the Garmin 1000 integrated cockpit system (ICS). Power is supplied to the dual VHF
communications transceivers when the ICS is switched on. The COM selector knob is located at the
top-right corner of each ICS display panel. A digital display in the top right corner of the primary flight
display (PFD) screen shows which COM system and frequency is in use.
Both the active and standby frequencies are shown for both COM 1 and COM 2 systems. Pushing the
inner knob of the COM selector will toggle the active COM system between COM 1 and COM 2. Push
the COM FREQUENCY TRANSFER key to toggle between the active and standby frequency of the
selected communication system. A box is displayed around the stand by frequency.
Pressing and holding the COM FREQUENCY TRANSFER key for approximately 2 seconds will over-
ride all previous selections and select the EMERGENCY COM frequency of 121.5 MHz.
You can only change the frequency that is currently selected as the stand by frequency. You must
rotate the large outer COM selector knob to select the MHz value of the frequency and rotate the small
inner knob of the COM selector to select the kHz value of the frequency.
Above the COM knob is the VOL knob. You control the volume level of the active radio receiver with
the VOL knob. Press the knob to toggle the ON/OFF selection of the automatic squelch control.
The pilots use the audio control panel to control all the audio systems of the DA 42 NG. Both speech
and navigational audio can be sent to the pilots' or passengers' headphones. Or can be played on the
cockpit loudspeaker. Refer to Section 23-50 for more data about the audio control unit.
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Trouble-Shooting
1. General
This table tells you how to troubleshoot the speech communication system. See Section 23-50 for
troubleshooting the audio integrating system.
Radio check reports readability Mic. output low. Replace the defective mic.
good, strength poor due to low
% Faulty related GIA 6X W IAU. Replace the related GIA 6X W
modulation on COM 1/COM 2.
IAU.
% Radio check reports readability Faulty related GIA 6X W IAU. Replace the related GIA 6X W
poor, strength good. IAU.
Faulty mic. Replace the mic.
Radio check reports readability Coaxial cable connector faulty. Examine the coaxial cable and
poor, strength poor on connections for condition and
COM 1/COM 2. Received security.
%
audio is poor. Faulty related GIA 6X W IAU. Replace the related GIA 6X W
% IAU
Faulty antenna. Replace the antenna.
% Short range in transmit mode, Faulty related GIA 6X W IAU. Replace the related GIA 6X W
but reception is OK, IAU.
COM 1/COM 2.
No voice modulation when Audio integrating fault. Refer to Section 23-50.

transmitting from one pilot's
Related headset defective. Replace related headset.
side. The other pilot's side OK.
Cannot transmit. Transmit Faulty PTT switch. Replace PTT switch.

annunciator not shown in COM
% Do a test of the PTT wiring
display.
% circuit. Refer to Chapter 92 for
%
% PTT wiring circuit defective. wiring diagrams.
% Faulty related GIA 6X W IAU. Replace the related GIA 6X W

IAU.
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1. General
This Section tells you how to replace the main components of the speech communication system.
Refer to the equipment manufacturers’ manuals for more data about the equipment. The
% communications transceivers are integral with the GIA 6X W integrated avionics units (IAU). Refer to
% Section 31-40 for data about replacing the GIA 6X W IAUs.
2. Remove/Install a COM VHF Antenna
Use this procedure for both COM 1 and COM 2 antennas. Access to both the antennas is through the
rear baggage compartment.
A. Remove a COM VHF Antenna
(1) Remove the aft baggage compartment. Refer to Section 25-10.
(2) Identify the antenna that you will replace. Lower antenna COM 2,
top antenna COM 1.
(3) Disconnect the coaxial cable from the antenna. At the bayonet connector.
(4) Remove the antenna:
S Remove the 3 screws, nuts and washers

that attach the antenna to the airplane
structure.
S Move the antenna clear of the airplane. If necessary, cut the sealant around the
base of the antenna. You must not
damage the fuselage skin.
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B. Install a COM VHF Antenna
(1) Carefully remove any sealant from the area Take care not to damage the fuselage. If
where the antenna attaches to the fuselage. necessary, use a commercial solvent.
(2) Install the antenna:
S Move the antenna into position on the

fuselage.
S Make sure that the bonding strip for the

antenna is correctly located.
S Install the 3 screws, washers and nuts that

attach the antenna to the fuselage.
(3) Connect the coaxial cable to the antenna. At the bayonet connector.
(4) Do a test for the correct operation of the related Refer to the Airplane Flight Manual.
speech communications system.
(5) Install the aft baggage compartment. Refer to Section 25-10.
(6) Seal the outer edge of the antenna to the Use Terosat MS 9380, or equivalent.
fuselage skin with sealant. Follow the sealant manufacturer’s
instructions.
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3. Remove/Install a PTT Switch
Use this procedure for both pilot's and co-pilot's switches.
A. Remove a PTT Switch
(1) Set the ELECT. MASTER switch to OFF. Instrument panel, left side.
(2) Open the AUDIO circuit breaker. Instrument panel, right side.
(3) Remove the PTT switch:
S Leverage the switch with a small Handle with care. You must not damage
screwdriver out of the stick's bar end. the bar end.
S Disconnect the electrical cable from the

switch and move the switch clear of the
pilot's compartment.
(4) Remove the electrical cable, if necessary:
S Remove the appropriate pilot's seat. Refer to Section 25-10.
S Unplug the cable. At the connector behind the main

bulkhead.
S Pull the cable downward out. Through the hole in the stick.
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B. Install a PTT Switch
(1) Install the electrical cable, if removed before:
S Push the cable through the inside of the Through the hole in the stick.
stick.
S Connect the lower end of cable. At the connector behind the main
bulkhead.
(2) Install the PTT switch:
S Connect the electrical cable to the switch Put the single cables to the switch.
and move the switch into position at the bar
end of the stick.
S Push the switch in to the cut out of the bar Push carefully. You must not damage
end. the switch.
(3) Install the pilot's seat. If removed. Refer to Section 25-10.
(4) Reset the AUDIO circuit breaker. Instrument panel, right side.
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Section 23-15
Satellite Transceiver System (if OÄM 42-213 is carried out)
1. General
This Section tells you about the satellite transceiver system that can be installed in the DA 42 NG.
Refer to the manufacturer’s manual for more data about the equipment.
The Garmin GSR 56 provides airborne Iridium satellite telephone and SMS messaging service. Iridium
telephone and text messaging are available to the flight crew through the MFD, audio panel and
headset. The GSR 56 is also used to obtain worldwide weather information from Garmin Flight Data
Services (GFDS). The G1000 displays graphical weather information and associated text on the MFD
and the PFD inset map.
The GSR 56 satellite transceiver is tray mounted and is located under the passenger’s seats. The
antenna of the satellite transceiver system is mounted on the fuselage nose, just aft of the right-hand
baggage compartment door.
The AVIONICS BUS supplies power to the satellite transceiver system. The ELECT. MASTER switch
and the AV. MASTER switch must be set to ON to supply power through a circuit breaker to the
satellite transceiver system.
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Trouble-Shooting
1. General
The table below lists the defects you could have with the satellite transceiver system. If you have the
trouble detailed in the Trouble column read across to the Possible Cause column. Then do the repair
given in the Repair column.
GSR 56 does not operate. Circuit breaker open. Set circuit breaker.
Faulty cables/connectors. Do a test for continuity on each

cable. Do a test for short circuit
to ground and between cables.
Replace defective cables.
No or low-quality signal. Poor antenna performance. Ensure the iridium antenna has
an unobstructed view of
satellite constellation.
Check the antenna cable and

connectors.
No audio output. Faulty cables/connectors. Check wiring from GSR 56 to

the audio panel.
No subscription with Garmin Verify subscription with Garmin

Iridium Services. Iridium Services.
Unable to make a phone call. Faulty cables/connectors. Check wiring from GSR 56 to
the #2 GIA 63W.
No subscription with Garmin Verify subscription with Garmin

Iridium Services. Iridium Services.
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1. General
This Section tells you how to remove/install the components of the satellite transceiver system.
2. Remove/Install the GSR 56 Satellite Transceiver
A. Remove the GSR 56 Satellite Transceiver
(1) Set the ELECT. MASTER switch and the

AV. MASTER switch to OFF.
(2) Open the IRIDIUM circuit breaker.
(3) Remove the passengers seat. Refer to Section 25-10.
(4) Loosen the lock nut that attaches the transceiver

to its mounting tray.
(5) Remove the satellite transceiver from the

mounting tray.
B. Install the GSR 56 Satellite Transceiver
(1) Put the satellite transceiver in position in the

mounting tray.
(2) Tighten the lock nut that attaches the transceiver

to its mounting tray.
(3) Install the passengers seat. Refer to Section 25-10.
(4) Close the IRIDIUM circuit breaker.
(5) Do a test of the satellite transceiver. Refer to Paragraph 4.
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3. Remove/Install the Iridium Antenna
A. Remove the Iridium Antenna
(1) Open the forward, right baggage compartment

door.
(2) Open the IRIDIUM circuit breaker.
(3) Disconnect the connector of the Iridium antenna. At the antenna.

S Remove the 4 screws, washers and nuts that
attach the antenna to the structure.
S If necessary, use a knife to carefully remove Take care not to damage the airplane
the sealant that seals the antenna to the surface!
airplane outer surface.
S Move the antenna clear of the airplane.
(5) Remove the Iridium antenna from the fuselage

nose.
B. Install the Iridium Antenna
(1) Move the antenna into position.
(2) Install the 4 screws, washers and nuts that attach

the antenna to the airplane.
(3) Seal the outer edge of the antenna where it Refer to 34-50, Paragraph 4 for
contacts the airplane surface with sealant. approved sealants.
(4) Remove the excess sealant that has been forced

out of the joint between the antenna and the
airplanes surface.
(5) Connect the coaxial cable to the antenna. At the antenna.
(6) Reset the IRIDIUM circuit breaker.
(7) Do a test of the satellite transceiver system. Refer to Paragraph 4.
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4. Test of the GSR 56 Satellite Transceiver

AV. MASTER switch to ON.
(2) Select the AUX page group on the MFD. Using the large FMS knob.
(3) Select the AUX-TELEPHONE page. Using the small FMS knob.
(4) Ensure the system displays reasonable Iridium To improve signal strength move
signal strength. airplane out of the hangar.
% (5) Press the TEL button on the GMA 1347/1360

audio panel.
(6) Press the DIAL softkey on the MFD.
(7) Enter the test phone number in the ENTER Using the FMS knobs or the sofkeys on
PHONE NUMBER field. the MFD.
(8) Press ENT on the MFD. To accept the phone number.
(9) Press ENT on the MFD again. To initiate the dialing sequence.
(10) When the call is completed, press the HANGUP

softkey on the MFD to end the call.

AV. MASTER switch to OFF.
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Section 23-50
Audio Integration
1. General
The DA 42 NG has a voice-operated (VOX) intercom. This gives full hands free intercom when
headsets are used. The pilot controls the intercom system with the audio control panel. The audio
control panel is located in the instrument panel between the integrated cockpit system (ICS) display
screens. Figure 1 shows the audio control panel.
Push to talk (PTT) switches are installed in the handles of both control sticks (one in the LH side
control stick if OÄM 42-281 is installed. If OÄM 42-283 is installed, the RH control stick, including the
PTT switch is removable by the pilot). The jack sockets for all the headsets are located at the back of
the center console.
An amplifier in the radio receiver system operates a loudspeaker located in the roof of the passenger
cabin.
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%
%
%
%
%
%
%
%
%
%
If MÄM 42-1072 is If MÄM 42-1072 is
% NOT installed installed
%
%
COM1 COM1 COM1
COM1 MIC
%
MIC
% COM2 COM2 COM2 COM2

MIC MIC
%
COM3
% MIC
COM3 AUX
MIC
AUX
%
COM TEL
1/2 DME NAV1
%
%
PA SPKR ADF NAV2
%
% MKR
MUTE
HI
SENS PILOT TEL
ICS
%
% DME NAV1 COPLT
ICS MUS1
%
ADF NAV2 PASS MUS2
% ICS
% AUX
SPKR
PA PA
%
% MAN
SQ
PLAY MKR
MUTE
HI
SENS
% CREW
MAN
% PILOT COPLT PLAY SQ
ICS ISOLATION
% PILOT COPLT
PASS
% VOL
SQ
PUSH
TO
DIST
%
% CRSR HOLD
TO
PAIR
%
%
DISPLAY BACKUP
DISPLAY BACKUP
Figure 1: Audio Control Panel
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% Figure 1 shows the GMA 1347/1360 audio control panel of the DA 42 NG airplane. The audio control
panel is powered with the Garmin 1000 ICS and is an integral component of the integrated cockpit
system. The audio control panel makes an interface between the audio systems of the integrated
cockpit system (ICS) and the pilots'/crew headsets.
The audio control panel is located in the instrument panel between the ICS displays. The control panel
keys have LED annunciator labels and has backlighting which is controlled by the ICS. When a key
is active the annunciator is lit by the LED. The control panel performs a self-test when power is applied
to the panel which then resets the panel to the operating condition that was set when the panel was
last powered off. If the control panel fails the self-test the panel switches to a fail safe mode and all fail
safe audio output is directed to the pilot’s headset.
% If the audio panel GMA 1347 (MÄM 42-1072 is NOT installed) is installed, the control panel has these
% keys and selectors:
) COM 1 MIC key. Press this key to select COM 1 as the active microphone source and to
automatically deselect any COM MIC key that may have been previously selected. The COM 1 MIC
key annunciator illuminates and the COM 1 caption on the ICS display screen is highlighted.
) COM 2 MIC key. Press this key to select COM 2 as the active microphone source and to
automatically deselect any COM MIC key that may have been previously selected. The COM 2 MIC
key annunciator illuminates and the COM 2 caption on the ICS display screen is highlighted.
) COM 1/2 key. Press this key to toggle the selection of the split com function. When COM 1/2 is
selected COM 1 becomes the dedicated COM system for the pilot’s mic/audio and COM 2 becomes
the dedicated COM system for the co-pilot’s mic/audio. When the split com function is selected both
the pilot and co-pilot can transmit simultaneously using separate COM systems. The pilot can also
monitor all the NAV audio as selected. The co-pilot can only monitor the COM 2 audio.
) COM 1 key. Press this key to select COM 1 as the active audio source. Selecting COM 1 audio
using this key maintains COM 1 as an audio source independent of any other selection. The
annunciator illuminates when the COM 1 key is activated.
) COM 2 key. Press this key to select COM 2 as the active audio source. Selecting COM 2 audio
using this key maintains COM 2 as an audio source independent of any other selection. The
annunciator illuminates when the COM 2 key is activated.
) TEL key. This key is not active in the DA 42 NG installation.
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) AUX key. This key is not active in the DA 42 NG installation.
% ) SPKR/PA key. Press this key to select the cabin speaker. When selected, the cabin speaker will
broadcast all the selected audio channels and all unswitched/unmuted audio warnings. The
speaker will be muted when a COM microphone is keyed. The annunciator illuminates when the
SPKR key is activated.
) MKR/MUTE key. Press this key to select MKR audio. When selected the key annunciator is
illuminated. When a marker beacon audio tone is generated it can be heard over the headsets and
the related caption will show on the ICS primary flight display. Pressing the MKR/MUTE key while
a marker beacon tone is being generated will cause the audio to be muted but the caption on the
ICS display will remain. When the next marker beacon signal is generated the it will be heard over
the headsets. Pressing the MKR/MUTE key while the marker beacon audio system is in the mute
mode will cause the audio signal to be deactivated and the key annunciator will go out.
) HI SENS key. Press this key to increase the sensitivity of the marker beacon receiver. The
annunciator illuminates when the HI SENS key is activated.
) DME, ADF, NAV 1, NAV 2 keys. Press one of these keys to select the related audio source. The
related annunciator illuminates when the key is activated.
) MAN SQ key. Press this key to make the pilot/co-pilot/pass ICS volume control knob a push toggle
switch for setting ICS squelch levels manually. The annunciator illuminates when the MAN SQ key
is activated.
) PLAY key. Press this key to replay the digital recording made by the ICS. The digital recording of
recent audio activity will be heard over the headsets. The annunciator illuminates when the PLAY
key is activated.
) PILOT, COPLT keys. These keys control the intercom system (ICS) isolation system. The ICS
isolation system has 4 modes of operation which can all be selected using a combination of the
PILOT and COPLT keys. The system has these modes of operation:
) Pilot mode. Pilot mode is selected when only the PILOT key is annunciated. In pilot mode the
pilot can hear the selected radios. The co-pilot and passengers can only communicate with each
other.
) Co-pilot mode. Co-pilot mode is selected when only the COPLT key is annunciated. In co-pilot
mode the co-pilot's headset is isolated. The pilot and passengers can hear the selected radios,
and communicate with each other.
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) Crew mode. Crew mode is selected when both the PILOT and COPLT keys are annunciated.
In crew mode both the pilot and co-pilot can hear the selected radios and communicate with
each other.
) All mode. All mode is selected when neither the PILOT or COPLT keys are annunciated. In all
mode both the pilots and the passengers can hear the selected radios and are able to
communicate with each other.
) VOLUME/SQ knob. This knob has 2 functions depending on the selection of the MAN SQ key.
) MAN SQ key deselected. When the MAN SQ key is deselected the ICS squelch levels are set
automatically. The VOLUME/SQ knob acts as a volume control and the VOL caption to the
lower left of the knob illuminates. Rotate the inner knob clockwise to increase the volume level
of the pilot’s ICS and rotate the inner knob counterclockwise to reduce the volume of the pilot's
ICS. Rotate the outer knob clockwise to increase the volume level of the co-pilot’s and
passengers' ICS. Rotate the outer knob counterclockwise to reduce the volume level of the
co-pilot’s and passengers’ ICS.
) MAN SQ key selected. When the MAN SQ is selected the ICS squelch levels can set manually
and pressing the VOLUME/SQ knob toggles the manual squelch ON/OFF. Manual squelch is
toggled ON when the SQ caption to the lower right of the knob illuminates. Rotate the inner knob
clockwise to increase the squelch threshold of the pilot‘s ICS and rotate the inner knob counter-
clockwise to reduce the squelch threshold of the pilots ICS. Rotate the outer knob clockwise to
increase the squelch threshold of the co-pilot's and passengers’ ICS. Rotate the outer knob
counterclockwise to reduce the squelch threshold of the co-pilot’s and passengers’ ICS.
) DISPLAY BACKUP button. Pressing the red DISPLAY BACKUP button at the bottom of the audio
control panel selects the backup mode for all the displays.
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% If the audio panel GMA 1360 (MÄM 42-1072) is installed, the control panel has these keys and
% selectors:
% ) COM 1 MIC key. Press this key to select COM 1 as the active microphone source and to
% automatically deselect any COM MIC key that may have been previously selected. The COM 1 MIC
% key annunciator illuminates and the COM 1 caption on the ICS display screen is highlighted.
% ) COM 2 MIC key. Press this key to select COM 2 as the active microphone source and to
% automatically deselect any COM MIC key that may have been previously selected. The COM 2 MIC
% key annunciator illuminates and the COM 2 caption on the ICS display screen is highlighted.
% Pressing the COM 1 MIC and COM 2 MIC buttons simultaneously will activate split COM mode
% between those two COMs. The key annunciators of the COM MICs are illuminated while in split
% COM mode, the pilot transmits on COM 1 and the copilot transmits on COM 2.
% ) COM 1 key. Press this key to select COM 1 as the active audio source. Selecting COM 1 audio
% using this key maintains COM 1 as an audio source independent of any other selection. The
% annunciator illuminates when the COM 1 key is activated.
% ) COM 2 key. Press this key to select COM 2 as the active audio source. Selecting COM 2 audio
% using this key maintains COM 2 as an audio source independent of any other selection. The
% annunciator illuminates when the COM 2 key is activated.
% ) AUX MIC, AUX keys. These keys are not active in the DA 42 NG installation.
% ) DME, ADF, NAV 1, NAV 2 keys. Press one of these keys to select the related audio source. The
% related annunciator illuminates when the key is activated.
% ) PILOT ICS, COPLT ICS, PASS ICS keys. These keys control the intercom system (ICS) isolation
% system. The ICS isolation system has 8 modes of operation which can be selected using a
% combination of the PILOT ICS, COPLT ICS and PASS ICS keys. The system has these modes of
% operation:
% ) When neither the PILOT ICS, the COPLT ICS or the PASS ICS keys are annunciated the
% pilots hear selected radios and aural alerts and the passengers are able to communicate with
% each other.
% ) When the PILOT ICS key is annunciated and COPLT ICS and PASS ICS keys are not
% annunciated the pilots hear selected radios and aural alerts and the passengers are able to
% communicate with each other.
% ) When the COPLT ICS key is annunciated and PILOT ICS and PASS ICS keys are not
% annunciated the pilots hear selected radios and aural alerts and the passengers are able to
% communicate with each other.
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% ) When the PASS ICS key is annunciated and the PILOT ICS and COPLT ICS keys are not
% annunciated the pilots hear selected radios and aural alerts. The passengers are able to
% communicate with each other and hear selected radios and aural alerts.
% ) When the PILOT ICS and COPLT ICS keys are annunciated and PASS ICS is not
% annunciated the pilots hear selected radios, aural alerts and are able to communicate with each
% other. The passengers are able to communicate with each other.
% ) When COPLT ICS and PASS ICS keys are annunciated and the PILOT ICS is not
% annunciated the pilots and passengers hear selected radios and aural alerts. The copilot and
% the passengers are able to communicate with each other.
% ) When PILOT ICS and PASS ICS keys are annunciated and the COPLT ICS key is not
% annunciated the pilot and the passengers hear selected radios, aural alerts and are able to
% communicate with each other. The copilot hears selected radios and aural alerts.
% ) When PILOT ICS, COPLT ICS and PASS ICS keys are annunciated the pilots and
% passengers hear selected radios, aural alerts and are able to communicate with each other.
% ) TEL, MUS1, MUS2 keys. These keys are not active in the DA 42 NG installation.
% ) SPKR/PA key. Press this key to select the cabin speaker. When selected, the cabin speaker will
% broadcast all the selected audio channels and all unswitched/unmuted audio warnings. The
% speaker will be muted when a COM microphone is keyed. The annunciator illuminates when the
% SPKR key is activated.
% ) MKR/MUTE key. Press this key to select MKR audio. When selected the key annunciator is
% illuminated. When a marker beacon audio tone is generated it can be heard over the headsets and
% the related caption will show on the ICS primary flight display. Pressing the MKR/MUTE key while
% a marker beacon tone is being generated will cause the audio to be muted but the caption on the
% ICS display will remain. When the next marker beacon signal is generated the it will be heard over
% the headsets. Pressing the MKR/MUTE key while the marker beacon audio system is in the mute
% mode will cause the audio signal to be deactivated and the key annunciator will go out.
% ) HI SENS key. Press this key to increase the sensitivity of the marker beacon receiver. The
% annunciator illuminates when the HI SENS key is activated.
% ) PLAY key. Press this key to replay the digital recording made by the ICS. The digital recording of
% recent audio activity will be heard over the headsets. The annunciator illuminates when the PLAY
% key is activated.
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% ) MAN SQ key. Press this key to make the pilot/co-pilot/pass ICS volume control knob a push toggle
% switch for setting ICS squelch levels manually. The annunciator illuminates when the MAN SQ key
% is activated.
% ) VOLUME/SQ knob. This knob has 2 functions depending on the selection of the MAN SQ key.
% MAN SQ key deselected. When the MAN SQ key is deselected the ICS squelch levels are set
% automatically. Rotate the outer knob to select one of the active audio sources for volume adjustment. Only
% active audio sources are available for volume adjustment. Once the outer knob has been turned, the key
% annunciator of the selected audio source starts flashing, the VOL/ SQ annunciator flashes in time with the
% selected audio source, and a volume bar appears over the knob. The first source to be selected upon
% entering volume adjustment will be PILOT ICS, then COPLT, PASS, COM1, COM2, etc, assuming the
% outer knob is rotated clockwise. Counterclockwise from PILOT ICS selects MAN SQ, SPKR, etc. The inner
% knob can then be used to adjust the volume level of the selected source. Rotate the inner knob clockwise
% to increase the volume level and rotate the inner knob counterclockwise to decrease the volume level.
% Audio source volume adjustment ends after 20 seconds of not adjusting audio or changing the selected
% source. The end of volume adjustment is signaled by the annunciator of the previously selected audio
% source and the VOL annunciator becoming solid. When no audio source is selected, rotating the inner
% knob also initiates volume adjustment on the PILOT ICS.
% ) MAN SQ selected. If MAN SQ is active, it is available for selection. The text annunciator to
% the left of the knob changes from VOL to SQ to indicate squelch thresholds are being adjusted
% instead of volume levels. Upon activating an audio source or manual squelch, volume/ squelch
% adjustment for that source is automatically selected and remains selected until 20 seconds
% pass with no adjustment. The volume bar for that source is displayed during this time, but the
% key annunciator of the selected source will not flash unless the volume is adjusted. If the volume
% is adjusted, the key annunciator and the corresponding VOL/ SQ annunciator are flashing in
% time, indicating the volume/ squelch adjustment mode.
% ) DISPLAY BACKUP button. Pressing the red DISPLAY BACKUP button at the bottom of the audio
% control panel selects the backup mode for all the displays.
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Trouble-Shooting
1. General
This table tells you how to trouble-shoot the audio integrating system. See Section 23-10 for trouble-
shooting the speech communication system.
No voice modulation when Faulty headset. Replace headset.

transmitting from co-pilot’s side
Open mic audio line. Do a test of the mic audio
on headset. Pilot’s side OK.
wiring. Refer to Chapter 92 for
the wiring diagrams.
% Faulty GMA 1347/1360. Replace GMA 1347/1360.
No voice modulation when Faulty headset. Replace headset.

transmitting from pilot’s side on
Open mic audio line. Do a test of the mic audio
headset. Co-pilot’s side OK.
% Faulty GMA 1347/1360. Replace GMA 1347/1360.
No intercom audio on pilot’s ICS mode set incorrectly. Set mode to required position,
headset. Receives radio refer to Section 23-50
transmissions correctly. Paragraph 2.
% Faulty GMA 1347/1360. Replace the GMA 1347/1360.
No audio on pilot’s headset Faulty headset. Replace headset.

with the ICS set to OFF.
Open audio line. Do a test of the headset audio
No audio on co-pilot’s or Open audio line. Do a test of the headset audio

passenger headsets. wiring. Refer to Chapter 92 for
% Faulty GMA 1347/1360. Replace the GMA 1347/1360.
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1. General
% This Section tells you how to remove/install the GMA 1347/1360 audio control panel. It also tells you
how to adjust/test the ICS. Refer to the equipment manufacturers manuals for more data about the
audio integrating system.
% 2. Remove/Install the GMA 1347/1360 Audio Control Panel
% A. Remove the GMA 1347/1360 Audio Control Panel
(1) Make sure that the ELECT. MASTER switch is Instrument panel, lower center.
set to OFF.
(2) Remove the audio control unit:
S Insert a 3/32" hexagonal drive wrench into Refer to Figure 1.

the access hole in the front of the panel.
S Rotate the locking mechanism counter-

clockwise to release the lock.
S Pull the audio control panel towards you and

clear of the instrument panel.
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% B. Install the GMA 1347/1360 Audio Control Panel
(1) Examine the connecters at the rear of the audio

control panel. Look specially for bent or
damaged pins.
(2) Insert a 3/32" hexagonal drive wrench into the

access hole in the front of the panel and rotate
the locking mechanism 90° counter-clockwise to
make sure that the locking mechanism is in the
unlocked position.
(3) Install the audio control panel:
S Move the audio control panel into position at

the instrument panel.
S Carefully slide the panel into position in the Make sure that the audio control panel
instrument panel. fully engages with the connectors at the
rear of the panel.
S Insert a 3/32" hexagonal drive wrench into Make sure that you cannot pull the audio
the access hole in the front of the panel and control panel towards you!
rotate the locking mechanism clockwise to
lock the panel into position.
(4) Do a test for the correct operation of the audio Refer to the G1000 Line Maintenance
control panel. If you have installed a Manual for data about installing software
replacement audio control panel you may have and testing the audio control panel.
to update the Garmin G1000 integrated cockpit
system software.
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Section 23-60
Static Discharging
1. General
The static discharging system has 2 main parts, the airplane bonding system and the surface static-
discharging system. The bonding system gives the airplane good lightning protection.
A special bonding system is necessary for the composite structure of the DA 42 NG. The composite
structure does not conduct electricity. A series of metal tubes and strips make the airplane bonding
system. All the metal components or the airplane and the antenna ground planes connect to the
bonding system. Refer to Section 51-80 for more data about the airplane bonding system.
2. Description
The static discharging system removes the electrostatic charge which collects on the airplane
surfaces. The composite structure of the DA 42 NG does not let electricity flow through it. The airplane
surfaces are covered with a special conductive filler through which the electrostatic charges can flow
to the discharge wicks. The discharge wicks discharge the electrostatic charges back into the air.
Figure 1 shows the location of the static discharge wicks for the DA 42 NG airplane.
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Static Discharge
Right Horizontal
Stabilizer
Static Discharge
Left Horizontal
Stabilizer
Static Discharge
Right Wing (2x)
Static Discharge
Rudder
Static Discharge
Left Wing (2x)
Figure 1: Static Discharge Wick Locations DA 42 NG
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1. General
This Section tells you how to remove/install a static discharge wick and how to test a static discharge
wick.
Static Discharger
Mounting Plate
Screw
Figure 2: Static Discharge Wick Installation
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2. Replace a Static Discharge Wick
Use this procedure for all the static discharge wicks.
A. Replace a Static Discharge Wick
(1) Remove the 2 screws that attach the discharge Refer to Figure 2.
wick to the wick mounting.
(2) Make sure that the mounting is clean and

correctly bonded to the airplane structure.
(3) Move the new static discharge wick into

position at the mounting.
(4) Install the 2 screws that attach the wick to the

mounting.
(5) Do a test for the correct bonding of the static Refer to Section 51-80.
discharge wick to the airplane bonding system.
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CHAPTER 24
ELECTRICAL POWER
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TABLE OF CONTENTS
CHAPTER 24
ELECTRICAL POWER
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Electrical System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Power Supply Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Section 24-30
DC Generation
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install an Alternator Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4. Remove/Install an ECU Backup Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Section 24-31
Battery Systems
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Main Battery Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Main Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Disconnect/Connect the Main Battery for Maintenance . . . . . . . . . . . . . . . . . . . 204
5. Remove/Install the Battery Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6. Starter Relay Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Section 24-32
Emergency Power
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Emergency Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 24-33
Additional Alternator
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the AUX POWER Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Remove/Install the Additional Alternator Regulator . . . . . . . . . . . . . . . . . . . . . . 203
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Section 24-40
External Power
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the External Power Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Section 24-60
DC Electrical Load Distribution
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Avionics Master Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Remove/Install a Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5. Remove/Install an Instrument Panel Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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CHAPTER 24
ELECTRICAL POWER
1. General
The DA 42 NG has a 24 V DC electrical system. This Section describes the complete system from the
power supplies to the circuit breakers or other interface with the consumer components.
This Chapter has only simplified schematic diagrams and location diagrams. Refer to Chapter 92 for
the wiring diagrams. Refer to the related Chapter for data about systems. For example, refer to
Chapter 80 for data about the starter system.
For Trouble-Shooting and Maintenance Practices for this electrical system, refer to these Sections:
) Section 24-30. Electrical power generation.
) Section 24-31. Battery installation.
) Section 24-33. Additional alternator (if OÄM 42-204 is installed).
) Section 24-40. External power.
) Section 24-60. Power distribution.
Note: Equipment which is certified for installation in the DA 42 NG 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.
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Figure 1: Electrical Schematic (Simplified) - Sheet 1, if MÄM 42-403 is not carried out
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Figure 2: Electrical Schematic (Simplified) - Sheet 1, if MÄM 42-403 is carried out
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2. Electrical System Description and Operation
Figures 1 and 2 show the electrical system simplified schematic diagrams.
A. Power Supplies
(1) Main Battery
The main battery is located in the front baggage compartment and is mounted on the forward
RH side of the cockpit front bulkhead. It is a 24 V, 13.6 Ah sealed battery. The battery is
connected to the main airplane ground, the battery relay and the battery HOT BUS.
(2) Alternators
Each engine has an alternator located at the left rear of the engine. A flat multi-vee belt with
automatic tensioner turns the alternator. The alternator has an external regulator which is
located in the engine nacelle. The output from the alternators connects to the LH and RH
MAIN BUS, through terminal blocks, relays and fuses. In the event of a main battery failure the
alternators can be excited directly from the related ECU backup batteries which are located
below the passengers seat.
Optionally, the RH ECU backup batteries may be installed in the lower tail fin (if OÄM 42-247
is installed).
(3) External Power Connector
The external power connector is located below the forward baggage compartment. The external
power connector connects to the external power relay in the relay junction box in the forward
) The control pin connects to the relay coil through a diode to prevent reverse connection.
) The + pin connects to the relay main input connection.
) The – pin connects to ground.
CAUTION: WHEN OPERATING THE AIRPLANE ELECTRICAL SYSTEM WITH

ENGINE MASTER ON (LH OR RH) AND THE ENGINE IS NOT RUNNING
(e.g. EVENT LOG READOUT) ALWAYS CONNECT AN EXTERNAL
POWER SUPPLY WITH A PRESET VOLTAGE OF 29 V TO THE
AIRPLANE. OTHERWISE THE ALTERNATORS MAY BE DAMAGED.
ADDITIONALLY, IF MÄM 42-551 IS INSTALLED, SWITCH OFF BOTH

(LH AND RH) ALTERNATOR SWITCHES.
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Figure 3: Electrical Schematic (Simplified) - Sheet 2
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Figure 4: Electrical Schematic (Simplified) - Sheet 2, if MÄM 42-551 is carried out
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3. Power Supply Control
(1) Battery Relay
The battery relay is located on the relay panel in the front baggage compartment. The output
from the battery connects directly RELAY BOX BUS bar. The coil + of the battery relay is tied
to the battery + connection to the relay and the BATTERY BUS via diodes. The ELECT.
MASTER switch provides the coil ground when set to the ON position.
(2) External Power Relay
The external power relay is located on the relay panel in the front baggage compartment. The
relay output connects directly to the RELAY BOX BUS bar.
If a 28 V external power is connected, the +28 V DC on the control pin energizes the relay. The
relay operates and connects the external power to the RELAY BOX BUS bar.
(3) Starter Relay
The starter relay contacts connect to the RELAY BOX BUS bar. Power is applied to the coil of
the starter relay when the ELECT. MASTER switch is set to ON and the START switch is set
to START LEFT or START RIGHT. The energized coil operates the starter relay which connects
the power to the solenoid of related engine starter motor.
(4) Bus Structure
All buses (except the RELAY BOX BUS) are flat metal strips connecting rows of circuit breakers.
The circuit breakers are located on the instrument panel.
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RH Alternator Relay
LH Alternator Relay
Battery Relay
External Power Relay
Starter Relay
Terminal Blocks
Overvoltage Suppressor
Figure 5: Relay Locations in the Relay Box
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(5) Relay Box Bus
Figure 5 shows the relays in the relay box. The RELAY BOX BUS is located in the front luggage
compartment, next to the main battery. The bus is a metal strip which connects these relays:
) The battery relay.
) The starter relay.
) The external power relay.
The relay box also has these relays:
) LH alternator.
) RH alternator.
The RELAY BOX BUS has these outputs:
) RH MAIN BUS.
) LH MAIN BUS.
) Hydraulic pump motor.
(6) Hot Bus
The HOT BUS is connected to the main battery relay input connection. The HOT BUS supplies
power for the PILOT MAP LIGHT and the Emergency Locator Transmitter (ELT).
(7) LH Main Bus
The LH MAIN BUS is connected to the RELAY BOX BUS through a 90 Ampere circuit breaker.
The LH MAIN BUS supplies power for the consumers and the LEFT ECU BUS. Each consumer
or bus is protected by circuit breakers or fuses. The LH MAIN BUS is connected to the LH
alternator output through a 60 Ampere circuit breaker and a relay.
(8) RH Main Bus
The RH MAIN BUS is connected to the RELAY BOX BUS through a 90 Ampere circuit breaker.
The RH MAIN BUS supplies power for the consumers, the RIGHT ECU BUS and the AVIONICS
BUS. Each consumer or bus is protected by circuit breakers or fuses. The RH MAIN BUS is
connected to the RH alternator output through a 60 Ampere circuit breaker and a relay.
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(9) LH ECU Bus
If MÄM 42-403 is not carried out the LH ECU BUS is located on the right side, center (for fuel
pumps), and left side of the instrument panel at the bottom. If MÄM 42-403 is carried out the
LH ECU BUS is located on the right side and center (for fuel pumps) of the instrument panel at
the bottom. The LH ECU BUS has power when power is applied to the LH MAIN BUS or if the
left engine alternator is online.
The LH ECU BUS provides power for the both ECU A and ECU B functions of the LH engine
control unit and to the ECU A and ECU B fuel pumps. If MÄM 42-403 is not carried out both
ECU A and ECU B supplies are protected by 20 Ampere and 7.5 Ampere circuit breakers. If
MÄM 42-403 is carried out both ECU A and ECU B supplies are protected by a 20 Ampere
circuit breaker and a 5 Ampere fuse. If MÄM 42-403 is carried out the LH ECU BUS also
provides electrical power for the RH ECU B and its fuel pump.
(10) RH ECU Bus
If MÄM 42-403 is not carried out the RH ECU BUS is located on the right, center and left side
of the instrument panel at the bottom. If MÄM 42-403 is carried out the RH ECU BUS is located
on the right side and center (for fuel pumps) of the instrument panel at the bottom. The RH ECU
BUS has power when power is applied to the RH MAIN BUS or if the right engine alternator is
online.
The RH ECU BUS provides power for the both ECU A and ECU B functions of the RH engine
control unit and to the ECU A and ECU B fuel pumps. If MÄM 42-403 is not carried out both
ECU A and ECU B supplies are protected by 20 Ampere and 7.5 Ampere circuit breakers. If
MÄM 42-403 is carried out both ECU A and ECU B supplies are protected by a 20 Ampere
circuit breaker and a 5 Ampere fuse. If MÄM 42-403 is carried out the RH ECU BUS also
provides electrical power for the LH ECU B and its fuel pump.
(11) Avionics Bus
The AVIONICS BUS supplies power to avionic consumers through circuit breakers and fuses.
The power to the AVIONICS BUS is supplied by the RH MAIN BUS and is controlled by the
avionics master relay and AV. MASTER switch.
(12) Avionics Master Control System
The AV. MASTER switch and the avionics master relay make the main components of the
avionics master control system.
In normal operation the AV. MASTER switch is set to the ON position. In the OFF position the
power is supplied to the coil of the avionics master relay and the avionics master relay operates
and removes power from the AVIONICS BUS.
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(13) Avionics Master Relay
The avionics master relay connects the AVIONICS BUS to the RH MAIN BUS. The
AV. MASTER switch controls the avionics master relay.
(14) Elect. Master Switch
The ELECT. MASTER switch is located on the bottom of the instrument panel, left side. It is a
rocker switch that has 3 sets of contacts. When the switch is set to ON the contacts operate as
follows:
) The coil of the battery relay is connected to ground and the battery relay operates.
) The ground side of the LH alternator switch is connected to ground.
) The ground side of the RH alternator switch is connected to ground.
(15) Start Switch
The START switch is operated with a key. The switch can be turned to LH or RH and must be
held against a spring to maintain the selected position. Setting the START switch to LH or RH,
with the ELECT. MASTER switch set to ON and the related ENGINE MASTER switch set to ON
will cause the related engine starter motor to operate.
(16) Engine Master LH / RH
The LH and RH ENGINE MASTER switches are located either side of the START switch. Each
switch is similar and has 4 sets of contacts which operate as follows:
) The related engine starter control system is energized.
) The alternator regulator is enabled and the ECU backup battery relays are energized.
) The LH / RH ECU BUS is connected to the related engine ECU A and ECU B EECU system.
(17) Alternator LH and Alternator RH Switches
Each engine alternator relay has a control switch. The control switches are labeled ALT LH and
ALT RH. When the ELECT. MASTER switch is set to ON setting the ALT LH or ALT RH switch
to ON gives a ground to the related engine alternator relay. The alternator relay operates and
the related alternator output is connected to the related MAIN BUS.
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Section 24-30
DC Generation
1. General
The DC generation system for the DA 42 NG has these components:
) Alternators LH and RH.
) Alternator relays LH and RH.
) ENGINE MASTER switches LH and RH.
) ELECT. MASTER switch.
) Alternator current sensors LH and RH.
) Alternator regulators (including current sensors LH and RH, if MÄM 42-551 is installed).
) ECU backup batteries (LH and RH).
This Section gives you only the simplified description, Trouble-Shooting and Maintenance Practices
for the DC generating systems for the DA 42 NG. Refer to Section 24-00 for a general description of
complete electrical system.
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Figure 1: DC Generation Schematic Diagram, if MÄM 42-403 is not carried out
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Figure 2: DC Generation Schematic Diagram, if MÄM 42-403 is carried out
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Figure 3: DC Generation Schematic Diagram, if MÄM 42-551 is carried out
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Figure 1, 2 and 3 shows the generation system simplified schematic diagram.
A. Alternators
Each engine has an alternator supplied with the engine. Each alternator is 28 VDC machine with
a maximum output of 70 Ampere. The alternator is located at the rear left of the engine. A
multi-V flat belt drives the alternator. An automatic system keeps the belt at the correct tension.
The alternator has an external regulator which is located in the engine nacelle.
There is no approved maintenance that you can do to the alternator.
B. Alternator Relays
The alternator relays connect the output from each alternator to the related MAIN BUS. Each
alternator relay is controlled by a switch located on the instrument panel. The relays are located
in the relay box. The relay box is located in the front baggage compartment.
C. Alternator Current Sensors
A current sensor monitors the current flowing in the alternator outputs and indicates them on the
Garmin G 1000 system. This current sensor is located below the pilot's seat and monitors the
current flow between the alternator and the related alternator relay.
D. Alternator Regulators
Each alternator has an external regulator. The regulator controls the output of the alternator. If
MÄM 42-551 is carried out, additional current sensors are installed. These sensors are independent
from the sensors for the Garmin G1000 system. They are installed in the LH and RH engine
nacelles and connected to the LH alternator regulator only. The LH alternator regulator controls its
output depending on the output current of both alternators.
E. ECU Backup Batteries
To support the alternator electrical power supply to the ECUs in case of a malfunction of the main
battery, additional sealed-lead-acid batteries (ECU backup batteries) are connected to the RH and
LH ECU BUS.
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Trouble-Shooting
1. General
This table tells you how to trouble-shoot the DC generation system. If you find the trouble in
column 1 do the repair given in column 3.
LH or RH alternator warning Related alternator defective. Refer to the engine

light illuminated. manufacturer.
LH/RH alternator output Alternator regulators need Refer to the engine

paralleling insufficient. adjustment (if MÄM 42-551 is manufacturer.
not installed).
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1. General
This Section tells you how to replace components of the 28 V DC electrical generation system on the
airplane. Refer to the components manufacturers’ manuals for more data and for shop data.
2. Electrical Safety
The DA 42 NG has a low voltage DC electrical system. When correctly maintained it is safe to do work
on. The battery can supply heavy current through low resistance circuits (for example, if you ground
the battery positive with a wrench by accident).
Always follow the usual safety practices for working on electrical equipment. Allow only qualified
persons to maintain the electrical system.
CAUTION: DISCONNECT THE BATTERIES (MAIN AND ECU BACKUP) BEFORE

YOU DO ANY WORK ON THE ELECTRICAL SYSTEM. MAKE SURE
THAT YOU DISCONNECT THE NEGATIVE LEAD FIRST.
CAUTION: AFTER DOING ELECTRICAL MAINTENANCE ALWAYS DO A

CONFIDENCE TEST OF THE SYSTEM WITH A 24 VOLT POWER
SUPPLY THAT HAS OVER-CURRENT PROTECTION. DO THIS
BEFORE CONNECTING THE BATTERY.

CAUTION: USE ONLY DA 42 NG SPARE PARTS APPROVED BY THE

MANUFACTURER.
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Battery Box, Upper
Foam Insert
Screw
Washer
Foam Insert
Battery Serial
Fuse, 32A
Connection Cable
ECU Backup Battery

Cable Tie
Cable Tie
Base
Seal
Foam Insert
Foam Insert
Foam Insert
Battery Box, Lower
Foam Insert
Foam Insert
Figure 4: ECU Backup Batteries Installation (RH)
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Battery Box, Upper
Foam Insert
Fuse, 32A
Screw
Washer
Cable Tie
Foam Insert
Cable Tie
Base
Battery Serial
Connection Cable
ECU Backup Battery
Seal
Foam Insert
Foam Insert
Foam Insert
Battery Box, Lower
Foam Insert
Foam Insert
Figure 5: ECU Backup Batteries Installation (LH)
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Bolt
Washer
Washer
RH Alternator Relay
Ring Terminal
LH Alternator Relay
Figure 6: LH/RH Alternator Relay Installation
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Lower Tail Fin
Fuse, 32A
Washer
Screw
Battery Serial
Connection Cable
ECU Backup Battery
Battery Container Cover
Figure 7: ECU Backup Battery Installation (RH, if OÄM 42-247 is installed)
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3. Remove/Install an Alternator Relay
A. Remove an Alternator Relay
Use this procedure for both the LH and the RH alternator relay.
(1) Open the front baggage compartment door. Refer to Section 52-40.
(2) Remove the baggage compartment rear cover.
(3) Disconnect the battery and ECU backup Refer to Section 24-31.
batteries for maintenance.
(4) Disconnect the LH/RH alternator relay from the

RELAY BOX BUS bar:
S Remove the bolts and washers that attach

the relay to the RELAY BOX BUS bar.
(5) Disconnect the electrical cables from the

external relay terminals.
(6) Remove the LH/RH alternator relay:
S Lift the LH/RH alternator relay clear of the

relay box.
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B. Install an Alternator Relay
(1) Move the LH/RH alternator relay into position at Check for correct polarity.
the relay mounting and connect the control
cables to the terminal block.
(2) Lower the relay into position at the relay

mounting.
(3) Connect the LH/RH alternator relay to the

RELAY BOX BUS bar:
S Install the washers and bolts that attach the

relay to the RELAY BOX BUS bar.
(4) Connect the main battery and ECU backup Refer to Section 24-31.
batteries.
(5) Install the baggage compartment rear cover.
(6) Close and secure the front baggage Refer to Section 52-40.
compartment door.
(7) Do a test for the correct operation of the LH/RH

alternator relay:
S Do a ground run up of the related engine. Refer to Section 71-00.
S Make sure that the alternator comes online.
S Shut down the related engine. Refer to Section 71-00.
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4. Remove/Install an ECU Backup Battery
A. Remove the ECU Backup Batteries
(4) Remove the ECU backup batteries: Refer to Figure 4 and 5.
S Remove the passenger seats. Refer to Section 25-10.
S Disconnect the negative cable from the

batteries that you will remove.
S Disconnect the positive cable from the

batteries that you will remove.
S Disconnect the serial connection cable from

the batteries that you will remove.
S Release the battery pack hold cover.
S Move the related batteries clear of the

airplane.
(5) Remove the RH ECU backup batteries (if Refer to Figure 7.

OÄM 42-247 is installed):
S Remove the 14 screws and washers of the

battery container cover in the lower tail fin.
S Remove the battery container cover.
S Move the ECU batteries slightly out of the

lower tail fin to gain access to the terminals
of the batteries.
S Disconnect the negative cable from the

batteries.
S Disconnect the serial connection cable.
S Remove the batteries from the airplane.
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B. Install the ECU Backup Batteries
(1) Move the batteries into position in its mounts.
(2) Install the battery pack hold cover.
(3) Connect the related batteries:
S Connect the serial connection cable to the

batteries that you will install.
S Connect the positive cable to the batteries

that you installed.
S Connect the negative cable to the batteries Refer to Section 25-10.

that you installed.
S Install the passenger seats.
(4) Install the RH ECU backup batteries (if Refer to Figure 7.

OÄM 42-247 is installed):
S Move the ECU backup batteries slightly into

the lower tail fin.
S Connect the serial connection cable to the

batteries.
S Connect the positive cable to the positive

terminal of the batteries.
S Connect the negative cable to the negative

terminal of the batteries.
S Move the batteries in place in the lower tail

fin.
S Install the battery container cover with the

14 screws and washers.
(5) Connect the airplane main battery. Refer to Section 24-31.
compartment door.
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(8) Do an engine ground run-up. Make sure that the electrical system
operates correctly.
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Section 24-31
Battery Systems
1. General
This Section tells you about the battery systems for the DA 42 NG airplane. See Section 24-00 and
24-30 for the description and operation of the batteries in the electrical generation system.
The DA 42 NG has these battery systems:
) A main battery located in the front baggage compartment. This battery provides the usual airplane
electrical services.
) ECU backup batteries.
2. Main Battery Description and Operation
The main battery is a 24 V, 13.6 Ah sealed battery. A battery tray located on the forward face of the
cockpit bulkhead holds the battery. You can access the battery through the front baggage
compartment, right side after removing the baggage compartment rear cover. A clamp and two bolts
hold the battery in position. The positive and negative cables attach to terminals on the top of the
battery, at the front. The usual rubber caps protect the electrical connections.
When either, or both of the engine alternators are online and the system voltage is greater than the
battery voltage, the system charges the battery.
When either or both alternators are on-line the integrated cockpit system (ICS) display shows each
alternator voltage. When both alternators are offline, the ICS display shows the battery voltage.
The battery supplies current to the RELAY BOX BUS through the battery relay. There is no circuit
protection. The RELAY BOX BUS also supplies power to the LH MAIN BUS, RH MAIN BUS and the
hydraulic pump. Each of the main bus systems are protected by 90 Ampere circuit breakers. The
landing gear extension and retraction system is protected by a 50 Ampere fuse.
The battery also supplies the HOT BUS.
Regular maintenance of the battery system is necessary. Do not wait until a problem occurs.
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Battery Retaining Bolt
To Relay Box
Washer
Battery
Negative
Terminal
Battery
Battery
Positive
Terminal
Cockpit
Forward
Bulkhead
Battery Mount
Figure 1: Main Battery Installation
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Trouble-Shooting
1. General
This table tells you how to trouble-shoot the battery system. If you find the trouble in column 1 do the
repair given in column 3.
Main battery voltage low. Battery capacity low. Do a capacity test. If

necessary, replace the battery.
Alternator(s) low output. Trouble-shoot the alternator(s).

Main battery will not connect to Battery relay defective. Replace the battery relay.
the RELAY BUS.
ELECT. MASTER switch Replace the ELECT. MASTER

defective. switch.
Battery system wiring Do test of the battery system

defective. wiring. Refer to Chapter 92 for
Ammeter on ICS display Defective transducer. Replace the related

shows zero at all times for LH transducer.
or RH alternator.
Alternator regulator needs Refer to the engine

adjustment (if MÄM 42-551 is manufacturer.
not installed).
Voltmeter on ICS display Defective voltmeter. Trouble-shoot the ICS.

shows zero with the ELECT.
MASTER switch set to ON.
Defective wiring in the Do a test of the wiring. Refer to
voltmeter system. Chapter 92 for the wiring
diagrams.
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1. General
Keep the battery clean. Remove the grease and other contaminants from the battery case. Remove
dirt from the area of the terminals. Protect the terminals and cable lugs with Dow Corning compound 4
(DC4).
If you do not use the airplane regularly you must remove the battery for charging.
CAUTION: INSTALL ONLY A BATTERY WHICH IS APPROVED BY THE AIRPLANE

MANUFACTURER.
2. Safety Precautions
Obey the instructions of the battery manufacturer.
Always disconnect the battery before you do work on the airplane electrical system. You must
disconnect the negative cable first. Connect the negative cable last.
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3. Remove/Install the Main Battery
A. Remove the Main Battery from the Airplane
(3) Disconnect the negative cable from the battery: Refer to Figure 1.
S Pull back the rubber boot from the cable

end.
S Remove the bolt and washer that attaches

the negative cable to the battery terminal.
S Move the negative cable clear of the battery

terminal.
(4) Disconnect the positive cable from the battery:
S Pull back the rubber boot from the cable

end.

the positive cable to the battery terminal.
S Move the positive cable clear of the battery

terminal.
(5) Remove the battery retaining clamp:
S Remove the 2 bolts and washers that hold

the battery clamp.
S Remove the battery clamp.
(6) Remove the battery from the airplane.
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B. Install the Main Battery in the Airplane
(1) Make sure that the battery is clean and dry.
(2) Move the battery into position in the battery tray. Refer to Figure 1.
CAUTION: MAKE SURE THAT YOU CONNECT THE CABLES TO THE

CORRECT TERMINALS. INCORRECT CONNECTION CAN DAMAGE
THE ELECTRICAL AND AVIONICS SYSTEMS.
(3) Connect the positive cable to the positive

terminal of the battery:
S Move the cable end fitting into place over

the positive battery terminal.
S Install the washer and bolt that attaches the

cable to the battery terminal.
S Move the rubber boot into position over the

cable end.
(4) Connect the negative cable to the negative


the negative battery terminal.


cable end.
(5) Install the battery clamp:
S Move the battery clamp into position over

the battery cover.
S Install the washers on the battery clamp

bolts.
S Install and tighten the battery clamp bolts. Tighten the bolts equally.
compartment door.
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4. Disconnect/Connect the Main Battery for Maintenance
A. Disconnect the Main Battery for Maintenance
(3) Disconnect the negative cable from the battery: Refer to Figure 1.
S Pull back the rubber boot from the cable-

end.

the negative cable to the battery terminal.
S Move the negative cable clear of the battery

terminal.
(4) Disconnect the positive cable from the battery:
S Pull back the rubber boot from the cable-

end.

the positive cable to the battery terminal.
S Move the positive cable clear of the battery

terminal.
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B. Connect the Main Battery after Maintenance
CAUTION: MAKE SURE THAT YOU CONNECT THE CABLES TO THE

CORRECT TERMINALS. INCORRECT CONNECTION CAN DAMAGE
THE ELECTRICAL AND AVIONICS SYSTEMS.
(1) Connect the positive cable to the positive Refer to Figure 1.


the positive battery terminal.


cable end.
(2) Connect the negative cable to the negative


the negative battery terminal.


cable end.
compartment door.
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To Battery +
Bolt
Washer
Bolt
Washer
Battery Relay
To Battery -
Ring Terminal
Figure 2: Main Battery Relay Installation
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5. Remove/Install the Battery Relay
A. Remove the Battery Relay
(3) Disconnect the battery for maintenance. Refer to Paragraph 4 (A).
(4) Disconnect the positive cable from the battery

relay:
S Remove the bolt and washer from the

terminal of the battery relay.
S Move the positive cable clear of the relay.
S Move the 2 smaller cables clear of the relay

terminal.
(5) Disconnect the battery relay from the RELAY Refer to Figure 2.
BOX BUS bar:


terminal block.
(7) Remove the battery relay:
S Lift the battery relay clear of the relay box.
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B. Install the Battery Relay
(1) Move the relay into position at the relay Check for correct polarity.
mounting and connect the control cables to the
terminal block.
(2) Lower the battery relay into position at the relay

mounting.
(3) Connect the battery relay to the RELAY BOX

BUS bar:

(4) Connect the battery positive cable and the 2 Refer to the wiring diagrams in
smaller cables to the battery relay coil terminal: Chapter 92.
S Move the 2 smaller cables into position at

the battery relay.
S Move the battery positive cables into

position at the battery relay.
S Install the bolt and washer that attaches the

cables to the relay through all 3 cables and
into the relay mounting.
(5) Connect the main battery. Refer to Paragraph 4 (B).
compartment door.
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6. Starter Relay Functional Test
Do this test in an area where the engine can be run.
(1) Set the ELECT. MASTER switch to ON.
(2) Set the LH or RH ENGINE MASTER to ON.
WARNING: MAKE SURE THAT THE AREA OF THE PROPELLERS IS CLEAR

BEFORE YOU OPERATE THE STARTER MOTOR. PROPELLERS
CAN CAUSE INJURY OR DEATH.
(3) Turn the key of the START switch to the engine The engine starter motor must operate.
for the ENGINE MASTER switch that you set to You do not have to start the engine.
ON in step 2.
(4) Turn the key of the START switch to OFF.
(5) Set the ENGINE MASTER switch that you set

on in step 2 to OFF.
(6) Set the ELECT. MASTER switch to OFF.
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Section 24-32
Emergency Power
1. General
This Section tells you about the emergency battery system for the DA 42 NG airplane. Regular
maintenance of the emergency battery system is necessary. Figure 1 shows the main components of
the emergency power system.
Refer to Chapter 92 for the wiring diagrams.
2. Description
The emergency battery system consists of:
) An emergency battery pack.
) A sealed HORIZON EMERGENCY switch.
The emergency battery pack consists of 10 lithium manganese batteries, 3 V, 1,300 mAh. Refer to the
Equipment List in Section 6.5 of the Airplane Flight Manual for the approved battery pack type.
% If MÄM 42-1025 is installed, the batteries are located in a plastic battery box. All used cells must be
% replaced by a set of new cells with identical expiry dates.
The emergency battery pack is mounted behind the instrument panel, on the pilot's side.
When all other sources of electrical power fail during flight, the EMERGENCY HORIZON switch on the
top of the instrument panel is set to ON to use the emergency battery. It supplies the backup attitude
gyro (horizon), or standby attitude module (if OÄM 42-270 is installed) and the flood light with power
for at least 1 hour and 30 minutes.
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Trouble-Shooting
1. General
The table below lists the defects you could have with the emergency battery system. If you have the
% Batteries leaking. Batteries expired. Replace battery pack. If MÄM

% 42-1025 is installed: replace all
% battery cells. All used cells
% must be replaced by a set of
% new cells with identical expiry
% date, update placard on cover.
Clean all items that are

contaminated.
% Voltage on the back side of the Batteries expired. Replace battery pack. If MÄM
% emergency switch less than 42-1025 is installed: replace all
% 30.0 V. battery cells. All used cells
% Batteries have been used. Replace battery pack. If MÄM

% 42-1025 is installed: replace all
% battery cells. All used cells
Emergency battery system Repair the emergency battery

% wiring defective. system wiring.
% If MÄM 42-1025 is installed: Install battery cells, correctly.

% Batteries installed incorrectly in
% battery box.
%
% Note: Expiration date must be the same on all cells and at least five years in the future at
% time of installation in airplane.
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1. General
This Section tells you how to replace the emergency battery pack. It also tells you how to test the
emergency battery system.
Refer to Chapter 92 for the wiring diagrams.
2. Remove/Install the Emergency Battery Pack
A. Remove the Emergency Battery Pack
(2) Disconnect the electrical plug of the battery Refer to Figure 1.

pack.
% (3) Remove the GEA 71/B of its mounting rack.
(4) Remove the two screws and nuts of the Hold the battery pack.
battery pack.
(5) Remove the battery pack clear of the airplane.
% (6) If MÄM 42-1025 is installed: Refer to Figure 1.
% Remove all battery cells from the plastic battery

% box.
CAUTION: THE BATTERY PACKS CANNOT BE RE CHARGED. DO NOT TRY TO

RECHARGE THE BATTERY PACKS. IF YOU TRY TO RECHARGE THE
BATTERY PACKS, THEY CAN EXPLODE OR LEAK.
CAUTION: DISPOSE OF THE BATTERY PACKS PROPERLY (ASK YOUR

BATTERY DEALER FOR ADVISE). BATTERIES CONTAIN POISONS
WHICH HARM THE ENVIRONMENT. DO NOT THROW THE USED
BATTERY PACKS INTO THE GARBAGE. DO NOT EXPOSE BATTERIES
TO FIRE. DO NOT DISMANTLE BATTERY PACKS.
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%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
Figure 1: Emergency Battery Pack
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B. Install the Battery Pack
CAUTION: USE ONLY NEW BATTERY PACKS. REFER TO THE EQUIPMENT LIST
IN THE AIRPLANE FLIGHT MANUAL, SECTION 6.5, FOR THE
CORRECT BATTERY TYPE.
CAUTION: DO NOT SHORT CIRCUIT THE BATTERY PACK.
% (1) If MÄM 42-1025 is installed, install the battery Make sure that the cells are installed
% cells in the plastic battery pack. Apply correctly.
% Electrolube SGB Contact Treatment Grease 2x
% on all cell contacts. Always use new, unused
% battery cells. All battery cells must have the
% same expiry date. All battery cells must have an
% output voltage of at least 3.0 V each.
% (2) Measure the voltage of the battery pack. On the connector for the electrical plug.
If the voltage is less than 30 V, then the
batteries are used. Use a new battery
pack.
% (3) Put the battery pack in place in the instrument

panel on the pilot's side.
% (4) Install the two screws and nuts of the battery

pack.
% (5) Connect the electrical plug of the battery pack. Ensure correct polarity.
% (6) Install the GEA 71/B.
% (7) Measure the voltage on the back side of the If the voltage is below 30 V, it is
EMERGENCY HORIZON switch. probable that the wiring is defective.
Repair wiring.
% (8) Install the instrument panel cover. Refer to Section 25-10.

% Note: Update date on placard on battery box cover, when cells are replaced.
% Note: Expiration date must be the same on all cells and at least five years in the future at
% time of installation in airplane.
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%
%
%
%
%
%
%
%
%
%
%
%
%
% Figure 2: Battery Cell Orientation (Top View)
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Section 24-33
Additional Alternator
1. General
If OÄM 42-204 is carried out, an additional alternator is installed on the LH engine. The additional
alternator generates electrical DC - power for optional airplane equipment. The additional alternator
and its consumers form an additional electrical system which is not connected to the airplanes
standard electrical system.
The additional alternator system has the following components:
) Alternator.
) Alternator fuse.
) Voltage regulator.
) Excitation battery.
) AUX POWER switch.
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Figure 1: Additional Alternator Electrical System Schematic Diagram
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Figure 1 shows the additional alternator electrical system schematic diagram.
A. Additional Alternator
The additional alternator is mounted to the LH engine gearbox and to the RH forward engine
mounting arm. The alternator is driven via a v-belt and generates up to 100 A at 28 V. The
alternator has an external voltage regulator.
There is no scheduled maintenance for the additional alternator. If the additional alternator fails,
it must be replaced.
B. Additional Alternator Excitation Battery
A separately installed small battery is used for the excitation of the additional alternator.
C. Alternator Fuse
A 100 A fuse is located in the engine compartment.
D. Additional Alternator Regulator
The alternator regulator is located in the engine compartment. It measures the alternator output
voltage and controls the current through the alternator field coils via a pulse-width modulated signal.
To keep the output voltage stable at all load and speed conditions, the alternator field signal is
modulated accordingly.
The AUX POWER switch controls the circuit to the alternator regulator.
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Trouble Shooting
1. General
The table below lists the defects you could have in the additional alternator electrical system. If you
the repair in the Repair column.
Alternator provides no electrical Alternator defective. Replace alternator.

power.
Voltage regulator defective. Replace voltage regulator.
Alternator fuse open. Replace fuse.
Alternator control fuse open. Replace fuse.
Alternator v-belt loose/broken. Adjust/replace the v-belt.

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1. General
This Section provides instructions how to remove/install and adjust the components of the additional
28 VDC electrical generating system. Refer to the component manufacturers' manuals for more
detailed information and instructions.
The additional electrical system is a low voltage DC system. When correctly maintained it is safe to
work on.
Maintenance carried out must be of good workmanship strictly considering the guidelines of
AC 43-13.1B. It is important that maintenance is carried out in accordance with the best available
techniques and properly trained maintenance personnel, in order to eliminate possible failures.


MANUFACTURER.
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3. Remove/Install the AUX POWER Switch
A. Remove the AUX POWER Switch
(1) Remove the console from the LH sidewall. Refer to Section 25-10.
(2) Unplug the electrical connector of the AUX

POWER switch.
(3) Remove the nut and washer of the AUX POWER Note the orientation of the switch.
switch.
(4) Move the AUX POWER switch clear of the

console.
B. Install the AUX POWER Switch
(1) Position the AUX POWER switch in place in the Verify correct orientation of the switch.
console.
(2) Insert the washer and the nut of the AUX

POWER switch. Tighten the nut.
(3) Install the electrical connectors on the AUX

POWER switch.
(4) Install the console on the LH sidewall. Refer to Section 25-10.
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4. Remove/Install the Additional Alternator Regulator
A. Remove the Voltage Regulator
WARNING: MAKE SURE THAT THE ENGINES ARE SAFE BEFORE YOU DO ANY
WORK ON THE ADDITIONAL ALTERNATOR REGULATOR. IF THE
ENGINE IS TURNED, THE PROPELLER CAN CAUSE INJURY OR
DEATH.
(1) Make sure that the engines are safe:
S Set the ENGINE MASTER switches to OFF.
S Set the power levers to 0%.
(2) Remove the LH engine upper cowling. Refer to Section 71-10.
(3) Disconnect the voltage regulator wiring harness. Refer to Figure 4.
(4) Remove the two attachment bolts with the two

bushings of the regulator.
(5) Move the voltage regulator clear of the airplane.
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B. Install the Voltage Regulator
WORK ON THE ADDITIONAL ALTERNATOR REGULATOR. IF THE
DEATH.
(2) Position the alternator regulator on the regulator Refer to Figure 4.

mounting bracket.
(3) Install the two bolts with the two bushings which
attach the alternator regulator on the regulator
mounting bracket.
(4) Connect the electrical wiring harness to the Refer to Section 24-33.
alternator regulator.
(5) Install the LH engine upper cowling. Refer to Section 71-10.
(6) Do an engine run-up. Do a test for correct Refer to Section 71-00.

operation of the regulator.
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Section 24-40
External Power
1. General
The DA 42 NG has an external power socket located on the lower surface of the fuselage nose
section. It is a standard 28 V DC power socket. When you connect external power to the external
power socket, the external power control relay is energized and the external power comes online.
2. Description
Figure 1 shows a simple schematic diagram of the external power system. The external power system
has these components:
A. 28 Volt Socket
The 28 V DC power socket is located on the lower surface of the fuselage nose section. The socket
has 3 pins:
) A large negative pin.
) A large positive pin.
) A small positive pin.
A diode connected between the small positive pin and the external power relay solenoid protects the
system from reverse polarity.
B. External Power Relay
The external power relay is located in the relay box mounted on the forward face of the cockpit front
bulkhead. You can access the relay box through the front baggage compartment. A heavy duty cable
connects the large positive pin to the input terminal of the relay. Another heavy duty cable connects
the large negative pin to a ground point.
The small positive pin connects to the solenoid of the external power relay via the diode.
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Figure 1: External Power Supply System Schematic
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3. Operation
When you connect a 28 V DC power supply to the external power socket these things happen:
) Current can flow from the small positive pin to the solenoid of the external power relay, the solenoid
operates and closes the relay.
) Current can flow from the large positive pin through the external power relay to the relay bus.
) The large negative pin is connected to ground.
If the polarity of the power supply is incorrect, then the diode will prevent current from flowing through
the solenoid. The solenoid will not operate and current cannot flow through the external power relay
to the RELAY BOX BUS.

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Trouble-Shooting
1. General
The table below lists the defects you could have with the external power system. If you have the
External power will not come No external power. Make sure that the external
on line. power plug is securely in the
socket.
External power relay is Make sure that the external

defective. power is operating correctly.
Do a test of the external power

relay, if necessary, replace the
external power relay.
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1. General
This Section tells you how to remove/install the external power relay. Refer to the component
manufacturers manuals for more data and shop data.
The DA 42 NG has a low voltage DC electrical system. When correctly maintained it is safe to work
the positive output with a wrench by accident).

DOING MAINTENANCE ON THE ELECTRICAL SYSTEM. MAKE SURE
THAT YOU DISCONNECT THE NEGATIVE CABLE FIRST.


CAUTION: USE ONLY DA 42 NG PARTS THAT ARE APPROVED BY THE

MANUFACTURER.
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To External
Power Socket
Bolt
Washer
Washer
External Power Relay
Ring Terminal
Figure 2: External Power Relay
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3. Remove/Install the External Power Relay
A. Remove the External Power Relay
(2) Remove the front baggage compartment rear

cover.
(3) Disconnect the battery for maintenance. Refer to Section 24-31.
(4) Disconnect the cable from the external power

relay:
S Remove the bolt and washer from the

terminal of the external power relay.
S Move the cable clear of the relay.
(5) Disconnect the external power relay from the

RELAY BOX BUS bar:


external relay terminals.
(7) Remove the external power relay:
S Lift the external power relay clear of the

relay box.
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B. Install the External Power Relay
(1) Move the relay into position at the relay Check for correct polarity.
mounting and connect the control cables to the
terminal block.
(2) Lower the external power relay into position at

the relay mounting.
(3) Connect the external power relay to the RELAY

BOX BUS bar:

(4) Connect the cable to the external power relay Refer to the wiring diagrams in
terminal: Chapter 92.
S Move the cables into position at the external

power relay.
S Install the bolt and washer that attaches the

cable to the relay through he cable and into
the relay mounting.
(5) Connect the main battery. Refer to Section 24-31.
(6) Remove the front baggage compartment rear

cover.
compartment door.
(8) Do a test for the correct operation of the

external power relay.
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Section 24-60
DC Electrical Load Distribution
1. General
This Section tells you about the system which supplies DC electrical power to other systems. The DC
electrical load distribution system has these components:
) RELAY BUS.
) HOT BUS.
) LH MAIN BUS.
) RH MAIN BUS.
) LH ECU BUS.
) RH ECU BUS.
) AVIONICS BUS.
) Battery relay.
) Starter relay.
) Avionics master relay.
) Switches.
) Circuit breakers.
) Fuses.
Figure 1 and 2 shows the electrical bus structure for the DA 42 NG. Figure 3 shows the layout of the
switches and circuit breakers in the instrument panel.
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Figure 1: Electrical System Bus Structure Simplified Diagram, if MÄM 42-403 is not carried out
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Figure 2: Electrical System Bus Structure Simplified Diagram, if MÄM 42-403 is carried out
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D E F G O
KM N L C I H J A B
FUEL PUMPS LH ENGINE FUEL PUMPS LH ENGINE
SWITCHES FUEL
PUMP A
FUEL
PUMP B
FUEL
PUMP A
FUEL
PUMP B
A - ELECT MASTER
B - AV. MASTER
C - PITOT
D - LANDING
E - TAXI NO SMOKING LH MAIN BUS
F - POSITION COM1 GPS/NAV1 XPDR ENG INST
D E IC E
G - STROBE 5 5 5 5
H - START SWITCH
I - ENGINE MASTER LH PITOT
XFER PUMP
DE-ICE
J - ENGINE MASTER RH 10 10
K - VOTER LH
TAXI/MAP FLOOD
L - VOTER RH ACL OXY
M - ALT LH 5 5
N - ALT RH GEAR WRN
O - HORIZON EMERGENCY PFD ADC AHRS ELEV LIMIT GEAR
5 5 5 5 5
RH MAIN BUS
5 3 10 5 5 5 3 25 2
AVIONICS BUS
5 5 5 7½ 5 3 2 3 3
LH ENG ECU BUS LH RH RH ENG ECU BUS
30 20 20 60 90 90 60 30 20 20
Figure 3: Location of Electrical Switches and Circuit Breakers
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Trouble-Shooting
1. General
This table tells you how to trouble-shoot the DC electrical distribution system. It does not tell you about
the equipment. For faults on an item of equipment, or a system, refer to the applicable chapter. For
example, for no oil pressure indication, see Chapter 77 - ENGINE INDICATING. Make sure that there
is 28 V DC on both the LH MAIN BUS and the RH MAIN BUS and that the alternators are supplying
power.
There is 28 V DC on the RH AV. MASTER switch set to Set the AV. MASTER switch to
MAIN BUS but not on the OFF. ON.
AVIONICS BUS.
MASTER CONTROL circuit Set the MASTER CONTROL

breaker not set. circuit breaker.
AVIONICS BUS circuit breaker Set the AVIONICS BUS circuit

not set. breaker.
Avionics master relay Replace the avionics master

defective. relay.
A failure of the cables which Do a continuity test of the

connect the AVIONICS BUS to cables. Refer to Chapter 92 for
the RH MAIN BUS. the wiring diagrams.
Repair/replace defective
wiring.
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1. General
This Section tells you how to remove/install components of the DC load distribution system. Refer to
the component manufacturers’ manuals for more data and shop data.
The DA 42 NG has a low voltage DC electrical system. When correctly maintained it is safe to do work
the battery positive with a wrench by accident).

YOU DO ANY WORK ON THE ELECTRICAL SYSTEM. MAKE SURE
THAT YOU DISCONNECT THE NEGATIVE LEAD FIRST.



MANUFACTURER.
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Nut
Washer
Avionics Master Relay
Instrument Panel Shelf
Bolt
Figure 3: Avionics Master Relay Installation
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3. Remove/Install the Avionics Master Relay
A. Remove the Avionics Master Relay
(1) Open the forward baggage compartment door. Refer to Section 52-40.
(2) Remove the battery cover.
(3) Disconnect the battery for maintenance. Refer to Section 24-31.
(5) Locate the avionics master relay. Refer to Figure 3.
(6) Disconnect the electrical cables from the relay. Make a note of the connections.
(7) Remove the nut, washer and bolt that attaches

the relay to the instrument panel floor.
(8) Move the relay clear of the airplane.
B. Install the Avionics Master Relay
(1) Move the new relay into position on the

instrument panel shelf.
(2) Connect the electrical cables to the relay. Refer to the wiring diagrams and
Paragraph 3.A(6) above.
(3) Install the bolt, washer and nut that attaches the
relay to the instrument panel floor.
(4) Install the instrument panel cover.
(5) Reconnect the main battery. Refer to Section 24-31.
(6) Install the battery cover.
(7) Close the forward baggage compartment doors. Refer to Section 52-40.
(8) Do a test of the relay:
S Set the AV. MASTER switch to ON. All avionics must operate.
S Set the AV. MASTER switch to OFF.
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4. Remove/Install a Circuit Breaker
To remove some circuit breakers and switches it may be necessary to remove a placard panel from the
instrument panel. Refer to Section 11-30.
A. Remove a Circuit Breaker
(2) Disconnect the main battery and the ECU Refer to Section 24-31.
backup batteries for maintenance.
(4) Remove the nuts and washers that attach the Do this for all the circuit breakers that
circuit breakers to the instrument panel. are attached to the same bus bar.
(5) Remove the screw that connects the circuit

breaker that you will replace to the bus bar.
(6) Disconnect the electrical cables(s) from the

circuit breaker that you will replace.
(7) Move the bus bar and all the circuit breakers
attached to it away from the instrument panel.
(8) Remove the circuit breaker clear of the

instrument panel.
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B. Install a Circuit Breaker
(1) Move the circuit breaker into position in the

instrument panel.
(2) Move the bus bar back into position with the
remaining circuit breakers.
(3) Reconnect the electric cables to the circuit Refer to Chapter 92 for the wiring
breaker. diagrams.
(4) Install the screw that attaches the circuit breaker

to the bus bar.
(5) Install the washers and nuts that attach the

circuit breakers to the instrument panel.
(7) Reconnect the main battery and the ECU Refer to Section 24-31. Connect the
backup batteries. positive cable first.
(8) Close and secure the baggage compartment Refer to Section 52-40.
door.
(9) Do a test for the correct function of the circuit

breaker:
S Set the ELECT. MASTER to ON. Apply the full electrical load to the
system.
S Operate the electrical system related to the
circuit breaker that you will test.
The system must stop operating. Make
S Pull the circuit breaker.
sure that there is no power to the
system.
S Set the circuit breaker.
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5. Remove/Install an Instrument Panel Switch
To remove some circuit breakers and switches it may be necessary to remove a placard panel from
the instrument panel. Refer to Section 11-30.
Use the procedures at Sub-paragraphs A and B for these clip secured switches:
) ELECT. MASTER.
) AV. MASTER.
) FUEL PUMPS.
) PITOT.
) LANDING LIGHT.
) TAXI LIGHT.
) POSITION LIGHTS.
) STROBE.
Use the procedures given in Sub-paragraphs C and D for the other switches.
A. Remove a Clip-Secured-Type Instrument Panel Switch
(2) Disconnect the main battery and the ECU Refer to Section 24-31.
backup batteries for maintenance.
(4) Disconnect the electrical cables for the switch

that you will remove.
(5) Remove the switch from the instrument panel: With your fingers, from the back of the
instrument panel.
S Press the locking clips at the sides of the
switch to release the switch from the
instrument panel.
S Move the switch clear of the instrument

panel, from the pilot's side of the instrument
panel.
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B. Install a Clip-Secured-Type Instrument Panel Switch
(1) Hold the clips on the switch compressed and From the pilot's side of the instrument
move the switch into position in the instrument panel. Make sure that the clips have
panel. expanded and that the switch is
correctly located.
(2) Connect the electrical cables to the switch. Refer to Chapter 92 for the wiring
diagrams.
(4) Reconnect the main battery and the ECU Refer to Section 24-31. Connect the
backup batteries. positive cable first.
door.
(6) Do a test for the correct function of the switch:
S Set the switch that you installed to ON. The system must operate correctly.
S Set the switch that you installed to OFF. The system must switch off.
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Use the procedures in Sub-paragraphs C and D for these nut secured switches:
) START SWITCH.
) ENGINE MASTER LH.
) ENGINE MASTER RH.
) ALT LH.
) ALT RH.
) VOTER LH.
) VOTER RH.
) ECU TEST LH/RH.
) HORIZON EMERGENCY.
C. Remove a Nut-Secured-Type Instrument Panel Switch
(2) Disconnect the main battery and ECU backup Refer to Section 24-31.
batteries for maintenance.
(4) Remove the nut and washer that attaches the

switch to the instrument panel.
(5) Move the switch forward and clear of the

instrument panel to give access to disconnect
the electrical cables from the switch.
(6) Disconnect the electrical cables from the switch

and move the switch clear of the airplane.
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D. Install a Nut-Secured-Type Instrument Panel Switch
(1) Move the switch into position near to the switch

electrical cables.
(2) Connect the electrical cables to the switch. Refer to Chapter 92 for the wiring
diagrams.
(3) Move the switch into position in the instrument Hold the switch in position.
panel.
(4) Install the washer and nut that attach the switch
to the instrument panel.
(6) Reconnect the main battery and ECU backup Refer to Section 24-31. Connect the
batteries. positive cable first.
door.
(8) Do a test for the correct function of the switch:
S Set the switch that you installed to ON. The related system must operate.
S Set the switch that you installed to OFF. The related system must switch off.
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DA 42 NG AMM Equipment/Furnishings
AIRCRAFT
CHAPTER 25
EQUIPMENT/FURNISHINGS
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AIRCRAFT
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TABLE OF CONTENTS
CHAPTER 25
EQUIPMENT FURNISHINGS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 25-10
Flight Compartment
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Pilot’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Additional Maintenance Practices for Seats with Adjustable Backrest . . . . . . . 204
4. Remove/Install a Pilot’ s Seat Access Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
5. Disassemble/Assemble the Adjustable Backrest Mechanism . . . . . . . . . . . . . . 213
6. Remove/Install the Passenger Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
7. Remove/Install a Safety Harness (if OÄM 42-324 is NOT installed) . . . . . . . . . 222
8. Remove/Install the Instrument Panel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
9. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
10. Remove/Install the Short Baggage Extension (OÄM 42-207 installed) . . . . . . . 225
Section 25-50
Aft Baggage Compartment
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Access Panel in the Baggage Compartment Floor . . . . . . . 201
3. Remove/Install the Aft Baggage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . 203
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Section 25-60
Emergency Equipment
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Description of the Artex ME406 ELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Description of the Kannad 406 AF-Compact ELT or Kannad AF-Integra ELT . . . . 4
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the ELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Replace the ELT Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4. Remove/Install the Artex ME 406 or Kannad 406 AF-Compact ELT or
Kannad AF-Integtra ELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5. Replace the ELT Battery Pack of the Artex ME406 . . . . . . . . . . . . . . . . . . . . . . 212
6. Remove/Install the ELT RCPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
7. ELT Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
8. Kannad 406 AF-Compact ELT Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . 217
Page 2
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CHAPTER 25
EQUIPMENT FURNISHINGS
1. General
This Chapter tells you about the equipment and the furnishings in the flight compartment of the
DA 42 NG airplane. Figure 1 shows the location of the cabin equipment. Section 25-10 includes the
flight compartment trim panels, the cabin seats and the safety harnesses. Section 25-60 tells you
about the emergency location transmitter (ELT) and the first aid kit. Refer to Chapter 26 for data about
the hand fire extinguisher.
of the Airplane Flight manual. Such equipment may be installed in accordance with
Note: Any equipment which is not listed in Section 6.5 of the Airplane Flight Manual is
Service Bulletin.
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Baggage Compartment
Passengers Seats
Fire Extinguisher Co-Pilot's Seat

Safety Belt
First Aid
Kit
ELT
Pilot's Seat
Map Storage
Carpets
Figure 1: Cabin Equipment
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Section 25-10
Flight Compartment
1. General
The flight compartment of the DA 42 NG has fixed seats for the two pilots and two passengers.
If OÄM 42-067 or OÄM 42-259 is carried out, the pilots’ seats are equipped with adjustable backrests.
Each seat has a safety harness. The fuselage shell is trimmed with fabric wall panels. Carpets cover
the floor areas and the aft baggage compartment floor. Map pockets are located on the cockpit side
by each pilot.
GFRP moldings make the instrument panel cover and the center console. Refer to Section 25-60 for
data about the ELT and the first aid kit.
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Gaiter for
Control Stick
Bolt
Washer
Anchor Plate
Press Studs for Washer

Seat Cushion Bolt
Inner Crash Element
Front Main Bulkhead
Outer Crash Element
Rear Face of Floor Panel
Figure 1: Pilot’s Seat Installation
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Padded Cushion
Lumbar Support Cushion
Flexible Gaiter
Backrest
Lumbar Support
Cover
(2 per seat)
Inboard Hinge
Lamella Package
Seat Pan
Friction Adjustment
Screw
Seat Lever
Outboard Hinge
Bowden Cable
Lumbar Support Lever
Figure 2: Pilot’s Seat Installation (if OÄM 42-067 is carried out)
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Padded Cushion
Lumbar
Support
Cushion
Flexible Gaiter Backrest
Lumbar Support
Hydraulic Cylinder RH
Inboard Hinge
Seat Pan Hydraulic Cylinder LH
Bowden Cable
Outboard Hinge
Lumbar Support Lever
Release Button
Figure 3: Pilot’s Seat Installation (if OÄM 42-259 is carried out)
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A. Pilots’ Seats
(1) Fixed Pilots’ Seats
Figure 1 shows the pilot’s seat installation. Each pilot’s seat is GFRP/Carbon/Kevlar molding.
Rivets attach a metal plate to the bottom of the seat pan at the back. Two bolts go through the
seat pan and the metal plate to hold the lap straps of the safety harness. These bolts also hold
metal anchor plates which attach to anchor nuts in the large cut out in the front main bulkhead.
The front of the seat pan curves down to locate over the rear vertical wall of the front floor panel.
Two bolts with washer plates attach the front seat to the floor panel.
A padded seat cushion covers the molding. Velcro tapes attach the forward part of the seat
cushion to the seat pan. A flexible gaiter attaches to the front seat pan with velcro tapes. The
control stick passes through the gaiter. A velcro tape seals the top of the gaiter to the control
stick.
(2) Pilots’ Seats with Adjustable Backrest (if OÄM 42-067 or OÄM 42-259 is carried out)
CAUTION: DO NOT LOOSEN THE LEVER FOR THE ADJUSTABLE BACKREST OF

THE FRONT SEATS UNINTENTIONALLY. THE SPRING LOADED
Figure 2 and Figure 3 show the variants of pilots’ seats with adjustable backrest installations.
Each pilots’ seat consists of a seat pan and a backrest made of GFRP/Carbon/Kevlar. Rivets
attach a metal plate to the bottom of the seat pan at the back. Two bolts go through the seat pan
and the metal plate to hold the lap straps of the safety harness. These bolts also hold metal
anchor plates which attach to anchor nuts in the large cut-out in the front main bulkhead. The
front of the seat pan curves down to locate over the rear vertical wall of the front floor panel.
The backrest is attached to the seat pan via an inboard and an outboard hinge. If OÄM 42-067
is installed each hinge is formed by two lamella packages - one is bolted to the seat pan, the
other to the backrest with hexagon head bolts. The lamella packages act as a friction brake
controlled by a friction adjustment screw and the seat lever on the outboard side of each
backrest. To preload the friction brake to the correct setting refer to the Maintenance Practices
in this Section. Additionally the backrest is forced forward by a GFRP/Carbon spring element
mounted to the bottom of the seat pan.
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If the OÄM 42-259 is installed, the seat pan and backrest are bolted similarly to the inboard and
outboard hinges. The hinges are linked twice, once thru brackets with the Hydrolok cylinder and
once with a bolt allowing rotation. A button operates via bowden cable a valve allowing the
Hydrolok cylinder retract/extend forcing the hinges rotating around their connecting bolt.
Additionally the backrest is forced forward by a spring integrated in the Hydrolok cylinder.
The upright position of the backrest is determined by a placard on the roll-over bar.
A lumbar support cushion is integrated to the lower part of the backrest. The cushion is operated
via a Bowden cable by use of a lever mounted to the outboard side of the seat pan.
A padded cushion covers the seat pan molding and the backrest. Press studs attach the forward
part of the seat cushion to the seat pan. A flexible gaiter attaches to the front seat pan with
press-studs. The control-stick passes through the gaiter. A velcro band seals the top of the
gaiter to the control stick.
B. Passenger Seat
Figure 4 shows the passenger seat installation. The passenger seat has three main parts. It has
a double seat pan which is the full width of the cockpit. The rear seat pan also makes the baggage
compartment floor. The passenger seat also has two seat backs which attach to the seat pan with
hinges. A latch at the left side of each seat back locks the seat in the upright position. You can lift
the latch pin to fold the seat-back forward for access to the aft baggage compartment.
A padded seat cushion covers the seat molding. Velcro tapes attach the forward part of the seat
cushion to the seat pan. Padded cushions also cover the seat backs.
Rivets attach a metal plate under each half of the seat pan at the back. Two bolts go through each
half of the seat pan and the metal plate to hold the lap straps of the safety harness. Three bolts with
washer plates on each side of the seat pan go through the seat pan and metal plate to anchor nuts
in metal anchor plates. The anchor plates are bolted to the fuselage structure. Two bolts with
washer plates attach the front of the seat pan to ribs on top of the rear main bulkhead. Five bolts
with washer plates attach the rear of the seat pan to the top face of the aft baggage compartment
frame.
C. Crash Elements
Each seat rests on crash elements. Each crash element has layers of fiber composite and a special
rigid foam bonded together. The crash elements compress under the high loads which occur in
accidents. They reduce the injuries to pilots and passengers in an accident.
The rear of each pilot’s seat rests on two crash elements. They are located just outboard of the
safety harness attachments. The passenger seat pan rests on two crash elements. They are
located under the anchor plates on each side.
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Bolt
Plate Reinforcing
Bolt
Washer
Bolt
Plate
Reinforcing
Crash
Element
Anchor Plate
Rear Main Bulkhead
Figure 4: Passenger Seat Installation
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Fuselage Structure
Inertia Reel
Cover
Washer
Bolt
REAR SAFETY BELT ATTACHMENT

FOR SHOULDER STRAP
Bolt
Washer
Spring Washer
Bolt LH Shown, Roll Bar
RH Opposite
Washer
Rear Seat Pan

Washer
FRONT SAFETY BELT TOP ATTACHMENT
Nut Bolt FOR SHOULDER STRAP
Washer
Cover
Metal Plate
Washer
REAR SAFETY BELT ATTACHMENT
Nut
FOR LAP BELT
Bolt
Fuselage Structure
Bolt Washer
Inertia Reel
Washer Front Seat
Pan
FRONT SAFETY BELT ATTACHMENT
FOR INERTIA REEL
Front Main
Bulkhead
Washer
Bolt
Metal Plate
Bolt
Washer Washer
Nut Anchor Plate
Front Main
Frame
FRONT SAFETY BELT ATTACHMENT

FOR LAP BELT
Figure 5: Safety Harness Installation
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D. Safety Harness
Figure 5 shows the safety harness installation. Each seat has a fixed lap strap and an inertia
sensitive shoulder strap. The lap belt has two straps. The outboard strap has an adjuster to tighten
the strap in use. It also has tongue to engage the buckle on the inboard strap. The inboard strap
is a fixed length. The buckle has a red button at the outboard end to release the tongue of the
outboard lap strap. Push the tongue into the end of the buckle to lock them together.
Bolts with washer plates and anchor nuts attach each lap strap to the seat pan. You must remove
the seat to remove the lap strap.
The shoulder strap attaches to an inertia reel. The inertia reel has a latch which senses
acceleration. With the airplane flying straight and level, the inertia reel lets the shoulder strap pull
out against a light spring tension. If the airplane is accelerated (for example, in turbulence), the
latch stops the shoulder strap from pulling out.
The inertia reel for the pilot’s safety harness is located on the fuselage wall behind the pilot’s seat.
The strap passes up through a guide attached to the roll-bar just above the pilot’s shoulder and
down to the tongue on the outboard lap strap. The end fitting on the shoulder strap hooks onto a
stud on the tongue.
The inertia reels for the rear passenger’s safety harnesses are located above and to the rear of the
passengers. They are mounted on the fuselage top inner surface.
If OÄM 42-324 is installed: Refer to AmSafe Maintenance Documentation for further information.
E. Fabric Wall Panels
Fabric wall panels bond to the inside of the fuselage shell. Each front outboard side-panel has a
map pocket.
F. Instrument Panel Cover
A GFRP cover goes over the instrument panel. Screws attach the cover to the instrument panel.
The instrument panel cover has a defrost manifold to direct defrost air from the heating system onto
the inside of the canopy to prevent canopy misting. Flexible hoses connect the manifold to the
airplane heating system.
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G. Center Console Panel
A GFRP panel goes between the rear wall of the floor panel and the front face of the main front
bulkhead. The center console panel covers the trim mechanism. It also seals the gap between the
pilot’s seats.
H. Baggage Compartment
If OÄM 42-207 is carried out, a short baggage extension is installed.
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1. General
These Maintenance Practices tell you how to remove/install the seats, the safety harnesses and other
furnishings. See Section 25-60 for data about the ELT and other safety equipment.
2. Remove/Install a Pilot’s Seat
Note: Some maintenance procedures described in this AMM require the removal of a
front seat. However, if the maintenance hole in the seat gives sufficient access to
the system beneath it, it is acceptable to leave the seat in place and remove only
the maintenance access panel. Refer to Paragraph 3.
A. Remove a Pilot’s Seat
If the adjustable front seats (OÄM 42-067 or OÄM 42-259) are installed:
CAUTION: DO NOT ENGAGE THE LEVER OR THE BUTTON FOR THE

ADJUSTABLE BACKREST OF THE FRONT SEATS
UNINTENTIONALLY. THE SPRING LOADED BACKREST MAY SNAP
FORWARD AND CAN CAUSE INJURY.
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OÄM 42-259) are installed:
Set backrest to the upright position:
S Sit down in the front seat.
S Lift the seat lever.
S Adjust the backrest to the upright position.
S Release and press down the seat lever.
(2) Release the top of the gaiter from the control Refer to Figure 1 (fixed backrest) or
stick. Figure 2 and 3 (adjustable backrest).
(3) Release the press-studs at the front of the seat Move the cushion to give access to the
cushion. attaching bolts for the seat.
(4) Remove the 2 bolts with washer plates which From the passenger compartment behind
attach the anchor plates to the front main the pilot’s seat.
bulkhead.
(5) Remove the 4 bolts with washer plates which

attach the front of the seat to the rear wall of the
floor panel.
(6) Remove the lap strap from the seat.
(7) Lift the seat forward and out of the cockpit. Take care that the stick gaiter does not
catch on the top of the control stick.
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B. Install a Pilot’s Seat
If the adjustable front seats (OÄM 42-067 or OÄM 42-259) are installed:

(1) Examine the crash elements. Look specially for Refer to Figure 1.
delaminating and buckling.
(2) Make sure that the area below the seat is clean For example, tools.
and has no unwanted objects.
(3) Move the seat into position so that the anchor Make sure that the stick gaiter locates
plates go through the large holes in the front correctly over the control stick.
main bulkhead.
(4) Install the bolts and washer plates which attach Torque 6.4 Nm (4.7 lbf.ft.).
the seat to the floor panel.
(5) Install the bolts and washer plates which attach From the passenger compartment behind
the anchor plates to the front main bulkhead. the pilot’s seat.
Torque 16 Nm (11.8 lbf.ft.).
(6) Fasten the press-studs which attach the seat

cushion.
(7) Tighten the top of the gaiter around the control Make sure that the control stick is free to
stick. move throughout its range of operation.

OÄM 42-259) are installed:
S Do a test of the backrest adjustment Refer to Paragraph 3.

mechanism.
S Do a test of the lumbar support mechanism. Refer to Paragraph 3.
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3. Additional Maintenance Practices for Seats with Adjustable Backrest
Perform test procedures the following test of the adjustable backrest mechanism.
If the test fails refer to Paragraph (2), (3).
(1) Test Procedures
(a) Test the Backrest Adjustment Mechanism of a Front Seat (optional, OÄM 42-067 or
OÄM 42-259)

Note: If the adjustable backrest mechanism does not pass the following test, perform
a visual inspection. Refer to Paragraph 3.
(1) Sit down in the front seat.
(2) Lean against the backrest. To counteract the spring loaded backrest
mechanism.
(3) Carefully lift the seat lever or press button.
(4) Move the backrest fully rearward:
S Check for limited range of movement and

interference.
S Release the seat lever or button in different Release the seat lever or button to
backrest angles and check for improper ensure proper locking. Apply a test load
fixation. of 90 daN (200 lbf) to the top of the
backrest at room temperature.
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(5) Allow the backrest to move forward to the

upright position:
S Check for interference.
S Check for lack of spring force. The spring must be strong enough to
move the backrest from the full rearward
position to the upright position
designated by a placard on the roll-over
bar.
(6) Pull forward on the backrest to move it forward

beyond the designated upright position.
S Check for limited range of movement and

interference.
S Let the seat lever move to the locking Press down the seat lever to ensure
position or release the button at different proper locking. Apply a test load of
backrest angles and check for improper 90 daN (200 lbf) to the top of the
fixation. backrest at room temperature.
(7) Move the seat back to the upright position.
(8) Let the seat lever move to the locking position. Press down the seat lever to ensure
proper locking.
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(b) Test the Lumbar Support Mechanism of a Front Seat (optional, OÄM 42-067 or
OÄM 42-259)
(1) Sit down in the front seat.
(2) Turn the lumbar support lever. You must feel the mechanism increasing
and decreasing the effect of the lumbar
support cushion in the backrest.
(2) Adjust the Friction of the Backrest (optional, OÄM 42-067)

(1) Remove the seat.
(2) Pull away the lining from the inboard hinge to Through the access hole in the cover.
gain access to the inboard friction adjustment
screw.
(3) Adjust the friction:
S Set the locking lever to the „unlocked“

position.
S Loosen the friction adjustment screws

(LH and RH).
S Tighten friction adjustment screws

(LH and RH) with finger force.
S Tighten friction adjustment screws

(LH and RH) with 10 mm hexagon nut in
increments of approx. 15 degrees
(1/24 turns) until friction in the hinge
mechanism increases notably.
S Turn back the adjustment screws

(LH and RH) one-quarter turn.
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(4) Re-attach the lining to seat.
(5) Install the seat.
(6) Do a test of the backrest adjustment Refer to Paragraph (1)(a).

mechanism.
(3) Visual Inspection of the Adjustment Mechanism (optional, OÄM 42-067)
(1) Remove the seat from the airplane. Refer to Paragraph 2.
(2) Remove the seat lever from the seat:
S Remove the plug from the lever.
S Remove the lever mounting screw.
S Remove the lever from the seat.
(3) Carefully separate the leather lining from the Turn lining inside out together with the
backrest: bag while pulling off.
S Remove the cushion from the seat pan

(attached with velcro).
S Drill out one blind rivet each attaching the

two plastic brackets for the rubber bands to
the seat pan.
S Pull off the rubber bands from the plastic

brackets.
S Untie the knots of the 3 strings which tie the

lower edge of the backrest cushion to the
seat pan.
S Carefully remove the leather lining from the

cover by opening all velcro fasteners.
(4) Move the cover forward to remove it from the The cover remains attached to the
hinge. cushion.
(5) Check the lamella package for deformation,

corrosion and lack of lubrication.
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(6) Install cover by moving it over the hinge.
(7) Reinstall the leather lining to the seat:
S Attach the leather lining to the cover using

the velcro fasteners.
S Tie the backrest cushion to the seat pan

with the 3 strings.
S Put the rubber bands into the plastic

brackets.
S Use blind rivets to fasten the plastic

brackets to the seat pan.
S Attach the cushion to the seat pan using

the velcro.
(8) Install the seat lever:
S Put the lever onto the adjustment

mechanism in correct position.
S Install the lever mounting screw.
S Install plug to lever.
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(4) Visual Inspection of the Adjustment Mechanism (optional, OÄM 42-259)
(1) Remove seat from airplane.
backrest bag while pulling off.
(3) Check the Hydrolok cylinder for leakage, Use mirror and flashlight to be able to
contamination, check actuator cable for inspect the mechanism installed in the
damage. Replace items if necessary, for backrest tunnel.
disassembly of the mechanism refer to
Maintenance Practices, Paragraph 5.
(4) Re-install the leather lining to the seat.
4. Remove/Install a Pilot’ s Seat Access Panel
A. Remove a Pilot’s Seat Access Panel
(1) Remove the cloth coating from the seat.
(2) Remove the 10 bolts which attach the access

panel to the seat.
(3) Lift the access panel clear of the airplane.
B. Install a Pilot’s Seat Access Panel
(1) Move the access panel in place in the seat.
(2) Install the 10 bolts which attach the access

panel to the seat.
(3) Fasten the cloth coating on the seat.
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Backrest
Seat Pan Lamella Package
Clamping
Nut 0.5mm
Disc, Backrest 0.3mm
Strong Inner 0.5mm
0.3mm
0.5mm
0.3mm
0.5mm Fitting Backrest

Discs,
Backrest Disc, Backrest
(x20) Strong Outer
Hexagon Screw
1.6mm with Stop for Lever
Discs, Driver Sheet
Seat (x20)
Coil II
0.3mm
0.5mm Axial Needle
0.3mm Roller Bearing
0.5mm 1.6mm
0.3mm
Coil I
Fitting Seat
Tension
Spring Coil I
Locking Plate
Figure 6: Adjustable Backrest Assembly (if OÄM 42-067 is installed)
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Backrest
Seat Pan
Release Button
35 mm (1.38 in)
Hydrolok Fixing Bracket
Hydraulic Cylinder Bush
PAF Bush
Backrest Bracket
Side Bracket Seat Side
Bush
Bracket Seat Side
PAF Bush
Figure 7: Seat Adjustment Mechanism (if OÄM 42-259 is installed)
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Hydrolok Fixing Bracket

Bolt x 1
Washer x 1
Bolt x 3
Hydraulic Cylinder
Backrest
Washer x 2
Bolt x 2
Backrest Bracket
Side Bracket Seat Side

Washer x 5
Bolt x 5
Seat Pan
Figure 8: Adjustable Backrest Assembly (if OÄM 42-259 is installed)
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5. Disassemble/Assemble the Adjustable Backrest Mechanism
A. Remove the Backrest Assembly from the Seat (optional, OÄM 42-067)
Each seat contains a left and right side mechanism. Before you can disassemble the backrest
mechanism you must carry out the following steps:
(1) Remove the seat from the airplane. Refer to Paragraph 2.
(2) Remove the seat lever from the seat:
S Remove the plug from the lever.
S Remove the lever mounting screw.
S Remove the lever from the seat.
(3) Carefully separate the leather lining from the

backrest:
S Remove the cushion from the seat pan

(attached with velcro).
S Drill out one blind rivet each attaching the

two plastic brackets for the rubber bands to
the seat pan.
S Pull off the rubber bands from the plastic

brackets.
S Untie the knots of the 3 strings which tie the

lower edge of the backrest cushion to the
seat pan.
S Carefully remove the leather lining from the Turn the lining inside out together with
cover by opening all velcro fasteners. the bag while pulling off.
(4) Move the cover forward to remove it from the The cover remains attached to the
hinge. cushion.
(5) Peel away the leather lining from the bottom of

the seat pan on the side which points towards
the middle of the fuselage. The nine hexagon
screws of the seat fitting become accessible.
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(6) Remove the screw with the distancing bushing

and the washer from the torsion bar.
(7) Remove the nine hexagon screws on both

sides of each seat fitting.
(8) Remove the LH and the RH mechanism.
(9) Remove the torsion bar from the backrest.
Fitting Seat
Hexagon Screw
with Stop for Lever
Fitting Backrest
Figure 9: Arrangement of the Fitting Seat, Fitting Backrest and Screws

(LH side shown, if OÄM 42-067 is installed)
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B. Remove Backrest Assembly from Seat (optional, OÄM 42-259)
Each seat contains a left and right side mechanism. Before you can disassemble the backrest
mechanism you must carry out the following steps:
(1) Remove seat from airplane.
backrest. bag while pulling off.
(3) Disconnect the lumbar actuator bowden cable.
(4) Remove the 5 outboard and 1 inboard hexagon Refer to Figure 8.

screws from the backrest brackets as they
become accessible on both sides.
(5) Pull off the backrest shell.
C. Disassemble the Adjustable Backrest Mechanism (optional, OÄM 42-067 or OÄM 42-259)
Disassemble the adjustable backrest mechanism carefully. Refer to the table in Paragraph D or E
and carry out the steps in the opposite order.
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D. Assemble the Adjustable Backrest Mechanism (optional, OÄM 42-067)
The following table describes the assembling of a single backrest mechanism. The assembly
procedure is used for both sides.
Step Seat Fitting Thickness Backrest Fitting Thickness Remark

No.
Arrange the seat fitting and the backrest fitting and place the 7 hexagon screws (M6 x 32) and
(1) a hexagon screw with stop for lever as shown in Figure 6. Use some adequate bars to put
under the fittings.
Disc, Backrest
(2) 4 Washers 1.6 mm 1.6 mm
Strong Outer
(3) Stick the bolt (10 mm) through the outer backrest disc.
(4) Lamella 0.3 mm 4 Washers 0.5 mm
(5) 4 Washers 0.3 mm Lamella 0.3 mm Repeat steps

(5) and (6)
(6) Lamella 0.3 mm 4 Washers 0.3 mm four times.
(7) 4 Washers 0.5 mm Lamella 0.3 mm

(9) and (10)
(11) 4 Washers 2 x 0.3 mm Lamella 0.3 mm
(12) Lamella 0,3 mm 4 Washers 2 x 0.3 mm

(13) and (14)

(17) and (18)
4 Self Locking
(20) M5 4 Washers 0.5 mm
Hexagon Nuts
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Step Seat Fitting Thickness Backrest Fitting Thickness Remark

No.
Disc, Backrest
(21) --- --- 4 mm
Strong Inner
Screw the hexagon screw (M5x6) with the washer (17 mm) into the thread of the bolt and
(22)
apply Loctite 262 screw locking or equivalent.
In order to check the correct arrangement of the lamella, view the assembly from side and
(23)
observe the regular pattern of the lamella formed the varying thickness of the washers.
Screw the thinner hexagon nuts on the 4 hexagon screws of the strong backrest disc and
(24)
apply Loctite 262 screw locking or equivalent.
(25) Insert the brass bushing next to the seat fitting side.
Insert the clamping nut from the backside with the 3 disc springs, ensuring the outer diameter
(26) of the disc springs points towards the backrest disc and the inner diameter points towards the
clamping nut.
LH side: place coil 1 so that 1 stamped point can be seen, place one bearing on the coil 1,
(27) place coil 2 onto the bearing so that 2 stamped points can be seen, place a bearing on coil 2,
place another coil 1 on the bearing so that 1 stamped point can be seen.
RH side: place coil 1 so that 2 stamped point can be seen, place one bearing on the coil 1,
(28) place coil 2 onto the bearing so that 1 stamped point can be seen, place a bearing on coil 2,
place another coil 1 on the bearing so that 2 stamped point can be seen.
Screw the clamping screw into the internal thread of the clamping nut, and just tighten it by
(29)
hand.
(30) Insert the distancing bushing through the holes of the two coils.
Put the M4 x 20 screw with the washer and the locking plate through the distancing bushing,
(31)
screw it into the backrest fitting, but do not tighten it yet.
Tighten the clamping screw as far as possible by hand and apply a quarter additional turn
(32)
with the screw wrench.
Place the locking plate over the hexagon screw and tighten the distancing bushing with the
(33)
hexagon screw (M4 x 20) and the washer and secure it with Loctite 262 screw locking.
Put the driver into the hole of coil 2, mount the lower driver sheet, mount the upper driver
(34)
sheet and insert the washer between the driver sheets.
(35) Fix the driver sheets and the washer to the brass bushing with a cable clip.
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E. Assemble the Adjustable Backrest Mechanism (optional, OÄM 42-259)
The following table describes the assembling of a single backrest mechanism. The assembly
procedure is used for both sides.
(1) Screw the Hydrolok hydraulic cylinder into the Refer to Figure 7.
actuating shaft, so that the cylinder rod end and
the center of the actuating shaft are 35 mm
apart.
(2) Attach the lower end of the hydraulic cylinder to

the side bracket seat shell.
(3) Attach the side bracket seat shell to the seat

bracket seat side using 2 hexagon screws.
(4) Attach the backrest bracket to the actuating

shaft using a bush and a hexagon screw.
(5) Attach the backrest and the seat bracket with a

hexagon screw and nut thru the rotation hole.
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F. Assemble a Pilots’ Seat (optional, OÄM 42-067)
After assembling the adjustable backrest mechanism carry out these steps:
(1) Fix the inboard mechanism with the 17 hexagonal

screws.
(2) Insert the torsion bar into the backrest, insert the torsion
bar through the driver blades of the mechanism.
(3) Insert the outboard mechanism through the clearance

(hole) of the seat pan.
(4) Place the mechanism on the backrest and insert the

torsion bar through the driver blades of the mechanism.
(5) Fix the outboard mechanism with the 17 hexagon

screws.
(6) Screw the torsion bar screw with the washer and the
distance bushing into the inside thread.
(7) Install cover by moving it over the hinge.
(8) Reinstall the leather lining to the seat:
S Attach the leather lining to the cover using the

velcro fasteners.
S Tie the backrest cushion to the seat pan with the

3 strings.
S Put the rubber bands into the plastic brackets.
S Use blind rivets to fasten the plastic brackets to the

seat pan.
S Attach the cushion to the seat pan using the velcro.
(9) Install the seat lever:
S Put the lever onto the adjustment mechanism in

correct position.
S Install the lever mounting screw.
S Install plug to lever.
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G. Assemble a Pilots’ Seat (optional, OÄM 42-259)
After assembling the adjusting mechanisms on both sides install the backrest using the steps in the
opposite sequence as described in Maintenance Practices, Paragraph 5(B).
6. Remove/Install the Passenger Seat
% If OÄM 42-324 is installed and OÄM 42-334 is NOT installed:
A. Remove the Passenger Seat
(1) Release the velcro tapes at the front of the seat Refer to Figure 4. Move the cushion to
cushion. give access to the attaching bolts for the
seat.
(2) Remove the 6 bolts and washer plates which

attach the seat pan to the anchor plates.
(3) Remove the 2 bolts and washer plates which

attach the front of the seat pan to the rib on top
of the rear main bulkhead.
(4) Fold the seat-backs forward. Lift the latch pins at the left side of each
seat back.
(5) Remove the 5 bolts and washers which attach

the rear of the seat pan to the aft baggage
compartment frame.
(6) Remove the 2 inertia reels attachment points

from the through roll over bar duct.
(7) Lift the seat forward and up out of the cockpit.
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B. Install a Passenger Seat
(1) Examine the crash elements. Look specially for Refer to Figure 4.
delaminating and buckling.
(2) Make sure that the area below the seat is clean For example, tools.
and has no unwanted objects.
(3) Move the seat into position in the fuselage with Lift the latch pins at the left side of each
the seat-backs folded forward. seat-back.
(4) Attach the inertia reels to the through roll over

bar.
(5) Install the 5 bolts and washer plates which Torque 6.4 Nm (4.7 lbf.ft.).
attach the rear of the seat pan to the aft
baggage compartment frame.
(6) Install the 6 bolts and washer plates which Torque 6.4 Nm ( 4.7 lbf.ft.).
attach the seat pan to the anchor plates.
(7) Install the 2 bolts and washer plates which Torque 6.4 Nm (4.7 lbf.ft.).
attach the front of the seat pan to the rib on top
of the rear main bulkhead.
(8) Fasten the velcro tapes which hold the seat

cushion.
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7. Remove/Install a Safety Harness (if OÄM 42-324 is NOT installed)
% If OÄM 42-324 is NOT installed:
Use this procedure for both the pilots’ seats and the passenger seat harnesses.
% If OÄM 42-324 is installed and OÄM 42-334 is NOT installed, refer to AmSafe Documentation.
% If OÄM 42-334 is installed, use this procedure for the passenger seats and refer to the AmSafe
% Documentation for the pilots’ seats.
A. Remove a Safety Harness
(1) Remove the seat. Refer to Paragraph 2 or 3.
(2) Remove the anchor nuts, washers and plates Refer to Figure 5.
which attach the straps to the seat.
For the pilots’ seats only:
S Make a note of the position of the

anchor plates which these bolts also
hold.
(3) Move the straps through the holes in the seat

pan and remove them.
(4) Release the bolt and washer which attach the

inertia reel and its cover to the fuselage
structure.
(5) Release the bolt and washer which attach the For the pilots’ seats only:
guide to the roll-bar.
S Make a note of the position of the
washers.
(6) Remove the shoulder strap.
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B. Install a Safety Harness
(1) Put the lap straps through the holes in the seat The buckle goes to the inboard side of
pan. the pilots’ seats (front) and the outboard
side of the passenger seat (rear).
(2) Put the lap straps between the seat pan and the
metal plate. Install the bolts and washer plates
from the top of the seat pan.
(3) Move the anchor plates into position on the For the pilots’ seats only.
bolts.
(4) Install the seat. Refer to Paragraph 2 or 3.
(5) Install the bolt and washer which attach the For the pilots’ seats only.
guide to the roll-bar.
(6) Install the bolt and washer which attach the Refer to Figure 5 (1).
inertia reel and its cover to the structure.
(7) Install washer plates and self-locking nuts onto Torque 16 Nm (11.8 lbf.ft.).
the bolts.
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8. Remove/Install the Instrument Panel Cover
A. Remove the Instrument Panel Cover
(1) Remove the screws which attach the instrument

panel cover to the instrument panel and the
fuselage.
(2) Lift the cover for access to the defrost system

flexible hoses.
(3) Loosen the tie wraps that hold the flexible hoses
to the defrost manifold.
(4) Lift the cover clear of the instrument panel and

the airplane.
B. Install the Instrument Panel Cover
(1) Make sure that the area below the instrument For example; tools.
panel cover is free of unwanted objects.
(2) Move the instrument panel cover into position

near the instrument panel.
(3) Connect the flexible hoses to the defrost

manifold:
S Move the tie wraps into position on the

flexible hoses.
S Push the flexible hoses onto the defrost

manifold of the cover.
S Tighten the worm-drive-clamps.
(4) Lower the cover into position on the instrument

panel.
(5) Install the screws which attach the instrument

panel cover to the instrument panel and the
fuselage.
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9. Cleaning
A. Seats
The seat cushions are made from a fire resistant material. Clean the cushions with a vacuum
cleaner. Use a mild soap solution to remove stains. Make sure that the area is well ventilated after
cleaning to remove all moisture.
B. Safety Harnesses
Use a mild soap solution to clean the straps of the harnesses.
% If OÄM 42-324 is installed and OÄM 42-334 is NOT installed:
Refer to AmSafe Maintenance Documentation.
% If OÄM 42-334 is installed:
% Refer to AmSafe Maintenance Documentation for both pilots’ seats and use a mild soap solution
% to clean the straps of the harnesses of the passenger seats.
10. Remove/Install the Short Baggage Extension (OÄM 42-207 installed)
A. Remove the Short Baggage Extension
(1) Remove access panel. Refer to Paragraph 4.
(2) Release 4 screws with washers which attach the

front of the baggage tray to the rear seats.
(3) Release the 2 screws with washers which attach

the rear of the tray to the baggage bulkhead.
(4) Remove the upholstery pieces which cover the Attached with velcro.
sides of the baggage bulkhead.
(5) Open the baggage tray and unplug the electrical

connectors of the cabin fan (if installed).
(6) Release the seven 1/4-turn fasteners which

attach the short baggage extension to the
baggage bulkhead.
(7) Remove the short baggage extension from the Do not damage the upholstery.
airplane.
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B. Install the Short Baggage Extension
(1) Do a check for unwanted items in the area below For example: tools.
the short baggage extension.
(2) Put the short baggage extension in place in the Do not damage the upholstery.
baggage bulkhead.
(3) Fasten the seven 1/4-turn fasteners which attach

the short baggage extension to the baggage
bulkhead.
(4) Install the upholstery pieces which cover the sides Attached with velcro.
of the baggage bulkhead.
(5) Put the baggage tray in place on the baggage

floor.
(6) Fasten the 4 screws with washers that attach the Torque: 3.6 Nm (2.7 lbf.ft.).
front of the baggage tray to the rear seat base.
(7) Fasten the 2 screws with washers that attach the Torque: 3.6 Nm (2.7 lbf.ft.).
rear of the baggage tray to the baggage bulkhead.
(8) Plug the electrical connectors of the cabin fan (if

installed) to the plug on rear panel of the short
baggage extension.
(9) Install the access panel. Refer to Paragraph 4.
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Section 25-50
Aft Baggage Compartment
1. General
This Section tells you about the aft baggage compartment, the baggage tie-downs and baggage net.
For data about the forward baggage compartment doors refer to Section 52-00.
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Rear Door
A
Access Panel
A
Hinged Floor Panel
Screw
Washer
A
C
Quick-Release
Fastener
Figure 1: Aft Baggage Compartment
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AIRCRAFT
2. Description
Figure 1 shows the aft baggage compartment.
GFRP makes the aft baggage compartment. Quick-release fasteners attach the front of the baggage
compartment to the fuselage baggage compartment frame. The rear of the baggage compartment
locates in the fuselage ring frame 1. You can remove the aft baggage compartment.
The aft baggage compartment has a rear section that is accessed through a door. The door is hinged
along the lower edge. The forward section of the baggage compartment has an access panel in the
floor section of the compartment. Quick-release fasteners attach the access panel to the baggage
compartment floor. You can remove this access panel to gain access to the aft fuselage. Carpet covers
the floor of the baggage compartment.
A cargo net covers the front of the aft baggage compartment and secures the contents of the aft
baggage compartment. The cargo net attaches to special net tie-down brackets that are bolted to the
front of the baggage compartment frame.
From backside of the baggage extension to the G1000 box is a flexible air hose fixed with two worm
drive clamps.
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AIRCRAFT
1. General
These Maintenance Practices tell you how to remove the access panel in the aft baggage
compartment floor. They also tell you how to remove the aft baggage compartment from the airplane.
2. Remove/Install the Access Panel in the Baggage Compartment Floor
A. Remove the Access Panel
(1) Fold the passenger seat-backs forward into the Refer to Section 25-10.
down position.
(2) If necessary remove the cargo net and move

any equipment stowed in the baggage
compartment clear of the airplane.
(3) Fold the carpet on the floor of the baggage

compartment forward to gain access to the
panel.
(4) Remove the access panel: Refer to Figure 1.
S Remove the 4 quick-release fasteners that

attach the access panel to the baggage
compartment.
S Lift the access panel up from the baggage

compartment floor and move it clear of the
airplane.
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B. Install the Access Panel
(1) Make sure that the rear fuselage is clear of For example, tools, cleaning cloths or
loose objects. other hardware.
(2) Install the access panel:
S Move the access panel into position at the

baggage compartment floor.
S Install the 4 quick-release fasteners and

washers that attach the access panel to the
(3) Move the floor carpet back into position on the

(4) If necessary, install any equipment that you

removed from the baggage compartment and
install the cargo net.
(5) Move the passenger seat backs into the upright Make sure that the seat backs are
position. correctly locked into position.
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3. Remove/Install the Aft Baggage Compartment
A. Remove the Aft Baggage Compartment
(1) Fold the passenger seat backs forward into the Refer to Section 25-10.
down position.
(2) If necessary remove the cargo net and move

any equipment stowed in the baggage
compartment clear of the airplane.
(3) Fold the carpet on the floor of the baggage

compartment forward and clear of the baggage
compartment.
(4) Open the 4 quick-release fasteners of the Refer to Figure 1.

access panel to remove the access panel with
the hinged floor panel.
(5) Remove the aft baggage compartment:
S Remove the 4 quick-release fasteners that

attach the baggage compartment to the
fuselage baggage frame.
S Move the baggage compartment forward out

of the rear fuselage then upwards and clear
of the airplane.
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B. Install the Aft Baggage Compartment
(1) Make sure that the rear fuselage is clear of For example, tools, cleaning cloths or
loose objects. other hardware.
(2) Install the aft baggage compartment: Make sure that the aft end of the
baggage compartment locates correctly
S Move the baggage compartment into
in fuselage ring frame 1.
position at the rear fuselage.
S Install the flexible air hose on the G1000 box

and attach the worm drive clamp.
S Move the baggage compartment aft and into

the rear fuselage:
SMake sure that baggage compartment is

fully into position and install the 4 quick-
release fasteners that attach the baggage
compartment to the fuselage baggage
frame.
(3) Install the hinged floor-panel:
S Move the hinged floor panel into position at

the front of the baggage compartment.
S Align the 4 quick-release fasteners from the

floor panel in to the baggage compartment
floor and attach.
(4) Move the floor carpet back into position on the

(5) If necessary, install any equipment that you

removed from the baggage compartment and
install the cargo net.
(6) Move the passenger seat backs into the upright Make sure that the seat backs are
position. correctly locked into position.
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Section 25-60
Emergency Equipment
1. General
This Section tells you about the emergency equipment installed in the DA 42 NG airplane. It tells you
about the emergency location transmitter (ELT) and the first aid kit. Refer to the equipment
manufacturers manuals for more data.
Refer to Chapter 26 for data about the hand fire extinguisher which is installed in the cabin of the
DA 42 NG.
2. Description
Figure 1 shows the location of the main components of the ELT system.
The ELT is located in the rear fuselage, below the aft baggage compartment. A protective case
attached to a mounting bracket holds the ELT in position. The ELT antenna is mounted on the upper
surface of the fuselage, above the ELT. A remote control panel/indicator (RCPI) is mounted on the
instrument panel, right side.
The ELT transmits signals automatically after a crash on the emergency frequencies of 121.5 and
243.0 Megahertz (MHz). Every 50 seconds the transmitter also transmits a signal on the 406.025 MHz
frequency to a satellite. The signal to the satellite contains the serial number of the ELT transmitter or
the airplane ID, a country code and a unique identity code. The satellite will also give the emergency
services a more accurate location for the airplane.
The ELT has its own battery pack to supply electrical power. When the ELT is ON and transmitting the
batteries will keep the ELT transmitting for up to 72 hours on the 121.5 and 243.0 MHz frequencies
and for up to 24 hours on the 406.025 MHz frequency.
It is important to monitor the battery expiry dates for the battery pack. The expiry date for the battery
pack is shown on the identity plate for the transmitter. The battery pack must be replaced when:
) After use in an emergency.
) After the transmitter has been accidentally switched ON for an unknown period of time.
) After 1 hour of accumulated use (testing).
) On or before the battery pack expiry date.
You must do regular functional tests. Refer to the Maintenance Practices in this Section.
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ELT Control Panel
Antenna
Warning Buzzer
ELT
B
In-Line Connector
for RCPI
Antenna
Connector
Mounting Tray
Figure 1: ELT Main Components
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AIRCRAFT
3. Description of the Artex ME406 ELT
The ELT is located in the rear fuselage, below the aft baggage compartment. A velcro strap attached
to a mounting bracket holds the ELT in position. The ELT antenna is mounted on the upper surface
of the fuselage, above the ELT. A remote control panel/indicator (RPCI) is mounted on the instrument
panel, right side.
406.028 Megahertz (MHz). Every 50 seconds the transmitter transmits a signal on the 406.028 MHz
The ELT has its own battery pack to supply electrical power. When the ELT is ON and transmitting the
batteries will keep the ELT transmitting until battery power is gone on the 121.5 MHz frequency and
for up to 24 hours on the 406.028 MHz frequency.
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% 4. Description of the Kannad 406 AF-Compact ELT/ AF Integra ELT
The ELT is located in the rear fuselage, below the aft baggage compartment. A velcro strap attached
% to a mounting bracket holds the ELT AF Compact in position. A draw latch strap attached to a mouting
% bracket holds the ELT AF-Integra in position. The ELT antenna is mounted on the upper surface of the
fuselage, above the ELT. A Remote Control Panel/Indicator (RPCI) is mounted on the instrument
panel, right side.
406.028 Megahertz (MHz). Every 50 seconds the transmitter transmits a signal on the 406.028 MHz
% The ELT has its own battery pack to supply electrical power. When the ELT AF Compact is ON and
% transmitting the batteries will keep the ELT transmitting until battery power is gone for over 48 hours
% on the 121.5 MHz and on 406.028 MHz. When the ELT AF-Integra is ON and transmitting the batteries
% will keep the ELT transmitting until battery power is gone for over 48 hours on 121.5 MHz and for over
% 24 hours on 406.028 MHz.
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22 Dec 2021 25-60-00 Rev. 5
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the ELT. If you have the trouble detailed in the
Trouble column read across to the Possible Cause column. Then do the repair given in the Repair
column.
ELT does not operate on test. ELT batteries discharged. Replace the ELT batteries.
ELT defective. If the ELT batteries are

serviceable then replace the
ELT.
RCPI/cables defective. Do a continuity test of the

cables between the RCPI and
the ELT. Replace defective
cables. If the cables are not
defective then replace the
RCPI.
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22 Dec 2021 25-60-00 Rev. 5
AIRCRAFT
1. General
This Section tells you how to remove and install the ELT and the RCPI. It tells you how to test the ELT
in the airplane and how to replace the ELT batteries. It also tells you how to replace the ELT antenna.
See the ELT manufacturer’s Operator’s Manual for more data about the ELT.
2. Remove/Install the ELT
A. Remove the ELT
(1) Remove the access panel in the floor of the aft Refer to Section 25-50.
(2) Remove the ELT protective cover:
S Loosen the 2 thumbscrews on the ELT

end-cap.
S Move the end cap forward and clear of the

ELT.
S Lift the top protective cover at the aft end

and pull the cover aft and up from the ELT.
S Move the top protective cover clear of the

ELT.
(3) Disconnect these cables at the front of the ELT:
S The coaxial cable. At the bayonet connector.
S The electrical cables. At the inline connector.
(4) Remove the ELT from the ELT mounting tray: Use a flat bladed screwdriver to carefully
lift the front end of the ELT.
S Lift the ELT from the mounting tray at the
forward end.
S Move the ELT forwards and upwards, clear

of the mounting tray.
S Move the ELT clear of the airplane.
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Rev. 5 25-60-00 22 Dec 2021
AIRCRAFT
Top Protective Cover
ELT Assembly
In-Line Connector
End Cap
Electrical
Cables
Mounting Tray
Mounting Plate
Thumbscrews
Figure 2: ELT Installation (Standard Equipment)
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B. Install the ELT
(1) Make sure that the battery pack is serviceable

and the battery expiration date is valid.
(2) Install the ELT into the mounting tray:
S Move the ELT into position at the mounting

tray.
S Make sure that the ON/OFF switch at the

front of the ELT is set to OFF.
S Lower the aft end of the ELT into the

mounting tray so that the locking ‘ears’ at
the aft end of the ELT engage with the slots
in the mounting tray.
S Lower the ELT fully into the mounting tray.
S Install the top protective cover onto the

mounting tray. Make sure that the slots on
the top cover engage over the ears on the
ELT.
(3) Connect the electrical cables. At the in-line connector. Make sure that
the cables pass through the end cap
before you connect them!
(4) Connect the coaxial cable. At the bayonet connector. Make sure
that the cable passes through the end
cap before you connect it!
(5) Install the end-cap:
S Move the end-cap into position over the top

protective cover and the mounting tray.
S Align and tighten the thumbscrews. Finger tight only!
(6) Make sure that both the electrical cable

connector and the coaxial bayonet connector
are correctly located.
(7) Do a test for the correct operation of the ELT. Refer to Paragraph 7.
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Rev. 5 25-60-00 22 Dec 2021
AIRCRAFT
ELT Assembly
Battery Pack
8 Pin Connector
Screw with O-Ring
2 Pin Connector
Seal
Screw with O-Ring

Screw with O-Ring
Figure 3: ELT Battery Pack Installation
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AIRCRAFT
3. Replace the ELT Battery Pack
You must only use a battery pack that is supplied by the equipment manufacturer.
Note: The battery pack contains components that are sensitive to static electricity. You
must take electro-static discharge precautions before doing work on the battery
pack.
Note: The battery pack is connected to the ELT by a short electrical cable assembly. You
must take care not to strain this cable when you separate the battery pack from the
ELT.
(1) Remove the ELT from the airplane ELT Refer to Paragraph 2A.
mounting.
(2) Remove the battery pack: Refer to Figure 3.
S Remove the 4 screws that attach the battery Hold the battery pack to the ELT with
pack to the ELT. your hand to prevent the battery pack
separating from the ELT.
S Lay the ELT with battery pack on it’s side on

a suitable work surface.
S Carefully move the battery pack a short

distance clear of the ELT.
S Disconnect the wiring harness. At the 8 pin in-line connector. Take care
not to ‘short’ any of the pins.
At the 2 pin connector.

S Disconnect the 2 smaller cables.
S Move the battery pack clear of the ELT.
(3) Do a visual inspection of the underside of the

ELT (the battery pack side). Look specially for
corrosion or other damage to the ELT casing.
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(4) Prepare the new battery pack for installation:
S Remove the paper backing from the rubber

seal at the connector end of the battery
pack.
S Lubricate the seal. Use G GE-635 non-petroleum based

silicone grease or similar.
(5) Install the new battery pack:
S Connect the 8 pin connector from the ELT

wiring loom to the connector on the battery
pack.
S Connect the 2 pin connector from the Connecting the 2 pin connector will
battery pack cables to the recessed activate the ELT. Reset the ELT by
connector on the ELT. setting the ELT ON/OFF switch to ON
then to OFF.
S Move the battery pack into position on the Make sure that none of the electrical
ELT. cables are trapped between the mating
surfaces of the ELT and the battery
pack.
S Install the 4 screws that attach the battery
pack to the ELT.
(6) Install the ELT in the airplane mounting and Refer to Paragraph 2.
attach the 'Battery Pack Replacement Date'
label to the top surface of the ELT protective
cover where it can be easily seen.
(7) Record the details of the ELT battery pack

replacement date in the airplane log-book.
(8) Do a functional test of the ELT. Refer to Paragraph 7.
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% 4. Remove/Install the Artex ME 406 or Kannad 406 AF-Compact ELT or Kannad AF-Integra ELT
% A. Remove the Artex ME 406 or Kannad 406 AF-Compact ELT or Kannad AF-Integra ELT
(1) Remove the access panel in the floor of the aft Refer to Section 25-50.
(2) Disconnect these cables at the front of the ELT:
S The coaxial cable. At the bayonet connector.
S The electrical cables. At the in-line connector.
(3) Open the velcro strap.
(4) Remove the ELT from the ELT mounting tray:
S Lift the ELT from the mounting tray at the

forward end.
S Move the ELT forward and upward, clear of

the mounting tray.
S Move the ELT clear of the airplane.
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AIRCRAFT
ELT Assembly
Electric Cables
Co-Axial Cable
Velcro Strap
Mounting Tray
Figure 4: Artex ME406 ELT Installation
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AIRCRAFT
ELT Assembly
Co-Axial Cable
Electric Cables
Velcro Strap
Mounting Tray
Figure 5: Kannad 406 AF-Compact ELT Installation
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Rev. 5 25-60-00 22 Dec 2021
AIRCRAFT
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
% Figure 6: Kannad AF-Integra ELT Installation
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22 Dec 2021 25-60-00 Rev. 5
AIRCRAFT
% B. Install the Artex ME406 or Kannad 406 AF-Compact ELT or Kannad AF-Integra ELT
(1) Make sure that the battery pack is serviceable

and the battery expiration date is valid.
% (2) If the Kannad AF-Integra is installed: Refer to Section 05-00.
% Refer to the Initial Installation Manual.
% For the Artex ME 406 or the Kannad 406 AF

% Compact:
Install the ELT into the mounting tray:
S Move the ELT into position at the mounting

tray.
S Make sure that the ON/OFF switch at the

front of the ELT is set to OFF.
S Lower the aft end of the ELT into the

mounting tray so that the locking ‘ears’ at
the aft end of the ELT engage with the slots
in the mounting tray.
S Lower the ELT fully into the mounting tray.
(3) Fasten the velcro strap around the ELT so that it

is firmly held in place.
(4) Connect the electrical cables. At the in-line connector.
(5) Connect the coaxial cable. At the bayonet connector.
(6) Make sure that both the electrical cable

connector and the coaxial bayonet connector
are correctly located.
(7) Do a test for the correct operation of the ELT. Refer to Paragraph 7.
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Rev. 5 25-60-00 22 Dec 2021
AIRCRAFT
ELT Unit
Coax Wire
Mounting Strap
Battery Pack
Seal
Mounting Tray
Screw
Washer
Warning Buzzer
Washer
Nut
% Figure 7: Battery Pack Installation - Artex ME406
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AIRCRAFT
5. Replace the ELT Battery Pack of the Artex ME406
You must only use a battery pack that is supplied by the equipment manufacturer.
Note: The battery pack contains components that are sensitive to static electricity. You
must take electrostatic discharge precautions before doing work on the battery
pack.
Note: The battery pack is connected to the ELT by a short electrical cable assembly. You
must take care not to strain this cable when you separate the battery pack from the
ELT.
(1) Remove the ELT from the airplane ELT Refer to Paragraph 2A.
mounting.
% (2) Remove the battery pack: Refer to Figure 7.
S Remove the 8 screws from the battery-side Hold the battery pack to the ELT with
cover. your hand to prevent the battery pack
separating from the ELT.
S Carefully move the battery pack a short
distance clear of the ELT.
S Disconnect the wiring harness.
S Move the battery pack clear of the ELT.
(3) Do a visual inspection of the underside of the

ELT (the battery pack side). Look specially for
corrosion or other damage to the ELT casing.
(4) Prepare the new battery pack for installation.
(5) Lay the battery pack on the work surface with

the batteries facing up.
(6) Install the replacement seal. In the slot along the perimeter housing.
(7) Position the ELT over the battery pack and plug Make sure that the cable is not twisted
the connector into the battery assembly. and that the connector is correctly
attached.
(8) Mate the ELT to the battery. Make sure that the seal is positioned
correctly.
(9) Install the 8 screws that attach the battery pack

to the ELT.
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(10) Install the ELT in the airplane mounting and Refer to Paragraph 2.
attach the battery pack replacement date label
to the top surface of the ELT protective cover
where it can be easily seen.
(11) Record the details of the ELT battery pack

replacement date in the airplane log-book.
(12) Do a functional test of the ELT. Refer to Section 25-60, Paragraph 7.
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6. Remove/Install the ELT RCPI
A. Remove the ELT Remote Control Panel/Indicator RCPI
% (2) Disconnect the electrical cables from the rear of Refer to Figure 8. At the in-line
the RCPI. connector.
(3) Remove the RCPI: Hold the RCPI.
S Remove the 4 nuts, washers and screws

that attach the RCPI to the instrument panel.
S Move the RCPI towards the rear of the

airplane and clear of the instrument panel.
S Move the RCPI clear of the airplane.
B. Install the ELT Remote Control Panel/Indicator RCPI
(1) Move the RCPI into position at the instrument

panel.
(2) Install the RCPI:

From the cockpit side.
S Move the RCPI into position in the
instrument pane.

attach the RCPI to the instrument panel.
(3) Connect the electrical cables to the rear of the At the inline connector.
RCPI.
(5) Do a functional test of the ELT system. Refer to Paragraph 7.
Doc # 7.02.15 Page 215

Rev. 5 25-60-00 22 Dec 2021
AIRCRAFT
ARTEX KANNAD
ARTEX
ELT ELT
EMERGENCY USE ONLY
ON
ON
ARM
TEST/RESET
PRESS ON
WAIT 1 SECOND
PRESS ARM
RC 200
Nut
Washer
Screw
ELT Control Panel
% Figure 8: RCPI Installation
Page 216 Doc # 7.02.15

22 Dec 2021 25-60-00 Rev. 5
AIRCRAFT
7. ELT Functional Test
Note: Do this test only in the first 5 minutes of each hour. If you are at a location with a
control tower or other monitoring facility, tell them before you do the test.
Note: For maintenance done to FAR 91 (airplanes registered in the USA) an additional
functional test of the ELT is required. Refer to FAA Action Notice 8150.3 for more
data.
(2) Set the AV MASTER switch to ON.
(3) Set the communications radio to receive

121.50 MHz.
WARNING: DO NOT OPERATE THE ELT FOR MORE THAN 5 SECONDS. IF YOU
OPERATE THE ELT FOR MORE THAN 5 SECONDS THE ELT WILL
TRANSMIT AN EMERGENCY SIGNAL TO THE SATELLITE
MONITORING SYSTEM. THE SATELLITE MONITORING SYSTEM
WILL REACT TO THE ELT SIGNAL AS IT WOULD TO A VALID
EMERGENCY SITUATION.
(4) Set the ELT RCPI to ON for about 3 sweeps of The LED in the RCPI must illuminate.
the receiver (approximately 1 second). The test
MUST NOT last longer than 3 audio sweeps!
(5) Monitor the communications receiver for the

ELT sweep tone.
(6) Set the ELT RCPI switch to ARM. The LED should switch off within 1 sec.
If the LED switches off and then flashes
it indicates that there is a fault with the
ELT system. Refer to the ELT
manufacturer’s manual for more data
about ELT fault diagnosis.
(7) Set the AV MASTER switch to OFF.
Doc # 7.02.15 Page 217

Rev. 5 25-60-00 22 Dec 2021
AIRCRAFT
% 8. Kannad 406 AF-Compact ELT and Kannad AF-Integra ELT Functional Test
Note: Do this test only in the first 5 minutes of each hour. If you are at a location with a
control tower or other monitoring facility, tell them before you do the test.
Note: For maintenance done to FAR 91 (airplanes registered in the USA) an additional
functional test of the ELT is required. Refer to FAA Action Notice 8150.3 for more
data.
(2) Set the AV MASTER switch to ON.
(3) Set the communications radio to receive

121.50 MHz.
WARNING: DO NOT OPERATE THE ELT FOR MORE THAN 5 SECONDS. IF YOU
OPERATE THE ELT FOR MORE THAN 5 SECONDS THE ELT WILL
TRANSMIT AN EMERGENCY SIGNAL TO THE SATELLITE
MONITORING SYSTEM. THE SATELLITE MONITORING SYSTEM
WILL REACT TO THE ELT SIGNAL AS IT WOULD TO A VALID
EMERGENCY SITUATION.
(4) Switch the RCPI to “ON” (max. 5 sec.). RCPI visual indicator flashing.
ELT buzzer modulated activation.
(5) Monitor the communications receiver for the ELT

sweep tone.
(6) Switch the RCPI to “TEST/RESET” at least ELT transmission stops if:
1 sec., then back to “ARMED”.
S RCPI visual indicator is OFF.
S ELT buzzer stops.
(7) Set the AV MASTER switch to OFF.
Page 218 Doc # 7.02.15

22 Dec 2021 25-60-00 Rev. 5
DA 42 NG AMM Fire Protection
AIRCRAFT
CHAPTER 26
FIRE PROTECTION
Doc # 7.02.15 Page 1

Fire Protection DA 42 NG AMM
AIRCRAFT
Page 2 Doc # 7.02.15

AIRCRAFT
TABLE OF CONTENTS
CHAPTER 26
FIRE PROTECTION
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install an Engine Overheat Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Overheat Detector Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Doc # 7.02.15 Page 1

AIRCRAFT
Page 2 Doc # 7.02.15

AIRCRAFT
CHAPTER 26
FIRE PROTECTION
1. General
This Chapter tells you about the fire extinguisher installed in the airplane. It also tells you about the
installation of the overheat detector installed in each engine nacelle. See the fire extinguisher
manufacturer's manual for more data about the extinguisher and see the overheat detector
manufacturer’s manual for more data about the overheat detector.
called "Additional Equipment". The installation of Additional Equipment is a
Service Bulletin.
Doc # 7.02.15 Page 1

Rev. 5 26-00-00 22 Dec 2021
AIRCRAFT
Container
Carry Handle
Release Lever
Safety Guard
Pressure
Seal Wire Gauge
Extinguisher
Nozzle Mount
Screw
Washer
Nut
Figure 1: Fire Extinguisher Installation
Page 2 Doc # 7.02.15

22 Dec 2021 26-00-00 Rev. 5
AIRCRAFT
2. Description
A. Fire Extinguisher
Figure 1 shows the installation of the fire extinguisher in the airplane. The fire extinguisher is
located behind the co-pilot's seat. Screws attach the extinguisher mounting bracket to the closing
rib between the front and the rear main bulkhead. The extinguisher uses a liquid gas which is
non-toxic and does not have a residue.
The only on-airplane maintenance is:
) Monitor the pressure indicator. It must show in the green sector.
) Make sure that the seal wire is not broken.
) Make sure that the extinguisher is correctly held in the mounting.
If the seal wire is broken, remove the extinguisher for weighing. Weight data is given on the label
attached to the extinguisher body.
You must replace the extinguisher (or return it to the manufacturer for repair):
) When the weight is incorrect.
) When the pressure is too low.
) When the extinguisher has been used.
) If the extinguisher is damaged.
) At the ‘Next Overhaul Date’ that is given on the label attached to the extinguisher body.
Doc # 7.02.15 Page 3

Rev. 5 26-00-00 22 Dec 2021
AIRCRAFT
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
% Nuts
% Safety Wire Thermal Switch
%
Screw
%
% Washer
% Fire Sensor
% Mounting Bracket Ground Wire
%
%
% if MÄM 42-1093
is installed
% Nut
%
Bolt
%
%
%
% Safety Wire Washer
%
%
Figure 2: Engine Overheat Detector Installation
Page 4 Doc # 7.02.15

22 Dec 2021 26-00-00 Rev. 5
AIRCRAFT
B. Overheat Detector
Figure 2 shows the overheat detector installation in an engine nacelle. Each engine has an
overheat detector installed on the right side of the engine. The detector is mounted on a bracket
and connects with ring terminals to the wiring harness.
A bi-metal switch makes the fire detector. If the fire detector reaches a temperature of 260 °C
(500 °F) the switch closes and a LH/RH ENG FIRE warning is displayed on the integrated cockpit
system (ICS) display screen. You cannot cancel the LH/RH ENG FIRE warning.
Operating the TEST button for the landing gear will by-pass the bi-metal switch and will cause the
LH/RH ENG FIRE warning of ICS to operate. This test system will test the serviceability of the
electrical cables for the overheat detectors and the operation of the LH/RH ENG FIRE warning of
the ICS. Refer to Section 31-40 for more data about the ICS.
Doc # 7.02.15 Page 5

Rev. 5 26-00-00 22 Dec 2021
AIRCRAFT
Page 6 Doc # 7.02.15

22 Dec 2021 26-00-00 Rev. 5
AIRCRAFT
Trouble-Shooting
1. General
This Section lists some defects you could have with the fire protection system. If you have the trouble
shown in the Trouble column read across to the Possible Cause column. Then do the repair given in
the Repair column.
The LH/RH ENG FIRE warning Wiring defective. Do a continuity test of the
fails to display when the wiring. Repair/replace
landing gear TEST button is defective wiring. Refer to
operated. Chapter 92 for the wiring
diagrams.
ICS display defective. Refer to Section 31-40 for

more data about the ICS.
An LH/RH ENG FIRE warning Defective overheat detector. Replace the related engine
shows when power is applied overheat detector.
to the ICS.
Wiring defective. Do a continuity test of the

wiring. Repair/replace
defective wiring. Refer to
Chapter 92 for the wiring
diagrams.
Doc # 7.02.15 Page 101

Rev. 5 26-00-00 22 Dec 2021
AIRCRAFT
Page 102 Doc # 7.02.15

22 Dec 2021 26-00-00 Rev. 5
AIRCRAFT
1. General
These Maintenance Practices only tell you how to replace an engine overheat detector. Refer to the
overheat detectors manufacturer’s manuals for more data about the overheat detector.
2. Remove/Install an Engine Overheat Detector
A. Remove an Engine Overheat Detector

INJURY TO PERSONS.
engine.
(3) Remove cable ties of the cable near the fire

sensor.
(4) Remove the overheat detector:
S Remove the safety wire form overheat

detector and mounting bracket.
S Carefully screw off the overheat detector

from the mounting bracket.
(5) Disconnect the electrical cables for the overheat Refer to Figure 2. At the ring terminals.
detector.
Doc # 7.02.15 Page 201

Rev. 5 26-00-00 22 Dec 2021
AIRCRAFT
B. Install an Engine Overheat Detector
(1) Connect the electrical cables for the overheat Refer to Figure 2. At the ring terminals.
detector.
(2) Install the overheat detector:
S Move the overheat detector into position at

the mounting bracket.
S Lower the overheat detector into the

mounting bracket from the top.
S Tighten the overheat detector on the

mounting bracket.
S Secure the overheat detector on the Use a new safety wire.

mounting bracket.
(3) Fix the cable with cable ties in the same way as
they were before removal.
(4) Do a test of the related overheat detector. Refer to Paragraph 3.
(5) Install the engine cowlings to the related engine. Refer to Section 71-10.
3. Overheat Detector Test
(1) Set the ELECT. MASTER switch to ON. In the cockpit.
(2) Press and hold the TEST button of the landing The LH/RH ENG FIRE warning must
gear. appear on the PFD.
(3) Release the TEST button of the landing gear. The LH/RH ENG FIRE warning must
disappear from the PFD.
Page 202 Doc # 7.02.15

22 Dec 2021 26-00-00 Rev. 5
DA 42 NG AMM Flight Controls
AIRCRAFT
CHAPTER 27
FLIGHT CONTROLS
Doc # 7.02.15 Page 1

Flight Controls DA 42 NG AMM
AIRCRAFT
Page 2 Doc # 7.02.15

AIRCRAFT
TABLE OF CONTENTS
CHAPTER 27
FLIGHT CONTROLS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Pushrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Control Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Push-Rod Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install Levers or Bellcranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Remove/Install a Control Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5. Measure the Play in a Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Section 27-10
Flight Controls - Aileron and Tabs
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Aileron Control System Test for Correct Range of Movement . . . . . . . . . . . . . . 201
3. Aileron Control System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Aileron Pushrod Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5. Aileron Bellcrank and Lever Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Doc # 7.02.15 Page 1

AIRCRAFT
Section 27-20
Flight Controls - Rudder
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Rudder Control System Test for Correct Range of Movement . . . . . . . . . . . . . . 201
3. Rudder Control System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Remove/Install the Rudder Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5. Remove/Install the Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
6. Rudder Control Cable and Yoke Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Section 27-21
Flight Controls - Rudder Trim
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Rudder Trim-Tab Control System Test for Correct Range of Movement . . . . . . 201
3. Adjust the Rudder Trim Tab Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Page 2 Doc # 7.02.15

AIRCRAFT
Section 27-30
Flight Controls - Elevator
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Elevator Control System Test for Correct Range of Movement . . . . . . . . . . . . . 201
3. Elevator Control System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4. Remove/Install the Variable Elevator Stop Assembly . . . . . . . . . . . . . . . . . . . . . 208
5. Test/Adjust the Variable Elevator Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
6. Operational Test of the Variable Elevator Stop . . . . . . . . . . . . . . . . . . . . . . . . . . 211
7. Operational Test of the STICK LIMIT Caution Message . . . . . . . . . . . . . . . . . . . 212
8. Elevator Pushrod Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
9. Elevator Bellcrank and Lever Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Section 27-37
Stall Warning System
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Stall Warning Switch (Lift Detector) . . . . . . . . . . . . . . . . . . . 201
4. Remove/Install the Stall Warning Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Doc # 7.02.15 Page 3

AIRCRAFT
Section 27-38
Flight Controls - Elevator Trim-Mechanical
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Elevator Mechanical Trim Control System Test for Correct Range of Movement
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Elevator Mechanical Trim Control System Adjustment . . . . . . . . . . . . . . . . . . . . 204
Section 27-39
Flight Controls - Elevator Trim-Electrical
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 27-50
Flight Controls - Flaps
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. Fail-Safe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Page 4 Doc # 7.02.15

AIRCRAFT
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Flap Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Test the Flap Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Adjust the Flap Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5. Flap Push-Rod Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
6. Flap Bellcrank and Lever Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Doc # 7.02.15 Page 5

AIRCRAFT
Page 6 Doc # 7.02.15

AIRCRAFT
CHAPTER 27
FLIGHT CONTROLS
1. General
This Chapter tells you about the flight controls of the DA 42 NG. It tells about the operation of the
controls and it tells you about the assembly and adjustment of the controls. Refer to the related Section
for the data about a specific system.
This Section tells you how standard parts are used to make the flight controls for each system.
Note: Equipment which is certified for use in the DA 42 NG 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 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.
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2. Description
Figure 1 shows the basic control surfaces of the DA 42 NG. The DA 42 NG has the usual flight
controls. An elevator attached to the horizontal stabilizer gives longitudinal control. Ailerons attaches
to the trailing edge of each wing gives lateral control. Rudder attached to the vertical stabilizer gives
yaw control. Flaps attach to the trailing edge of each wing to give extra lift for take-off and landing. The
rudder and the elevator both have trim systems.
Each pilot has a control stick. If OÄM 42-281 or OÄM 42-283 is installed, the RH control stick is
removed or removable. The pilot can set the elevator trim by using a hand wheel located in the center
console or electrically by using a switch mounted on the pilot’s control stick. The DA 42 NG is
equipped with an electrically operated variable elevator stop that limits the upward elevator deflection
as soon as the power setting of both engines exceeds approx. 20 %. The variable elevator stop is
controlled by two switches on the throttle quadrant (one for each power lever).
Each pilot has a set of rudder pedals. The rudder pedal assembly attaches to the cockpit floor. Each
pilot can adjust the position of the rudder pedals with an adjuster handle on the rudder pedal assembly.
A rudder trim adjuster is mounted in the front of the center console. A flexible drive cable connects the
rudder trim adjuster to the rudder trim tab.
The pilot uses the control stick to move the ailerons and elevator. Both the ailerons and elevator are
moved by a series of bellcranks and pushrods. Flexible cables connect the rudder pedal assembly to
the rudder. An electric actuator operates the flaps.
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Elevator
Trim Tab
Aileron RH
Flap Outer RH
Flap Inner RH
Rudder Trim
Rudder
Flap Inner LH
Flap Outer LH
Aileron LH
Figure 1: DA 42 NG Control Surfaces
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3. Pushrods
The pushrods used in the DA 42 NG have standard end fittings. Most control rods also use a standard
diameter tube. Only the length of the rods are special. Some rods have one fixed fork end fitting and
an adjustable eye end fitting. Other rods have two adjustable eye end fittings.
Figure 2 shows an example of a standard pushrod. The rod has adjustable end fittings. The adjustable
fittings have eye ends with a threaded shaft. The eye end has a spherical self-aligning bearing. A jam
nut on the threaded shaft locks the eye end in position. A toothed washer locks the nut. You can turn
the eye ends to adjust the length of the pushrod.
A steel tube makes the rod which connects the end fittings. Threaded inserts are welded into the ends
of the tube to make the connections for the eye ends. Safety holes are drilled into the tube at the end
fittings. The safety holes shows you if the installation of the eye end into the control rod is correct. If
you can push safety wire through the hole when the eye end is installed then the eye end fitting is NOT
installed correctly. You cannot push safety wire through the hole if the eye end fitting is installed
correctly.
Refer to the maintenance practices in this Section for the procedures for adjusting the length of
adjustable pushrods.
4. Control Rigging
The flight controls of the DA 42 NG have been designed to make correct rigging of the controls as easy
as possible. Most levers and bellcranks have holes for rigging pins. The rigging pins lock the levers
in the neutral position.
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Eye-End Fitting
with Spherical Bearing
Jam-Nut
Toothed Washer
Bonding Wire
Control Rod
Safety Test Hole
Toothed Washer
Jam-Nut
Threaded End Fitting
Welded into Place
Bonding Wire
Eye-End Fitting
with Spherical Bearing
Figure 2: DA 42 NG Standard Control Pushrod
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1. General
These Maintenance Practices tell you how to do procedures which apply to all of the control systems
(such as push-rod adjustment).
2. Push-Rod Adjustment
WARNING: IF YOU DO AN ADJUSTMENT OF A PUSHROD, YOU MUST MAKE

SURE THAT THE PUSHROD IS STILL IN SAFETY. IF YOU DO NOT DO
THIS, THE PUSH ROD CAN DISCONNECT. THIS CAN CAUSE DEATH
OR INJURY TO PERSONS.
(1) Release the bolt which attaches the pushrod

adjustable fitting to its related lever or bellcrank.
(2) Loosen the jam nut that locks the adjustable Refer to Figure 1.
fitting.
(3) Turn the eye end to adjust the length of the rod. Turn the eye end clockwise to make the
rod shorter, turn the eye end counter-
clockwise to make the rod longer.
(4) When you have adjusted the eye end do a test

for safety of the eye end:
S Try to push lock wire through the safety The lock wire MUST NOT go through
hole. the safety hole and out of the other side.
(5) Tighten the jam-nut. Torque 16 Nm (11.8 lbf.ft.).
(6) Move the eye end fitting into position in its

related lever or bellcrank.
(7) Install the bolt, washer and self locking nut that Torque 6.4 Nm (4.7 lbf.ft.). You must
attaches the control rod to its related lever or always use a new self locking nut.
bellcrank.
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(8) Do an inspection of the control that you have

adjusted:
S If necessary for your Airworthiness

Authority, do a duplicate inspection of the
control system that you adjusted.
S Do a friction check of the appropriate control Make sure that there is no undue friction
system. within the control system.
3. Remove/Install Levers or Bellcranks
The DA 42 NG has standard attachments for bellcranks and levers in the flight control systems. Refer
to the tables at the end of each Section for access data. Refer to the Figures in the related Section for
the correct orientation.
A. Remove a Lever or Bellcrank
(1) Release the bolts attaching the pushrods to the

lever or bellcrank.
(2) Remove the pivot bolt assembly from the lever

or bellcrank.
(3) If necessary, remove the lever or bellcrank Where you have access to both side of
mounting bracket: the attachment, bolts with washers and
nuts are used. In all other cases, anchor
nuts are used.
the mounting bracket to the structure.
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B. Install a Lever or Bellcrank
(1) If necessary, put the mounting bracket into

position.
Note: You must always use new self locking nuts when installing control levers or
bellcranks. Do NOT use a self locking nut more than once.
(2) Install the bolts, washers and nuts that attach Torque 6.4 Nm (4.7 lbf.ft.).
the mounting bracket to the structure.
(3) Put the lever or bellcrank into position at the Make sure that bushes and spacers are
mounting bracket. correctly located.
(4) Install the pivot bolt, washer and nut. Torque 6.4 Nm (4.7 lbf.ft.).
(5) Install the bolts, washers and self locking nuts Torque 6.4 Nm (4.7 lbf.ft.).
which attach the push rods.
(6) Do a test of the control system. Refer to the related Section.
(7) Do an inspection of the control that you have

adjusted:

S Do a friction check of the appropriate control Make sure that there is no undue friction
system. within the control system.
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4. Remove/Install a Control Stick
If OÄM 42-281 is installed, the RH stick lever replaces the RH control stick.
If OÄM 42-283 is installed, the RH stick can be removed by the pilot and consists of two parts, the
control stick base and the removable control stick. For removal / installation of the removable control
stick refer to Supplement O08 to the AFM.
A. Remove a Control Stick
(1) Remove the pilot’s seat. Refer to Section 25-10.
(2) Loosen the control stick electrical harness from

the airplane structure.
(3) Disconnect the control stick electrical harness

connectors.
Disconnect the AP/DISC relay from the control

stick base harness.
(4) Remove the nut, washer and the bolt attaching

the control stick / stick lever to the torque tube
assy and remove the control stick from the
torque tube assy.
(5) Disconnect the push rod from the control stick /

stick lever:
S Remove the bonding wire, the nut and the

bolt.
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LH Control
RH Stick Lever Stick
Control Stick
Connector
Control
Bulkhead
Figure 3: LH Control Stick and RH Stick Lever (if OÄM 42-281 is installed)
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Control Stick
Dust Cap (if Control

Stick is removed)
Sleeve Nut
Safety Pin
Control Stick Base Assy
Hood Seat Cover (GFRP)
Removeable Control Stick Assy, RH
Sleeve Nut Control Stick LH Control Stick

Connector
Autopilot Disc
Relay
Control Bulkhead
Figure 4: Control Sticks (if OÄM 42-283 is installed)
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B. Install a Control Stick
(1) Move the push rod and the control stick / stick Insert the bolt from the front to the rear.
lever into place and install the bolt, bonding
wire and nut.
(2) Move the control stick / stick lever into place Insert the bolt from the front to the rear.
and install the bolt, washer and nut attaching
the stick lever to the torque tube assy.
(3) Connect the the autopilot and the PTT

connectors.
Install the autopilot bridge connector.
Connect the AP / DSC relay to the control stick Refer to Chapter 92 for the wiring
base harness. diagrams.
(4) Secure the control stick harness to the airplane Use cable ties.
structure.
(5) Do an inspection of the control stick / stick

lever:

S Do a friction check of the control system. Make sure that there is no undue friction
within the control system.
(6) Install the pilot’s seat. Refer to Section 25-10.
(7) If OÄM 42-281 or OÄM 42-283 is installed:
S Fold the control stick gaiter and use the

Velcro strap to fix the gaiter to the pilot’s
seat.
(8) Perform an Elevator and an Aileron Control Refer to Section 27-10.

System Test Procedure.
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5. Measure the Play in a Hinge
A. Equipment
Caliper. 1 Commercial.
B. Measure the Axial Play of a Control Surface Hinge
Move the control surface by hand along the direction of the hinge line in both directions (up and
down for the rudder, inboard and outboard for the other control surfaces). Measure the maximum
travel from one limit position to the other.
C. Measure the Radial Play of a Control Surface Hinge
Move the control surface by hand perpendicular to the direction of the hinge line in both directions
(left and right for the rudder, up and down for the other control surfaces). Measure the maximum
travel from one limit position to the other.
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Section 27-10
Flight Controls - Aileron and Tabs
1. General
The DA 42 NG has two control sticks that operate the ailerons. If OÄM 42-281 or OÄM 42-283 is
installed, the RH control stick is removed or removable. The aileron control system uses pushrods and
bellcranks.
Figures 1 and 2 show the aileron controls in the fuselage. Figure 3 shows the aileron controls in the
wing.
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%
%
%
%
%
%
%
% Front Bulkhead
%
%
%
%
% Rear Bulkhead
% Control
% Bulkhead
%
%
%
% To Rear
Rigging Pin Hole Bellcrank
% Left Stick
% Idler Lever
Push Rod to Rigging
% Right Stick Pin Hole
%
%
%
%
Front Bellcrank Push Rod to
% Idler Lever
% Push Rod to
Left Stick
%
Adjustable Aileron Stop
%
% Rigging Pin Hole
% Torque Tube Assy
% Rigging
Pin Hole
%
% Control Stick Mounting Block
%
%
Figure 1: Aileron Controls in the Fuselage (Sheet 1)
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Push Rod to
Right Wing
Push Rod from

Idler Lever Centering Spring
Push Rod to
Left Wing
Rear Bellcrank
Rigging
Pin Hole
Front Bulkhead
Rear Bulkhead
Control
Bulkhead
Figure 2: Aileron Controls in the Fuselage (Sheet 2)
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Push Rod to
Right Wing
Push Rod to
Left Wing
Wing Root Rib
Rigging Pin Hole

Aileron Bellcrank 2
Guide Rollers
Guide Rollers
Flap Control Rib

Guide Rollers
Support Bracket
Aileron
Rigging Pin Hole
Aileron Horn
Aileron Control Rib LH System Shown,

Left Aileron Bellcrank RH System Opposite
Figure 3: Aileron Controls in the Wing
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2. Description
The DA 42 NG has a control stick for each pilot. If OÄM 42-281 or OÄM 42-283 is installed, the RH
control stick is removed or removable. The control sticks operate the ailerons and elevator via control
rods. Aileron pushrods connect to the bottom of the control sticks. The pushrods connect to the aileron
front bellcrank at the control bulkhead. The front bellcrank at the control bulkhead connects to a short
pushrod under the center console.
The short pushrod connects to an idler lever attached to the front main bulkhead. Another push-rod
connects the idler lever to the aileron rear bellcrank. The aileron rear bellcrank attaches to the rear
face of the rear main bulkhead.
The rear bellcrank connects to the two pushrods in the center section. Each of these rods connect to
long pushrod assemblies located in each of the wings.
Each long pushrod assembly has three pushrod guides. The first pushrod guide attaches to a rib
located in the wing center section. The second attaches to the outer flap control rib. A small rib holds
the third pushrod guide. The two long pushrod assemblies attach to the aileron bellcranks which are
mounted in each wing, at the aileron control rib.
Short pushrods connect the aileron bellcrank to the aileron horn. You can adjust the short pushrods
to move the aileron range-of-movement up or down.
The aileron stop which limits the movement of the control sticks to the right (right aileron up, left aileron
down) is located to the left of the pilot’s control stick (Figure 1). The aileron stop which limits the
movement o the control stick to the left (left aileron up, right aileron down) is located to the right of the
co-pilot’s control stick. Each aileron stop consists of a nut which is welded to the torque tube assembly,
a bolt which is installed in the nut and a jamnut which locks the assembly. The head of the bolt makes
the stop.
Additional, non adjustable stops are located in front of the leading edge of the LH and RH aileron.
Each stop consists of a GFRP block with a rubber coating, bonded to the inside of the upper wing skin.
When the aileron is deflected fully downward, the aileron paddle is deflected fully upward and contacts
the stop.
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3. Operation
If you move the control stick to the left:
) The pushrods connected to the stick move to the right.
) The front bellcrank moves the pushrod below the center console towards the rear.
) The push-rod below the center console moves the idler lever and second short pushrod to the rear.
) The second short pushrod moves the rear bellcrank so that the long pushrods in the wing move to
the left.
) The left aileron bellcrank in the left wing moves the short pushrod attached to the left aileron horn
to the rear.
) The left aileron moves up.
If you move the control sticks to the right:
) The left aileron moves down.
) The right aileron moves up.
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Trouble-Shooting
1. General
The table below lists defects you could have in the aileron control system. If you have the trouble
Airplane moves about the Aileron pushrods out of Adjust the aileron pushrods.
longitudinal axis in flight with adjustment.
no input from the pilot.
Aileron controls stiff/catch. Defective bearings in a control Replace the defective eyeend.
rod eye end.
Control rod guide(s) defective. Replace the guides.
Pushrod bent. Replace the pushrod.
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1. General
These Maintenance Practices tell you how to do tests on the aileron control system. They also tell you
how to adjust the aileron control system. This Section also gives you the access data on the pushrods
and bellcranks. Refer to Section 57-60 for data about removing/installing the ailerons.
WARNING: WHEN YOU DO WORK ON THE AIRPLANE CONTROLS, YOU MUST

MAKE SURE THAT THE AREA AROUND THE CONTROL SURFACES
ARE CLEAR OF PERSONNEL AND EQUIPMENT. IF YOU DO NOT DO
THIS, INJURY TO PERSONNEL AND DAMAGE TO THE CONTROL
SURFACES CAN OCCUR.
WARNING: WHEN YOU COMPLETE WORK ON THE CONTROLS, MAKE SURE

THAT YOU REMOVE ALL LOOSE ITEMS OR TOOLS FROM THAT
AREA. LOOSE ITEMS OR TOOLS CAN PREVENT FULL AND FREE
MOVEMENT OF THE AIRPLANE CONTROLS. THIS CAN CAUSE DEATH
2. Aileron Control System Test for Correct Range of Movement
A. Equipment
Control stick rigging pins. 2 VR-D41-2757-3000.
Ruler/measuring stick. 1 Commercial.
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B. Aileron Control System Test Procedure
Note: Use a ruler/measuring stick to make all measurements at the control surfaces.
Make the measurement between the top surface of the aileron and the top surface
of the wing.
(1) Make a copy of the Control Surfaces Refer to Chapter 06-00.

Adjustment Report. Use it to record the measurements.
(2) Remove the left pilot’s seat. Refer to Section 25-10.
(3) Install the control stick rigging pins: Refer to Figure 1.
S At the bottom of the left stick. To lock aileron movement.
S Through the left mounting bracket. To lock elevator movement.
(4) Measure the distance between the trailing edge Record these measurements.
of each aileron and the trailing edge of the wing The left aileron must align with the right
tip. aileron.
(5) Remove the rigging pins from the following:
S The bottom of the control stick.
S The left stick mounting bracket.

MAKE SURE THAT THE AREAS AROUND THE
CONTROLS/CON TR OL SU R F A C ES ARE CLEAR OF
PERSONNEL/EQUIPMENT. IF YOU DO NOT DO THIS, INJURY TO
PERSONNEL AND DAMAGE TO EQUIPMENT CAN OCCUR.
(6) Move the control stick fully to the left and hold it
against the stop.
(7) Measure the distance between the trailing edge Record the measurement. The distance
of the left aileron and the trailing edge of the must be as shown in the Control Surface
wing tip. Adjustment Report.
of the right aileron and the trailing edge of the must be as shown in the Control Surface
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(9) Move the control stick fully to the right and hold
it against the stop.
of the right aileron and the trailing edge of the must be as shown in the Control Surface
of the left aileron and the trailing edge of the must be as shown in the Control Surface
(12) Install the left pilot’s seat. Refer to Section 25-10.
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3. Aileron Control System Adjustments
If you cannot get the correct range of movement of the aileron control system, use this procedure to
adjust the system. Gust travel refers to the amount of travel remaining at the control surface with the
control stick held against the cockpit stop.
WARNING: IF YOU DO AN ADJUSTMENT OF A PUSHROD, YOU MUST MAKE

SURE THAT THE PUSHROD IS STILL IN SAFETY. IF YOU DO NOT DO
THIS, THE PUSHROD CAN DISCONNECT. THIS CAN CAUSE DEATH
A. Equipment
Rigging pins. 7 VR-D41-2757-3000.
Ruler/measuring stick. 1 Commercial.
B. Aileron Adjustment Procedure
(1) Remove these items for access: Refer to:
S Pilots’ seats. Section 25-10.
S Passenger seat.
S Pushrod access panels under the center Section 52-40.

section.
S Aileron bellcrank access panels under each

wing.
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(2) Install rigging pins in the following: Refer to Figures 1 and 2.
S The bottom of each control stick. To lock the stick to the torque tube.
S The left stick mounting bracket. To lock the elevator movement.
S The front bellcrank. On the control bulkhead.
S The idler lever. On the front main bulkhead.
S The rear bellcrank. On the rear main bulkhead.
S The left aileron bellcrank. In the left wing.
S The right aileron bellcrank. In the right wing.
Note: Keep the aileron rigging pins into position until you have finished making the
adjustments. Lock each lever or bellcrank in sequence.
(3) If you cannot put a rigging pin into a lever or Refer to Section 27-00 for the pushrod
bellcrank, adjust the pushrod(s) as necessary. adjustment procedure.
(4) Measure the distance between the trailing edge Record these measurements.
of each aileron and the trailing edge of the wing The left aileron must align with the right
tip. aileron.
WARNING: ALL RIGGING PINS MUST BE REMOVED TO AVOID DAMAGE OF

THE CONTROL SYSTEM.
S The bottom of each control stick.
S The left stick mounting bracket.
S The front bellcrank. On the control bulkhead.
S The rear bellcrank. On the rear main bulkhead.
S The left aileron bellcrank. In the left wing.
S The right aileron bellcrank. In the right wing.
(6) Do the Aileron Control System Test Procedure. Refer to Paragraph 1.
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(7) If necessary, adjust the pushrods between the Refer to Section 27-00.
aileron bellcranks in the wings and the ailerons. Adjust the rods to give the
measurements in the original Control
Surfaces Adjustment Report supplied
with the airplane.
(8) If necessary, adjust the aileron stop bolts in the Refer to Figure 1.
torque tube assembly:
S Release the jam nut on the stop bolt.
S Adjust the stop bolt to give the correct range The aileron positions must be the
of movement. distances shown in the original Control
Surfaces Adjustment Report (measured
from the neutral position).
S Tighten the jam nut on the stop bolt.
(9) Do an inspection of the controls that you have

adjusted. If necessary for your Airworthiness
controls.
(10) Install these items: Refer to:
S Pilots' seats. Section 25-10.
S Passenger seat. Section 25-10.
S Pushrod access panels under the center Section 27-50.

section.
S Aileron bellcrank access panels under each Section 27-10.

wing.
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4. Aileron Pushrod Access
Aileron Pushrod Remove/Install Access References
Between the control stick and the bellcrank at Pilot's seat. Section 25-10.
the control bulkhead.
Between the bellcrank at the control bulkhead Pilot's seat. Section 25-10.
and the idler lever at the front main bulkhead.
Between the idler lever at the front main Pilot's seat. Section 25-10.
bulkhead and the bellcrank at the rear main
Passenger seat.
bulkhead.
Between the bellcrank at the rear main Passenger seat. Section 25-10.
bulkhead and the center section closing rib.
Center section access Section 52-40.
panels.
Between the center section closing rib and Center section access Section 52-40.
the bellcrank in the left/right wing. panels.
Aileron bellcrank access
panels under each wing.
Between the bellcrank in the left/right wing Aileron bellcrank access Section 52-40.
and the ailerons. panels under each wing.
5. Aileron Bellcrank and Lever Access
Aileron Bellcrank/Lever Remove/Install Access References
Bellcrank at the control bulkhead. Pilot's seat. Section 25-10.
Idler lever at the front main bulkhead. Pilot's seat. Section 25-10.
Bellcrank at the rear main bulkhead. Passenger seat. Section 25-10.
Bellcrank in the wing. Aileron bellcrank access Section 52-40.

panels under each wing.
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Section 27-20
Flight Controls - Rudder
1. General
The DA 42 NG has the usual rudder control system. Each pilot has a rudder pedal assembly. The pilot
can adjust the pedal position. Control cables connect the pedal assembly to the rudder. The rudder has
an adjustable trim tab. Refer to Section 27-21 for data about the rudder trim system.
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Centering
Springs
Rudder Lower
Mounting-Bracket
Teflon Tubes which Turnbuckles

Guide Cockpit Cables
Pulley
Fuselage Cables
with Guide Tubes
Yoke
Control Bulkhead
Co-Pilot's Rudder Outboard Control Cable
Pedal Assembly
Inboard Control Cable Pilot's Rudder

Pedal Assembly
Figure 1: Rudder Control System
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2. Description
The DA 42 NG has a set of rudder control pedals for each pilot. The pedal assembly can be adjusted.
Figure 1 shows the rudder control system. Figure 2 shows the rudder pedal assembly with manual
pedal adjustment. Figure 3 shows the rudder pedal assembly with electrical pedal adjustment (optional
equipment, OÄM 42-070). Figure 4 shows the rudder control in the cockpit and Figure 5 shows the
rudder controls in the fuselage The system has these components:
) A rudder pedal assembly for each pilot at the front of the cockpit. The forward part of each pedal
connects to a brake master cylinder (refer to Section 32-40 for more data about the brake system).
) An adjuster handle for each pilot, attached to the aft face of each rudder pedal assembly or as
optional equipment, an adjuster switch for each pilot, located at the rear wall of the leg room.
) A yoke (a “T” shaped lever) assembly in the fuselage below the center console. The yoke attaches
to the bottom of the control bulkhead and to the fuselage shell.
) A rudder pedestal at the rear of the fuselage. The rudder lower mounting-bracket is attached to the
rudder leading edge. It connects the rudder to the rudder pedestal.
) Cable assemblies. Flexible control cables connect the cockpit front bulkhead to the yoke. Two long
flexible control cables connect the yoke to the rudder. Each of the long flexible cables has a
turnbuckle assembly for adjusting the length of the cable.
Six bolts attach each rudder pedal assembly to the cockpit floor.
Each rudder pedal assembly has two pedals. Each pedal has a lever and a foot pad. Each pedal has
an “S” shaped tube. The lower part of the tube aligns with the pivot of the pedal. The upper part of the
tube aligns with the foot pad of the pedal.
Four control cables (cockpit cables) go from the cockpit front bulkhead to enter the bottom of each “S”
shaped tube. A multihole fitting at the bulkhead gives adjustment for each fitting. Each cable goes
through an “S” shaped tube and comes ut at the top of the tube. Each cable then goes from the tube
to the yoke.
Each outboard control cable goes through a Teflon tube in the aft face of the floor panel. Each
outboard control goes inboard through a guide pulley on the control bulkhead. The cables connect
each outer pedal to the front arm of the yoke.
Each inboard control cable goes through a Teflon tube in the aft face of the floor panel. The cables
connect each inner pedal to the side arms of the yoke.
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AIRCRAFT
Right Rudder Pedal

Brake Pedals
'S' Tube for

Control Cables
Adjuster Handle
Brake Reservoir
(Co-Pilot only)
Brake Master Cylinder

Aft Attachment
Tension Springs to Floor Panel
Left Rudder Pedal
'S' Tube for

Control Cables
Front Attachment Adjuster Cable

to Floor Panel
Rudder Control Cable
Roll-Pins
Multi-Hole Bracket
Sledge Adjuster (Attachment for Cables)
Tubes Latch
Figure 2: Rudder Pedal Assembly
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AIRCRAFT
Right Rudder Pedal

Brake Pedals
'S' Tube for

Control Cables
Transmission Mechanism
Brake Reservoir
(Co-Pilot only)
Brake Master Cylinder
Left Rudder Pedal

Aft Attachment
to Floor Panel
'S' Tube for
Control Cables
Front Attachment
to Floor Panel Adjuster Rod
Roll-Pins Rudder Control Cable
Multi-Hole Bracket
Sledge (Attachment for Cables)
Tubes
Figure 3: Rudder Pedal Assembly with Electric Adjustment (OÄM 42-070 carried out)
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Two cable assemblies (fuselage cables) attach to the rear of the yoke. Each cable has a short front
cable and a longer rear cable. All cables go through Teflon tubes. Turnbuckles connect the front cable
to the rear cable. The turnbuckles can adjust the tension in the fuselage cables and the neutral position
of the rudder.
The two fuselage cables go through Teflon tubes in the rear fuselage. The cables attach to the rudder
lower mounting bracket. The cables cross over each other in the rear fuselage.
The rudder stop which limits the rudder deflection to the left side is located left of the lower rudder
hinge (Figure 4). The rudder stop which limits the ruder deflection to the right side is located right of
the rudder lower hinge. Each rudder stop consists of a nut which is welded to the rudder lower
mounting-bracket and a bolt which is held tight in the nut by a jam nut.
3. Operation
If you move the left rudder pedal forward:
) The top of the “S” shaped tube moves forward.
) The “S” shaped tube pulls the left cockpit cable.
) The left cockpit cable moves the yoke counterclockwise (seen from above).
) The yoke pulls the fuselage cable attached to its right arm forward. This cable connects to the left
of the rudder.
) The fuselage cable deflects the rudder to the left.
) The rudder movement pulls the other fuselage cable aft. This cable connects to the left of the yoke.
) The fuselage cable moves aft with the left side of the yoke.
) The left side of the yoke pulls both of the right cockpit cables aft. And the cables pull the “S” shaped
tube on the right rudder pedals aft.
If you move the right rudder pedal forward each part moves in the opposite sense. The rudder moves
to the right and pulls the left cables aft.
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%
T-Yoke Axle
%
% Rigging Pin Hole
% Control Bulkhead
% Mounting
Bracket
%
%
Fuselage Cables
% Right Inboard Cable
%
% Yoke
Left Inboard Cable
% Right Outboard
% Cable
Bush
%
Pulley Spacer
%
% Oetiker Clamp
Safety Plate Left Outboard
% Cable Plastic Washer
% Teflon Tube
Fokker
% Needle
% Pulley Assembly
Yoke
% Assembly Floor
Panel
%
%
%
%
%
%
%
%
%
% Co-Pilot's Rudder
Teflon Tube
% Pedal Assembly
Floor Panel
% Outboard Control Cable
% Inboard Control Cable
Pilot's Rudder Pedal Assembly
%
%
Figure 4: Rudder Controls in Cockpit
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A. Manual Adjustment
When you pull on the adjuster handle, the latch disengages from the bottom sledge tube. If you pull
further, the pedal assembly moves along the sledge tube towards you. Release the handle, then push
with your feet on both pedals. The latch will lock.
If you push with both feet while you pull the handle, the pedal assembly moves along the sledge tube
away from you. Release the handle, then push with your feet on both of the pedals. The latch will lock.
When you adjust the position of the pedals, the control cables move through the “S” shaped tubes.
B. Electrical Adjustment (Optional Equipment, OÄM 42-070)
Positioning switches are located on the LH and RH side, at the rear wall of the leg room. The
positioning switch causes the rudder pedals on the corresponding side to move along the guide rail.
To move the pedals towards you, press the upper side of the switch. Press the lower end of the switch
and the pedals will move away from you.
Releasing the switch will cause the motor to be switched off and the pedals will remain in the current
position.
When you adjust the position of the pedals, the control cables move through the "S" shaped tubes.
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AIRCRAFT
Rudder Lower
Mounting-Bracket Rudder Stop Bolt
Rudder Pedestal
A
Spacer
Fuselage Cables
with Guide Tubes
Bush
A
A
Teflon Tube
Plastic Turnbuckles
Washer
A
Frame
Oetiker
Clamp A
Rigging Pin A Fuselage Cables

with Guide Tubes
Spacer
A
Yoke Assembly on Bush
Control Bulkhead A
Figure 5: Rudder Controls in the Fuselage
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22 Dec 2021 27-20-00 Rev. 5
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have in the rudder control system. Refer to Section 27-21
for more data about the rudder trim system. If you have the trouble detailed in the Trouble column,
read across to the Possible Cause column and then do the repair given in the Repair column.
Airplane moves about its yaw Rudder control cable needs Adjust the rudder control
axis with no input from the adjusting. cables.
pilot.
Rudder trim system defective. Refer to Section 27-21.
Rudder controls stiff/catch. Bearings defective. Replace the defective bearing.
Cables chafing in the guide Replace the cables and guide

tubes. tubes.
Cable tension too low. Cable worn out. Replace rudder control cable.
Adjust rudder control system.
Pulley worn out. Replace pulley.
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1. General
These Maintenance Practices tell you how to do test procedures on the rudder control system. They
also tell you how to adjust the rudder control system. Refer to Section 52-40 for data about
removing/installing the rudder. Refer to Section 27-21 for data about the rudder trim system.

SURFACES CAN OCCUR.

2. Rudder Control System Test for Correct Range of Movement
A. Equipment
Rudder deflection gauge for S/N 42.N100 and 1 D64-5540-00-00-PL.

subsequent and 42.MN050 and subsequent.
Rudder deflection gauge for all other S/N. 1 D60-5540-00-00-PL.
B. Rudder Control Test Procedure
(1) Make a copy of the Control Surfaces Refer to Section 06-00. Use it to record
Adjustment Report. the measurements.
(2) Install the deflection gauge on the vertical

stabilizer.
(3) Raise the airplane on jacks and move the wing

and rear fuselage trestles into position to
support the airplane.
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(4) Set both rudder pedals fully forward.

MAKE SURE THAT THE AREAS AROUND THE
C O N T R O LS/CONTROL SURFACES ARE CLEAR OF
PERSONNEL/EQUIPMENT. IF YOU DO NOT DO THIS, INJURY TO
PERSONNEL AND DAMAGE TO EQUIPMENT CAN OCCUR.
(5) Set the rudder pedals central. The left pedal must align with the right
pedal.
Make sure that the rudder is in the
neutral position shown in the Control
Surfaces Adjustment Report for the
airplane.
(6) Set the rudder pedals to fully left. Make sure the rudder deflects to the left
at least 24°. The maximum left rudder
deflection according to the Control
Surfaces Adjustment report must be
achieved when the rudder is moved
directly by hand when hitting the rudder
stop.
(7) Set the rudder pedals to fully right. Make sure the rudder deflects to the
right at least 24°. The maximum right
rudder deflection according to the
Control Surfaces Adjustment report must
be achieved when the rudder is moved
stop.
(8) Make sure that the left and right rudder pedals
are free to move when they are set in all of the
adjustable positions.
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3. Rudder Control System Adjustments
If you cannot get the correct range of movement of the rudder control system, use this procedure to
adjust the system.
A. Equipment
Cable tension gauge (tensiometer). 1 Commercial.

Spring scale (up to 10 kg (22 lbf)). 1 Commercial.
B. Rudder Adjustment Procedure
(1) Remove these items for access: Refer to Section 25-10.
S The pilot's seat.
S The passengers seat.
(2) Set both rudder pedals fully forward.
(3) Set the rudder pedals central. Make sure that the rudder is in the
neutral position. The left rudder pedal
must align with the right rudder pedal.
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(4) If necessary, adjust the length of the cables Refer to Figure 4.

between the yoke and the rudder lower
mounting bracket:
S Remove the lock wire from the turnbuckles.
S Adjust the turnbuckles to set the rudder to Below the passenger seat.
neutral.
S Do a test for the correct cable tension. Use the tensiometer.

Required value: 15 daN (33.72 lbf.) -
17 daN (38.22 lbf.).
S If GFC700 autopilot (OÄM 42-102) is

installed:
S Pull on turnbuckle using a spring scale

applying a force of 10 kg (22 lbf).
S Deflection of turnbuckle should be

20 ± 5 mm (0.79 ± 0.2 in).
S If necessary adjust rudder tension

accordingly via the turnbuckle.
S Tighten the turnbuckles and install the

lockwire.
(5) Set the rudder pedals to fully left. Make sure the rudder deflects to the left
at least 24°. The maximum left rudder
deflection according to the Control
Surfaces Adjustment report must be
achieved when the rudder is moved
stop.
(6) If necessary, adjust the rudder stop bolt on the

left side of the rudder lower mounting bracket:
S Release the jam nut on the left stop bolt.
S Adjust the stop bolt to give the correct range The rudder position must be the
of movement. distance to the left shown in the Control
Surfaces Adjustment Report for the
airplane (measured from the neutral
position).
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(7) Set the rudder pedals to fully right. Make sure the rudder deflects to the
right at least 24°. The maximum right
rudder deflection according to the
Control Surfaces Adjustment report must
be achieved when the rudder is moved
stop.
(8) If necessary, adjust the rudder stop bolt on the

right side of the rudder lower mounting bracket:
S Release the jam nut on the right stop bolt.
S Adjust the stop bolt to give the correct range The rudder position must be the
of movement. distance to the right shown in the
Control Surfaces Adjustment Report for
the airplane (measured from the neutral
position).
(9) Do a test for the correct range of rudder Refer to Paragraph 2.

movement.
(10) Do an inspection of all the controls that you

have adjusted. If necessary for your
Airworthiness Authority do a duplicate
inspection of the controls.
(11) Install these items: Refer to Section 25-10.
S The passenger seat.
S The pilots’ seats.
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4. Remove/Install the Rudder Control Cables
A. Equipment
Cable tension gauge (tensiometer). 1 Commercial.
Swaging tool. 1 Commercial.
Nicopress oval and stop sleeve gauge (‘go/no-go 1

gauge’) for 1/8 in sleeves.
B. Remove the Cockpit Rudder Control Cables (Front Cables)
(2) Remove the cable between the cockpit front Refer to Figures 2 and 3.
bulkhead and the yoke:
S Remove the nut, washer, bolt and spacer

that attach the cable to the multihole bracket
at the bulkhead.
S Remove the nut, washer, bolt, bush and

spacer that attach the cable to the yoke.
S Cut the eye end from the cable that you will
remove, at the bulkhead end.
S Remove the old cable.
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C. Install the Rudder Control Cables (Front Cables)
WARNING: ONLY TRAINED AND AUTHORIZED PERSONS SHOULD INSTALL

CABLE EYE-ENDS. IF THE EYE-ENDS ARE NOT INSTALLED
CORRECTLY, THE RUDDER CONTROLS CAN FAIL. THIS CAN
CAUSE DEATH OR INJURY TO PERSONNEL.
Note: Install eye ends in accordance with FAA AC 43.13-1B, Chapter 7, Section 8.
Note: To make the work easier, install an eye end on one end of the cable before you
install it in the airplane.
(1) Install one new eye end to the cable before you
install it in the airplane:
S Use cables to specification LN9374 or ISO

2020 or MIL-DTL-83420, streched to 60 %
MBS.
S Make the eye-end using Locoloc thimbles

and Nico-Press clamps appropriate to the
installed 3.2 mm (1/8") diameter steel
cables.
S Inspect the cable eye end for correct Inspect cable swages with go/no go
assembly. gauge for 1/8 in Nicopress oval sleeve in
accordance with FAA AC 43.13-1B,
Chapter 7, Section 8.
Authority, send a sample eye end for proof
test.
(2) Push the control cable through the Teflon tubes Refer to Figure 3.
from the rear.
(3) Make sure the cable is in the correct position on

the pulley (for the outer cables only).
(4) Push the cable through the “S” shaped tube on

the rudder pedal assembly.
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AIRCRAFT
(5) Install a new eye end to the cable at the cockpit

front bulkhead end:

cables.
test.
(6) Install the cable to the yoke:
S Install the bolt, bush and spacer that attach

the cable to the yoke.
Torque to 6.4 Nm (4.7 lbf.ft.). Always
S Install a washer and new self-locking nut
use new self locking nuts.
onto the bolt.
(7) Install the cable to the bracket at the cockpit Adjust the position of the bolt in the
front bulkhead: multihole bracket to give the correct
rudder pedal position. The rudder pedal
S Install the bolt and spacer that attach the
lever must be vertical when the rudder is
cable to the bracket.
set to neutral.
Torque to 6.4 Nm (4.7 lbf.ft.). Always

S Install a washer and new self locking nut to use new self-locking nuts.
the bolt.

movement. If necessary adjust the rudder Refer to Paragraph 3.
controls.

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(11) Record type of cables installed (stainless or

non-stainless steel cables) in the airplane logs.
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D. Remove the Fuselage Rudder Control Cables (Rear Cables)
S The pilot’s seat.
(2) Remove the cable between the yoke and the Refer to Figure 4.
turnbuckle:

spacer that attach the cable to the yoke.
remove, at the yoke.
S Remove the old cable aft.
S Cut the eye end from the cable that you will,
remove, at the turnbuckle.
(3) Remove the cable between the turnbuckle and

the rudder:

spacer that attach the cable to the rudder
lower mounting bracket.
remove, at the rudder end.
S Remove the old cable forward.
remove at the turnbuckle.
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E. Install the Fuselage Rudder Control Cables (Rear Cables)
WARNING: ONLY TRAINED AND AUTHORIZED PERSONS SHOULD INSTALL

CABLE EYE ENDS. IF THE EYE ENDS ARE NOT INSTALLED
CORRECTLY, THE RUDDER CONTROLS CAN FAIL. THIS CAN
CAUSE DEATH OR INJURY TO PERSONNEL.
Note: Install eye ends in accordance with FAA AC 43.13-1B, Chapter 7, Section 8.
Note: To make the work easier, install an eye end on one end of the cable before you
install it in the airplane.
(1) Install a new eye end to the front of the cable at

the yoke end before you install the cable in the
airplane and:

MBS.

cables.
test.
(2) Push the control cable through the Teflon tube Refer to Figure 4. Through the front and
from the front. rear main bulkheads.
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AIRCRAFT
(3) Install a new eye end to the cable at the

turnbuckle end:

cables.
test.
(4) Install a new eye end to the rear cable before

you install the cable into the airplane:

MBS.

cables.
test.
(5) Push the cable through the Teflon tubes from Towards the rudder.
the front.
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AIRCRAFT
(6) Install a new eye end to the cable at the rudder

mounting bracket end:

cables.
test.
(7) Install the able to the rudder lower mounting- Refer to Figure 4.
bracket:

the cable to the rudder.
S Install a washer and new self-locking nut. Torque 6.4 Nm (4.7 lbf.ft.). Use a new
self-locking nut.
(8) Install the cable to the yoke: Refer to Figure 4.

he cable to the yoke.
S Install a washer and a new self-locking nut. Torque 6.4 Nm (4.7 lbf.ft.). Use a new
self-locking nut.
(9) Adjust both left and right rudder cable Refer to Paragraph 3.
turnbuckles to give the correct tension to the
control cables.

movement.

Airworthiness Authority, do a duplicate
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AIRCRAFT
(13) Record type of cables installed (stainless or

non-stainless steel cables) in the airplane logs.
5. Remove/Install the Pulleys
A. Remove the Pulleys
S The pilot’s seat.
(2) Remove the pulley: Refer to Figure 3.
S Remove the nut, washers and bolt that

attach the pulley to the mounting link at the
control bulkhead.
S Separate pulley and safety plate from the Handle with care. Do not spoil the
outer front cable. control cable.
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B. Install the Pulleys
(1) Install the pulley: Refer to Figure 3.
S Put the outer cable into the groove around

the pulley.
S Bring the safety plate into position. Check for correct guidance of the control
cable.
S Install the bolt, washers and nuts that attach
the pulley to the mounting link at the control
bulkhead.
(2) Make sure the cable is in the correct position on Check friction.
the pulley.

movement. If necessary adjust the rudder Refer to Paragraph 3.
controls.

S The pilot's seat.
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6. Rudder Control Cable and Yoke Access
Rudder Cable/Yoke Remove/Install Access References
Cockpit cables between the cockpit front Pilot’s seat. Section 25-10.
bulkhead and the yoke.
Rear fuselage cables between the yoke and Pilot’s seat. Section 25-10.
the rudder.
Passenger seat.
Rudder. Section 55-40.
Yoke. Pilots' seats. Section 25-10.
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Section 27-21
Flight Controls - Rudder Trim
1. General
The DA 42 NG has a rudder with a trim tab. The pilot uses a trim knob located at the front of the center
console to move the rudder trim tab. The rudder trim control system is a mechanical control system.
Figure 1 shows the main components of the rudder trim control system.
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Rev. 5 27-21-00 22 Dec 2021
AIRCRAFT
Trim Tab Control Horn
Trim Tab Operating Rods

Damper
Rod
Friction Block Assembly
Trim Handwheel Center Console

Trim Indicator
Cover Plate
Spindle
Threaded Portion
Spindle Block
Bellcrank Flexible Cable

Assembly
Bracket
Figure 1: Rudder Trim Control System - Main Components
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22 Dec 2021 27-21-00 Rev. 5
AIRCRAFT
2. Description
The mechanical rudder trim system has three main parts:
) A handwheel assembly with trim indicator.
) A long flexible cable which connects the handwheel to the trim tab operating mechanism.
) The trim tab actuator assembly.
A. Rudder Trim Handwheel Assembly
A handwheel assembly at the top of the center console controls the rudder system. The handwheel
attaches to a rectangular drive on the top of a long spindle. The rectangular drive at the top of the
spindle also drives the trim indicator. The trim indicator system is a mechanical device and attaches
to the lower surface of the center console cover plate.
The long spindle is supported at the top by the center console cover plate and at the bottom by a
bearing located on a bracket bolted to the structure of the center console.
The lower section of the spindle has an external thread. A spindle block with an internal thread is
positioned on the threaded portion of the spindle. The spindle block has spigots which engage with
slots on a bellcrank assembly. The bellcrank has two input arms with slots that engage with the
spindle block spigots and an operating lever that connects to a long flexible cable.
The two input arms of the bellcrank have a hole drilled through both arms that will align with a hole
drilled through the structure of the center console. When the holes are aligned the handwheel
assembly is in the neutral position. You can insert a rigging pin through the holes when you will
adjust the rudder trim control system.
B. Flexible Cable
A long flexible cable connects the trim handwheel assembly to the trim tab actuator assembly. The
cable goes through holes in all the fuselage bulkheads and through the bottom of vertical stabilizer.
From the rear of the vertical stabilizer the cable goes into the rudder lower mounting bracket where
it connects to the rudder trim tab actuator assembly.
The cable has an inner core with threaded end fittings. Fork end fittings attach to the threaded end-
fittings of the inner core. The fork end fittings attach to the operating lever of the handwheel
assembly at one end and to the trim tab operating rods at the other end.
The outer sleeve of the flexible cable has threaded sections at each end. These threaded sections
screw into fixings at the handwheel assembly and the trim actuator assembly. Locknuts are used
on the threaded ends to secure the flexible cable in position.
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AIRCRAFT
C. Trim Tab Actuator Assembly
The trim tab is a GFRP molding. The trim tab has a control horn with two integral levers. Two trim
tab operating rods connect the integral levers to the flexible cable fork end fitting. The operating
rods have spherical end fittings screwed into each end of the rods. The spherical end fittings are
bolted to the integral levers and the fork end fitting.
The end of the flexible cable outer sleeve screws into a friction block assembly. The friction block
assembly has a hole with an internal thread. The flexible cable outer sleeve screws into this
threaded hole.
The top section of the friction block has a hole drilled in it for the friction rod. The friction rod passes
through the upper section of the friction block and attaches to the fork end fitting. A friction shoe
in the top section of the friction block is held in contact with the friction rod by springs. This
clamping action on the friction rod dampens the movement of the trim tab actuator should the trim
tab control system fail.
3. Operation
If the pilots rotates the trim control knob clockwise during flight then these events occur:
) The trim control spindle rotates clockwise. The trim indicator moves to the right to show the position
of the spindle.
) The spindle-block moves up the threaded portion of the trim control spindle.
) The moving spindle block rotates the bellcrank and the bellcrank lever arm moves forward.
) The bellcrank lever arm pulls the inner core of the flexible cable forward.
) The flexible cable fork end fitting moves forward and the trim tab control rods move forward.
) The trim tab moves to the left and the dynamic forces acting on the rudder trim tab move the rudder
to the right.
If the pilot rotates the trim control knob counterclockwise during flight the system operates in the
reverse direction.
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Trouble-Shooting
1. General
The table below lists the defects you could have in the rudder control system. If you have the trouble
detailed in the Trouble column, read across to the Possible Cause column and then do the repair given
Airplane moves about its yaw Rudder control cables need Refer to Section 27-20.
axis with no input from the adjusting.
pilot.
Rudder trim system defective. Adjust the rudder trim tab
control system.
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1. General
This Section tells you how to test and adjust the rudder trim tab control system.
2. Rudder Trim-Tab Control System Test for Correct Range of Movement
If you cannot get the correct range of movement of the rudder trim tab control system, use this
procedure to adjust the system.
A. Equipment

Rudder trim deflection gauge for S/N 42.N100 and 1 D64-5545-00-00-PL.

Rudder trim deflection gauge for all other S/N. 1 D60-5545-00-00-PL.
Rigging pin (Ø 4 mm [0.16 in]). 1 VR-D41-2757-3000.
B. Adjust the Rudder Trim-Tab Control System
(1) Make a copy of the Control Surfaces Refer to Section 06-00. Use it to record
Adjustment Report. the measurements.
(2) Install the rudder deflection gauge.
(3) Install the rudder trim deflection gauge. Make sure the rudder trim gauge axle
marker corresponds with the rudder trim
tab axle.
Make sure the rudder trim gauge 0°
position is aligned with the rudder
trailing edge center line. Use shims to
achieve the correct gauge position.
(4) Make sure that the rudder is in the neutral Refer to Section 27-20. Hold the rudder
position according to Control Surface in position.
Adjustment Report.
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(5) Operate the rudder trim control knob fully clock- The system must operate smoothly
wise, then counterclockwise, then set the control throughout the full range of movement.
knob to the neutral position. The rudder trim tab must be in the
neutral position.
(6) Remove the access panel from the side of the

center console:
S Remove the 3 screws that attach the access

panel to the structure.
S Move the access panel clear of the center

console.
(7) Install a rigging pin through the holes in the The rudder trim tab indicator should
center console structure and the bellcrank. indicate neutral.
(8) The deflection angle of the trim tab must be in If necessary, adjust the lengths of both
accordance with the Control Surfaces trim tab control rods. Refer to
Adjustment Report. Paragraph 3.
Make sure that the trim rudder linkage
play is equal to the left and to the right
side of neutral position.
(9) Remove the rigging pin from the center console.
(10) Turn the rudder trim control wheel fully Record the measurement. The
clockwise and measure the position of the measurement must be the same as
rudder trim tab. shown in the Control Surfaces
Adjustment Report.
(11) Turn the rudder trim control wheel fully counter- Record the measurement. The
clockwise and measure the position of the measurement must be the same as
rudder trim tab. shown in the Control Surfaces
Adjustment Report.
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(12) Install the access panel in the side of the center

console that you removed:
S Make sure that there are no loose articles in For example: rags or tools.
the center console.

center console.
S Install the 3 screws that attach the access

panel to the center console.
(13) Release the rudder and make sure that both the
rudder and the rudder trim tab can move fully
and freely throughout their range of movements.
(14) Remove the rudder and the rudder trim

deflection gauges.
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3. Adjust the Rudder Trim Tab Control System
If you cannot get the correct range of movement of the rudder trim tab, use this procedure to adjust
the trim system.
A. Equipment

Rudder trim deflection gauge for S/N 42.N100 and 1 D64-5545-00-00-PL.

Rudder trim deflection gauge for all other S/N. 1 D60-5545-00-00-PL.
Rigging pin (Ø 4 mm [0.16 in]). 1 VR-D41-2757-3000.
B. Rudder Trim Control System Adjustment Procedure
(1) Make sure that the rudder is in the neutral Refer to Section 27-20. Hold the rudder
position. in this position.
(2) Install the rudder and the rudder trim deflection Make sure the rudder trim gauge axle
gauges. marker corresponds with the rudder trim
tab axle.
Make sure the rudder trim gauge 0°
position is aligned with the rudder
trailing edge center line. Use shims to
achieve the correct gauge position.
(3) Operate the rudder trim control knob fully The system must operate smoothly
clockwise, then counterclockwise, then set the throughout the full range of movement.
control knob to the neutral position.
(4) Remove the access panel from the side of the Refer to Figure 2.
center console:

panel to the structure.
S Move the access panel clear of the center

console.
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(5) Install a rigging pin through the holes in the The rudder trim tab indicator should
center console structure and the bellcrank. indicate neutral.
(6) Adjust the rudder trim tab operating rods to set In accordance with Control Surfaces
the rudder trim tab to the neutral position: Adjustment Report.
There is some play in the trim tab linkage, so

make sure the play is equal left and right when
the trim tab in neutral position.
S Remove the bolts that attach the spherical
end fittings of the operating rods to the trim
tab.
S Loosen the locknut on the lower operating

rod end fitting.
S Screw the end fitting in/out of the operating Screw the end fitting into the rod to
rod half a turn (as required). move the trim tab to the left, screw the
end fitting out of the rod to move the trim
Note: Do not expose more than 14 mm
tab to the right.
(0.55 in) of thread.
S Move the lower operating rod back into The center of the trailing edge of the trim
position at the trim tab lever and install the tab must align with the trailing edge of
attaching bolt. the rudder. If it does not then you must
adjust the lower operating rod until the
trim tab aligns correctly with the rudder.
S Adjust the end fitting of the top operating rod

until the end fitting aligns with the trim tab
lever.
S Tighten the lock-nuts on the end fittings of

both operating both operating rods.
S Install the bolts that attach the spherical end

fittings of the operating rods to the trim tab
levers.

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(8) Remove the rigging pin from the center control

console.
(9) Install the access panel in the side of the center

console that you removed:
S Make sure that there are no loose articles in For example: rags or tools.
the center console.

center console.

panel to the center console.
(10) Release the rudder and make sure that both the
rudder and the rudder trim tab can move fully
and freely throughout their range of movements.
(11) Remove the rudder and the rudder trim

deflection gauge.
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Figure 2: Adjust the Rudder Trim Tab Control System
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Section 27-30
Flight Controls - Elevator
1. General
The DA 42 NG has the usual elevator control system. An elevator attaches to the horizontal stabilizer
gives longitudinal control of the airplane. Two control sticks operate the elevator. The DA 42 NG has
an electrically operated elevator trim system and a mechanically operated trim system. Refer to
Section 27-38 for data about the mechanical trim system and refer to Section 27-39 for data about the
electric trim system.
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Front Main Bulkhead
Left Stick
Rigging
Idler Lever Pin Hole
Push Rod to
Idler Lever
Torque Tube Assy
Variable Elevator
Stop
Elevator Lever
Control Stick
Mounting Block
Figure 1: Elevator Control Installation in the Cockpit
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2. Description
Figure 1 shows the elevator controls in the cockpit. Figure 2 shows the elevator controls in the rear
fuselage.
Each pilot has a control stick that attaches to the torque tube assembly. The torque tube assembly has
a lever which attaches to a short pushrod. The short pushrod connects to an idler lever on the front
main bulkhead. The idler lever connects to a long pushrod.
The long pushrod has three guide bearings. The aft baggage frame, ring frame 1 and ring frame 2
have pushrod guides. Each guide has three rollers.
The long pushrod attaches to a bellcrank at the bottom of the vertical stabilizer. The bellcrank attaches
to a vertical pushrod in the vertical stabilizer. The vertical pushrod connects to the elevator horn. The
vertical pushrod has two balance springs attached to a bracket welded to the pushrod. These springs
assist the elevator to return to the neural position.
The elevator stop for the downward movement consists of a GFRP block which is bonded to the inside
of the upper skin of the horizontal stabilizer. When the elevator is deflected fully downwards, the
forward extension of the elevator horn is deflected fully upwards and contacts the stop.
The elevator stop for the upward movement consists of a bolt/bush assembly which is installed in the
trim actuator mounting bracket in a transverse direction (refer to Section 27-38). When the elevator
is deflected fully upwards, the forward extension of the elevator horn is deflected fully downward and
contacts the stop.
Figure 3 shows the variable elevator stop. The DA 42 NG is equipped with an electrically operated
actuator that limits the elevator up travel to 13° as soon as the power setting of both engines exceeds
approximately 20 %. The linear actuator acts as a movable stop and is controlled by two switches on
the throttle quadrant, one for each power lever. When power is reduced below approximately 20 %,
full elevator deflection is regained. The operation of the variable elevator stop is only controlled by the
position of the engine power levers and cannot be selected or deselected by the pilot.
An amber STICK LIMIT caution is provided on the PFD to inform the pilot in case a malfunction is
present. The STICK LIMIT caution appears when the variable elevator stop should be in place and is
actually not activated (power ON condition) or should be retracted and actually limits the elevator travel
(power OFF condition). The annunciation circuitry is not operative when one power lever is positioned
beyond the approach power setting, while the other is below or in idle position (engine failure or
training).
You cannot adjust the elevator stops.
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Additional Elevator Mass

(optional)
Elevator
Lever Rib
Balance Weight
Elevator Actuating Lever

Collar Bush
Large Washer Distance Bush
Elevator
Push Rod II
Centering Springs
Elevator Bellcrank
Rigging
Pin Hole
Ring Frame 2
Rigging
Pin Hole
Ring Frame 1
Baggage Frame
Elevator Push Rod I

Idler Lever To Bellcrank
Idler Lever
Figure 2: Elevator Controls in the Rear Fuselage
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3. Operation
If you move the control stick forward:
) The torque tube assembly turns.
) The lever below the torque tube assembly pushes the short pushrod aft.
) the short pushrod pushes the long pushrod aft.
) the long pushrod pushes the aft bellcrank rearward.
) The bellcrank pushes the vertical pushrod up.
) The vertical pushrod moves the front of the elevator horn upwards.
) The elevator moves down.
If you move the control stick aft:
) The torque tube assembly turns.
) The short and long pushrods move forward.
) The bellcrank pulls the vertical pushrod downwards.
) The elevator moves up.
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Operating Stop Rod

Stick Limiter Actuator of
Variable Elevator Stop
Actuator Bracket
Actuator Lever
Figure 3: Variable Elevator Stop
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Trouble-Shooting
1. General
The table below list the defects you could have in the elevator control system. If you have the trouble
Control vibration during flight. Too much backlash in the flight Examine the flight control
controls. system to isolate the problem.
Replace the defective part.
Elevator controls stiff/catch. Bearings defective. Replace the defective eye end.
Pushrod deformed. Replace the deformed

pushrod.
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1. General
These Maintenance Practices tell you how to do test procedures on the elevator control system. They
also tell you how to adjust the elevator control system. Refer to Section 55-20 for data on how to
remove/install the elevator. Refer to Sections 27-38 and Section 27- 39 for data about the elevator trim
systems.

SURFACES CAN OCCUR.

2. Elevator Control System Test for Correct Range of Movement
A. Equipment
Rigging pin. 1 VR-D41-2757-3000.
Ruler or deflection gauge. 1 Commercial.
Fuselage trestle. 1 Commercial.
Airplane jacks. 3 Commercial.
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B. Elevator Control Test Procedure
(1) Make a copy of the Control Surfaces Refer to Section 06-00.

Adjustment Report. Use it to record measurements.
(3) Install the rigging pin through the stick mounting Refer to Figure 1.
block and the torque tube.
Note: Place the elevator deflection indicator between the stabilizer tips and the
stabilizer so that the markings face backwards to the elevator.
(4) Make sure that the elevator deflection indicator At the stabilizer tips.
is placed correctly.
(5) Read the angle of deflection of the elevator on Record the measurement.
the elevator deflection indicator.
(6) Remove the rigging pin from the stick mounting

block.

MAKE SURE THAT THE AREA AROUND THE CONTROLS/CONTROL
SURFACES ARE CLEAR OF PERSONS/EQUIPMENT. IF YOU DO
NOT DO THIS, INJURY TO PERSONNEL AND DAMAGE TO
CONTROL SURFACES CAN OCCUR.
(7) Move the control stick fully forward and hold it

against the stop.
the elevator deflection indicator. The distance must be as shown in the
Control Surfaces Adjustment Report.
(9) Move the control stick fully aft and hold it

against the stop.
the elevator deflection indicator. The distance must be as shown in the
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C. Elevator Control Test Procedure Using the Protractor (Electronic Deflection Gauge)
Note: If you use a protractor, make sure that the airplane does not move in pitch during
the test procedure. It will cause errors in the test.
(1) Raise the airplane on jacks. Refer to Section 07-10.
(2) Put a trestle under the rear fuselage. To prevent a movement in pitch.
(3) Level the airplane. Refer to Section 08-00.

Adjustment Report.
Use it to record measurements.
(6) Install the rigging pin through the stick mounting Refer to Figure 1.
block and the torque tube.
(7) Remove the horizontal stabilizer tips: Hold the tips.
S Remove the 8 screws that attach the tip to

the stabilizer.
(8) Protractor reference:
S Place the protractor on the edge of the This is the 0° reference plane. Make
stabilizer onto the rib where the tips were sure that the protractor is placed
removed before. correctly. Refer to Figure 4.
S Reset the protractor.
(9) Protractor measurement:
S Place the protractor on the elevator surface Make sure to use the same orientation
and read the angle of deflection of the of the protractor like before, taking
elevator surface. measurement.
S Read the angle of deflection of the elevator Refer to Figure 4.

on the protractor. The correct angle must be Record the measurement.
6.5° because then the elevator is centered.
(10) Remove the rigging pin from the stick mounting

block.
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(11) Move the control stick fully forward and hold it

against the stop.
(12) Repeat step 9 and keep the bevelled angle Record the measurement.
(6.5°) in mind.
The angle must be as shown in the
(13) Move the control stick fully aft and hold it

against the stop.
(14) Repeat step 9 and keep the bevelled angle Record the measurement.
(6.5°) in mind.
The angle must be as shown in the
(15) Install the horizontal stabilizer tips:
S Install the 8 screws that attach the tip to the

stabilizer.
(17) Remove the trestle from under the rear

fuselage.
(18) Lower the airplane. Refer to Section 07-00.
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3. Elevator Control System Adjustments
If you cannot get the correct range of movements of the elevator control system, use this procedure
to adjust the system. Gust travel refers to the amount of travel remaining at the control surface with
the control stick held against the cockpit stop.
WARNING: IF YOU DO AN ADJUSTMENT OF A PUSH-ROD, YOU MUST MAKE

SURE THAT THE PUSH-ROD IS STILL IN SAFETY. IF YO DO NOT DO
THIS, THE PUSH-ROD CAN DISCONNECT. THIS CAN CAUSE DEATH
OR INJURY TO PERSONNEL.
A. Equipment
Protractor (electronic deflection gauge) or elevator 1 Commercial.

deflection indicator.
Rigging pins. 3 -
B. Elevator Control Adjustment Procedure
Refer to Figure 1.
(1) Remove these items for access: Refer to:
S The pilots’ seat. Section 25-10.
S The rudder. Section 55-40.
(2) Install rigging pins in the following: Refer to Figure 1 and 2.
S Through the stick mounting block and the On the control bulkhead.
torque tube.
S The rear bellcrank. On the vertical stabilizer rear web.
(3) If you cannot put a rigging pin into a lever or Refer to Section 27-00 for the push-rod
bellcrank, adjust the pushrods as necessary. adjustment procedure.
(4) Make sure that the elevator is in horizontal Refer to Figure 4.

position.
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(5) If the elevator does not align with the horizontal Refer to Section 27-00 for the push-rod
stabilizer, adjust the vertical push-rod at the rear adjustment procedure.
bellcrank.
S The stick mounting block and the torque On the control bulkhead.
tube.
S The rear bellcrank. On the vertical stabilizer rear web.
(7) Do a test for the correct range of elevator Refer to Paragraph 2.

movement.

(9) Install these items: Refer to:
S The pilots’ seats. Section 25-10.
S The rudder. Section 55-40.
C. Elevator Angle Limits Table
Elevator Position Elevator Deflection Indicator Angle Limits
Upper Limit. 15.5° ± 0.5°
Horizontal Position. 0°
Lower Limit. 13.0° ± 0.5°
Upper Limit (Vertical Elevator Stop Active). 13.0° ± 0.5°
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Protractor (15.5°±0.5°-6.5°)
UPPER LIMIT Reference Plane for Protractor (0°)
Measuring Surface
for Protractor (6.5°)
15.5° (±0.5°)
Ref Line:
Horizontal
Position
6.5°
13° (±0.5°)
Protractor (13°±1°+6.5°) Stabilizer with Removed Tips

LOWER LIMIT
AFT
Figure 4: Elevator Angle Measurement
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4. Remove/Install the Variable Elevator Stop Assembly
A. Remove the Variable Elevator Stop Assembly
(1) Remove the LH pilot's seat. Refer to Section 25-10.
(2) Open the GEAR WRN/ELEV. LIMIT circuit On the right side of the instrument
breaker. panel.
(3) Remove the variable elevator stop assembly:
S Disconnect the two in-line connectors. At the variable elevator stop assembly.
S Release the bolt which attaches the actuator Refer to Figure 1 and Figure 3.
lever adjustable fitting to the torque tube
assy.
S Remove the four bolts, washers and nuts

that attach the assembly bracket to the
control bulkhead.
S Move the variable elevator stop assembly

clear of the pilot's compartment.
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B. Install the Variable Elevator Stop Assembly
(1) Install the variable elevator stop assembly:
S Put the variable elevator stop assembly into

position on the control bulkhead.
S Install the four bolts, washers and nuts that

attach the assembly bracket to the control
bulkhead.
S Install the bolt which attaches the actuator Refer to Figure 1 and Figure 3.
lever adjustable fitting to the torque tube
assy.
S Connect the two in-line connectors. At the variable elevator stop assembly.
(2) Reset the GEAR WRN/ELEV. LIMIT circuit On the right side of the instrument
breaker. panel.
(3) Do an operational test. Refer to Paragraph 5.
(4) If necessary adjust the actuator lever. Refer to Section 27-00.
(5) Install the LH pilot's seat. Refer to Section 25-10.
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5. Test/Adjust the Variable Elevator Stop
A. Equipment
Ruler or deflection gauge. 1 Commercial.
B. Variable Elevator Stop Test/Adjustment Procedure
Note: If you use a deflection gauge, make sure that the airplane does not move in pitch
during the test procedure. It will cause errors in the test.
(1) If you will use a deflection gauge, put a trestle To prevent movement in pitch.
under the rear fuselage.
(2) Switch on the ELECT. MASTER. Refer to Section 24-00.
(3) Position both power levers approx. beyond the

20 % power level.
(4) Continue according to the elevator control test Refer to Paragraph 2.

procedure. Required upward deflection: 13° ± 0.5°
(51 mm ± 2 mm).
(5) If necessary adjust the actuator lever. Refer to Section 27-00, Paragraph 2.
(6) Do an operational test of the STICK LIMIT Refer to Paragraph 7.

caution message.
(7) Switch off the ELECT. MASTER. Refer to Section 24-00.
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6. Operational Test of the Variable Elevator Stop
(1) Switch on the ELECT. MASTER. Refer to Section 24-00.
(2) Position both power levers above approx. 20 % To activate the stick limiter.
power level.
(3) Test the system:
S Pull the control stick rearward to the stop.

Hold the stick fully rearward.
S Set both power levers to IDLE. The stick must move rearward.
S Set both power levers above approx. 20 %. The stick must move forward.
(4) Switch off the ELECT. MASTER. Refer to Section 24-00.
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7. Operational Test of the STICK LIMIT Caution Message
(1) Remove the pilot's seat. Refer to Section 25-10.
(2) Set the ELECT. MASTER to ON. Refer to Section 24-00.
(3) Set both power levers to IDLE. To test the system in the de-activated
configuration.
(4) Connect pin "A" on the printed circuit (PC) Refer to Chapter 92 for the wiring
board installed on the flap actuator assembly to diagram of the variable elevator stop
electrical ground. (stick limiter).
(5) The STICK LIMIT caution message must

appear on the G1000 PFD after 6 seconds.
(6) Remove ground connection from pin "A".
(7) Set both power levers above approx. 20 %. To test the system in the activated
configuration.
(8) Connect pin "D" on the printed circuit (PC) Refer to Chapter 92 for the wiring
board installed on the flap actuator assembly to diagram of the variable elevator stop
electrical ground. ("stick limiter").
(9) The STICK LIMIT caution message must

appear on the G1000 PFD after 6 seconds.
(10) Remove ground connection from pin "D".
(11) Set the ELECT. MASTER to OFF. Refer to Section 24-00.
(12) Install the pilot's seat. Refer to Section 25-10.
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8. Elevator Pushrod Access
Elevator Pushrod Remove/Install Access References
Between the control torque tube and the idler Pilot's seat. Section 25-10.
lever at the front main bulkhead.
Between the idler lever at the front main Pilot's seat. Section 25-10.
bulkhead and the bellcrank at the vertical
stabilizer rear web. Rudder. Section 55-40.
Between the bellcrank at the vertical stabilizer Rudder. Section 55-40.

rear web and the elevator.
9. Elevator Bellcrank and Lever Access
Elevator Pushrod Remove/Install Access References
Idler lever at the front main bulkhead. Pilots’ seats. Section 25-10.
Bellcrank at the vertical stabilizer rear web. Rudder. Section 55-40.
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Section 27-37
Stall Warning System
1. General
The DA 42 NG has a simple electrical stall warning system.
The stall system consists of the following items:
) Stall warning switch.
) Stall warning horn.
A stall warning switch is mounted on the left wing’s leading edge. The stall warning switch has heater
elements to prevent icing. A switch on the instrument panel controls the stall warning heat. To avoid
overheating the heaters are supplied via a resistor if the airplane is on ground. A circuit-breaker
protects the system. As the angle of attack increases and the airplane approaches an aerodynamic
stall, the stall warning switch closes and activates a stall warning horn, installed in the instrument
panel.
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Trouble-Shooting
1. General
CAUTION: DO NOT JACK THE AIRPLANE AND SWITCH ON THE STALL HEATER
(PITOT HEAT SWITCH)! THE HEATERS CAN BURN OUT IN A FEW
SECONDS.
The table below lists the defects you could have with the stall warning system. If you have the trouble
Stall warning horn does not Circuit-breaker not set. Set the circuit-breaker.
operate.
Stall warning horn defective. Replace the stall warning horn.
Stall warning switch (lift Replace the stall warning

detector) defective. switch.

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‘STAL HT FAIL’ caution is Vane, plate or case heater Replace the stall warning
indicated on the PFD in flight. defective. switch.
RH Weight on Wheel switch Replace the switch, refer to

defective. Section 32-60.
“PITOT”-switch defective. Replace the switch, refer to

Section 24-60.
Stall heat control relay Replace relay.

defective.

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1. General
This Section tells you how to remove/install the components of the stall warning system.
2. Equipment
% Stall warning installation gauge DA 42. 1 D60-2737-11-PL.
3. Remove/Install the Stall Warning Switch (Lift Detector)
A. Remove the Stall Warning Switch
(1) Open the STALL WRN circuit breaker.
(2) If the stall warning switch is mounted firmly and

the vane is not bent or damaged:
S Mark location and angle of the vane on the

stall warning switch installation gauge.
(3) Loosen the screws that attach the stall warning

switch to the wing.
(4) Disconnect the electrical wires. At the in-line connector.
(5) Remove the stall warning switch from the wing.
B. Install the Stall Warning Switch
(1) Connect the electrical wires. At the in-line connector.
(2) Put the switch in position in the wing. Use the stall warning installation gauge
Listed equipment) to align the vane with
the marking from step A(2).
Use the standard marking on the
gauge, if step A(2) was not performed.
(3) Install the screws that attach the switch to the

wing.
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(4) Close the STALL WRN circuit breaker.
(5) If step A(2) was not performed and the stall

warning switch vane was installed according to
the standard marking on the gauge:
Perform a flight check of the stall warning system: Conditions:
S Reduce airspeed at 1kts per second. CG-range: 2.40 m ± 0.01 m.
S Record stall warning speed and stall speed. Min. test altitude: 3000 ft AGL.
S If a minimum of 10 kts margin in between stall Max. test altitude: FL 65

warning speed and stall speed does not exist,
Trim speed: 100 KIAS.
or nuisance warnings are experienced during
take-off or approach, adjust the stall warning Flaps: UP.
switch following the scheme: Gear: UP.
S Down: if nuisance warnings and a margin of Power: IDLE.
more than 10 kts exists.
Attitude: Wings level.
S Up: if the stall warning is less than 10 kts.
S Repeat the flight check until the test is

passed.
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4. Remove/Install the Stall Warning Horn
A. Remove the Stall Warning Horn
(2) Open the STALL WRN circuit breaker.
(3) Disconnect the electrical wires of the stall Note the connections.
warning horn.
(4) Remove the nut which attaches the stall warning

horn to the instrument panel.
(5) Remove the stall warning horn from the

instrument panel.
B. Install the Stall Warning Horn
(1) Put the stall warning horn in position in the

instrument panel.
(2) Install the nut that attaches the stall warning horn
(3) Connect the electrical wires to the stall warning Refer to Section 92-00.
horn.
(4) Close the STALL WRN circuit breaker.
(6) Do a test of the stall warning system.
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Section 27-38
Flight Controls - Elevator Trim-Mechanical
1. General
The DA 42 NG has an elevator with a trim tab. The trim tab is mechanically operated. The elevator also
has an electric trim system which operates on the elevator via flexible cable. Refer to Section 27-39
for more data about the electrically operated trim system.
A handwheel on the center console controls the elevator trim tab. An indicator tells the pilot the trim
tab setting. A flexible cable moves the trim tab.
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Handwheel
Flexible
Cable
Frame Assembly
TRIM HANDWHEEL ASSEMBLY
Right Cover Plate
Left Cover Plate
Distance Trim Indicator Mark

Bush Lock
Nut Friction Bush
Damper Gear Segment with
Nut Lock Internal Teeth
Washer Bush
Ball Stud
Trim Gear
Assembly
Plastic
Friction Washer
Lock Nut
HANDWHEEL AND
TRIM INDICATOR INSTALLATION
Pivot Bolt
Figure 1: Elevator Mechanical Trim Mechanism in the Cockpit
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2. Description
The mechanical trim installation has three main parts:
) A handwheel assembly with trim indicator.
) A flexible cable which connects the handwheel to the trim tab.
) The trim tab actuator assembly.
Figure 1 shows the elevator trim mechanism in the cockpit. Figure 2 shows the trim tab actuator
assembly.
A. Trim Handwheel Assembly
A handwheel assembly on the center console controls the mechanical elevator trim system. The
assembly has a metal mounting frame. The frame attaches to the rear of the engine control
assembly and the top of the control bulkhead.
A long bolt through the mounting frame carries the handwheel. The bolt also holds friction discs,
plain washers and spring washers against the handwheel. Two jam nuts let you adjust the friction.
A small gear wheel attaches to the handwheel. The small gear wheel engages with a large gear
segment with internal teeth. The gear segment has a pivot bolt at the bottom of the mounting frame.
A ballstud attaches the eye end of a long flexible cable to the gear segment. An extension to the
mounting frame at the rear makes the anchor point for the outer sheath of the flexible cable.
The gear segment is also the trim indicator. The top face of the segment has a white line across
it midway between the front and back. The top face can be seen by the pilot through a slot in the
cover plate. The side of the cover plate have markings to show the trim position.
B. Flexible Cable
A long flexible cable connects the trim handwheel assembly to the trim tab. The cable goes through
holes in the front and rear main bulkheads, the aft baggage frame, and each of the fuselage ring
frames. It goes up the front face of the front web of the vertical stabilizer and through a slot near
the top. It goes through a large hole at the top of the rear web of the vertical stabilizer to the trim
tab actuator assembly.
The cable has an inner core with threaded end fittings. Spherical end fittings at each end connect
to the gear segment in the cockpit and the trim actuator assembly at the horizontal stabilizer.
Clamp blocks hold the outer core of the cable to the mounting frame at the front and a bracket from
the horizontal stabilizer at the back.
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Actuating Lever
Bolt
Fork End Cotter Pin
Washer
Castellated Nut
Trim Tab
Right Actuating lever
Friction Damper Left Actuating Lever
Flexible Operating Cable Inner

Friction Clamp Block
Flexible Operating Cable Outer
Figure 2: Trim Tab Actuator Assembly
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C. Trim Tab Actuator Assembly
The trim tab is a one-piece GFRP molding. The tab has two integral levers. Two cranked actuating
levers attach to the integral levers. The left cranked actuating lever connects to the long flexible
cable. The right actuating lever connects to a friction damper.
The friction damper has a clamp-block with a hole for a rod. The rod connects to the right actuating
lever on the trim tab. You can adjust the friction of the rod in the clamp block.
3. Operation
When you move the top of the trim handwheel forward these things happen:
) The small gear wheel moves the top of the gear segment forward.
) The gear segment pulls the inner core of the flexible cable forward.
) The inner core of the flexible cable pulls the left cranked actuating lever forward.
) The left cranked actuating lever pulls the trim tab lever forward to move the trim tab upwards.
) The up movement of the trim tab uses aerodynamic forces to push the elevator down in flight giving
nose-down trim.
When you move the top of the trim handwheel aft, the gear segment moves aft, the cable moves aft
and the trim tab moves down. This pushes the elevator up during flight to give nose up trim.
In each case the pilot can see the trim position from the white mark on the gear segment.
4. Emergency Operation
In the event of a failure of the mechanical trim control system between the handwheel and the trim
actuator lever, the friction damper will prevent the trim tab from fluttering.
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Trouble-Shooting
1. General
The table below list the defects you could have in the elevator mechanical trim control system. If you
Too much play in the Worn bearings or joints. Replace the defective items.
mechanical trim system.
Trim handwheel stiff to move. Flexible cable damaged. Replace the flexible cable.
Trim damper incorrectly Adjust the trim damper.

adjusted.
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1. General
These Maintenance Practices tell you how to test the elevator mechanical trim control system. They
also tell you how to adjust the system. Refer to Section 55-20 for data on how to remove and install
the elevator and trim tab. Refer to Section 27-39 for data about the electric trim system for the
DA 42 NG.
2. Elevator Mechanical Trim Control System Test for Correct Range of Movement
A. Equipment
Rear fuselage trestle. 1 Commercial.
Rigging pin. 1 VR-D41-2757-3000.
Protractor (electronic deflection gauge). 1 Commercial.
Elevator trim deflection indicator. 1 D60-5525-00-PL.
B. Elevator Mechanical Trim Control Test Procedure

(1) Raise the airplane on jacks and move the wing Refer to Section 07-10.
(2) Levelling the airplane. Refer to Section 08-00.

Adjustment Report.
Use it to record the measurements.
(4) Check elevator for correct range of movement. Refer to Section 27-30.
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(5) Set the elevator to horizontal position: Refer to Figure 1 in Section 27-30.
S Install the rigging pin through the stick Elevator should have 0° deflection
mounting block and the torque tube. referred later as the horizontal position.
(6) Place the elevator trim deflection indicator onto Refer to Figure 1.
the elevator.
(7) Set the elevator trim hand wheel to NEUTRAL.
(8) Check the elevator trim angle limits: Check your measurements with the
elevator trim angle limits table in this
S Read the angle deflection from the elevator
section.
trim deflection indicator
S Record your measurement.
(9) Set the elevator trim hand wheel to NOSE UP.
Repeat step 8.
(10) Set the elevator trim hand wheel to NOSE

DOWN.
Repeat step 8.
(11) Set the elevator to 10° inclined position. Refer to Figure 1.
Use a protractor or an elevator deflection

indicator to measure the inclined position.
Repeat step 8.
Repeat step 8.

DOWN.
(15) Set the elevator to 10° declined position. Refer to Figure 1.
Use a protractor or an elevator deflection

indicator to measure the declined position.
Repeat step 8.
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Repeat step 8.

DOWN.
Repeat step 8.
(19) If your measurements do not comply with the Refer to Section 27-38.
limits in the trim angle limit table, then re-adjust
the trim elevator.
(20) Move the wing and rear fuselage trestles clear

of the airplane.
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3. Elevator Mechanical Trim Control System Adjustment
If you cannot get the correct range of movement of the elevator mechanical trim control system, use
this procedure to adjust the system.
A. Equipment
Control clamp. 1 Commercial.
Inclinometer. 1 Commercial.
Fuselage trestle. 1 Commercial.
Spring balance. 1 Commercial.
B. Elevator Mechanical Trim Control Adjustment Procedure
S The pilot's seat.
S The center console cover.
(2) Put a trestle under the rear fuselage. To prevent movement in pitch.
(3) Hold the trailing edge of the elevator in line with Use a clamp at the tips.
the horizontal stabilizer.
(4) Set the trim handwheel to neutral. See the trim indicator.
(5) Adjust the flexible cable: Refer to Figure 1.
S Loosen the nuts that hold the outer sheath

of the flexible cable to the mounting frame
for the trim handwheel.
S Turn the nuts to move the outer sheath Move the outer sheath forward to move
forward or aft as necessary. the trim tab down. Move the outer
sheath aft to move the trim tab up.
S Tighten the nuts.
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S The pilot's seat.
(8) Remove the clamps from the elevator/horizontal

stabilizer tips.
(9) Remove the trestle from under the rear

fuselage.
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C. Elevator Mechanical Trim Friction Damper Adjustment Procedure
(1) Remove the horizontal stabilizer fairing. Refer to Section 55-10.
(2) Disconnect the right actuator lever from the Refer to Figure 2.
friction rod:
S Release the cotter pin locking the nut,

washer and bolt assembly which attaches
the fork end fitting to the actuator.
S Remove the nut, washer and bolt from the

fork end fitting.
S Move the fork end fitting clear of the

actuator.
(3) Measure the force needed to move the damper Use a spring balance. The friction force
rod through the clamp. must be 15-30 N (3.4 - 6.7 lbf.).
(4) If necessary, adjust the friction force:
S Tighten or loosen the clamping screw a

small amount.
(5) Do steps 3 and 4 again, as necessary.
(6) Connect the right actuating lever to the friction

rod:
S Move the fork end into position at the

actuating lever.
S Install the bolt, washer and nut that

connects the fork end to the actuating lever.
S Tighten the nut until it contacts the face of

the fork end and then turn it clockwise to
align the nut with a cotter pin hole in the
bolt.
S Install a new cotter pin.
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(8) Install the horizontal stabilizer fairing. Refer to Section 55-10.
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D. Elevator Mechanical Trim Handwheel Friction Damper Adjustment Procedure
The pilot's seat.
S The right cover plate of the trim handwheel

assembly
(2) Loosen the self-locking nut on the handwheel On the right side of the mounting frame.
pivot bolt.
(3) Loosen the lock nut for the handwheel friction Against the right inner face of the
damper. mounting frame.
(4) Adjust the friction damper nut. Against the pack of washers and spring
washers on the pivot bolt.
(5) Measure the friction force (clamp a spring The friction force must be 3.2 - 4.4 Nm
balance onto the handwheel and measure This corresponds to a force of
force). 60 ± 10 N on the corded area of the trim
handwheel.
(6) Do step 4 as necessary to set the correct friction

force.
(7) Tighten the locknut for the handwheel friction

damper.
(8) Tighten the self-locking nut on the handwheel

pivot bolt.

(10) Install these items: Refer to Section 25 -10.
S The right cover plate of the trim handwheel

assembly
S The pilot's seat.
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Section 27-39
Flight Controls - Elevator Trim-Electrical
1. General
This Section tells you about the elevator electrically controlled trim system. Refer to Section 27-38 for
data about the elevator mechanical trim control system.
A thumb switch on the pilot’s control stick operates the DA 42 NG electrically controlled elevator trim
system.
2. Description
The DA 42 NG elevator has a trim tab that can be operated mechanically via the usual trim wheel in
the center console or electrically via a trim switch on the pilot’s control stick. The elevator electrical trim
system is integrated with the autopilot control system. For more data about the autopilot control system
and the interaction with the elevator electrical trim system refer to Chapter 22.
The elevator electric trim system has two main components:
A. Pilot’s Control Stick Switch
A thumb switch on the pilot’s control stick operates the elevator electrical trim servo. The switch is
spring loaded at the neutral position. The switch can pushed against the spring in a forward or aft
direction. When pushed forwards the trim servo will trim the airplane more nose down and when
pushed aft the trim servo will trim the airplane more tail heavy.
B. Elevator Trim Servo
The DA 42 NG has a pitch trim servo located below the co-pilot’s seat. The servo is mounted on
an aluminum plate and is attached to the plate with a GFRP bracket. A chain gear on the servo,
a cardan shaft and a chain gear on the right side of the cockpit trim wheel transmits the movement
of the servo to the elevator trim wheel.
When the pilot operates the electric trim switch on the control stick the servo will operate and drive
the mechanical trim wheel to the required position.
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Trouble-Shooting
1. General
The table below list the defects you could have in the elevator electrical trim control system. If you
The elevator electrical trim Defective trim switch on the Replace the defective trim
system does not operate pilot’s control stick. switch.
correctly from the switch on the
pilot’s control stick but the
autopilot elevator trim control
system operates correctly.
The elevator electrical trim Autopilot circuit breaker open. Reset autopilot circuit breaker.
system does not operate
correctly from the switch on the
pilot’s control stick or with the Elevator trim servo defective. Replace elevator trim servo.
autopilot control system.
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1. General
For data about the removal/installation of the elevator trim electrical servo and the removal/installation
of the elevator trim servo clutch refer to Chapter 22.
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Section 27-50
Flight Controls - Flaps
1. General
The DA 42 NG has flaps for approach and landing. There are two flaps attached to the trailing edges
of each wing. The inboard and outboard flap assemblies of each wing are directly coupled. The
outboard end of the inner flap has a tongue which engages with a slot in the inboard end of the outer
flap.
An electric flap actuator moves the flaps. See Section 57-50 for data about the flap structure.
A three position toggle switch controls the flaps. The switch is in the right side of the instrument panel.
Lights located to the left of the flap toggle switch come on when these flap positions are set:
) Green lit, both white off - flaps UP.
) White lit, green and bottom white off - flaps at APPROACH.
) White lit, green and middle white off - flaps at LANDING.
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Push Rods
to Right Wing
Idler Lever
Rear Closing Rib
Flap Actuator
Push Rods
to Left Wing
Bolt
Washer
Push Rods Bonding Wire

to Right Wing
Toothed Lockwasher
Spacer
Flap Actuator Rear Main Bulkhead

Rigging
Pin Hole Spacer
Idler Push Rods

Lever to Left Wing
Toothed Lockwasher
Bonding Wire Washer
Nut
Figure 1: Flap Control System in the Fuselage
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2. Description
Figure 1 shows the flap control system in the fuselage. Figure 2 shows the flap pushrods and
bellcranks in the wing. Figure 3 shows the flap actuator installation.
A. Flap Actuator
An electric actuator operates the flaps. The electric actuator is under the left passenger seat. A
mounting bracket on the left rear closing rib attaches the actuator to the structure.
The actuator has an electric motor. The motor has a reduction gear which turns a spindle. The
spindle operates a pushrod. The pushrod connects to an idler lever attaches to the rear main
bulkhead.
A cam attached to the pushrod operates five micro switches. The micro switches are part of the
flaps electronic control circuit.
B. Push-Rods and Bellcranks
The idler lever on the rear man bulkhead connects to four pushrods. Two of the pushrods connect
to the inboard ends of longer pushrods in the wing and the other two pushrods connect to the inner
flap bellcranks. Two short pushrods connect the inner flap bellcranks to the inner flap horns.
The long pushrods connect to flap bellcranks in the outer wing. A guide bearing holds each long
push-rod at the root rib. Two short pushrods connect the outer flap bellcranks to the flap horns.
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Push Rods from Fuselage

To RH Wing
Actuator Control Rod
Flap Idler Lever

in the Fuselage
Push Rods
from Fuselage
LH Wing Shown,
RH Wing Similar
Rigging
Pin Hole
Left Flap Rib
Left Inner Flap
Guide Rollers
To Left Outer Flap
Figure 2: Flap Push-Rods and Bellcranks in the Wings
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C. Flap Electrical Control
Figure 4 shows the flap electrical control system. The main bus supplies the power for the flaps.
A circuit breaker protects the system. See Chapter 92 for the Wiring Diagrams.
The flap electrical control system uses solid state electronics. It has an electronic control unit and
a switchboard. The electronic control unit is mounted on the instrument panel. Then switchboard
attaches to the flap actuator.
The electronic control unit has a 3-position selector switch and a flap position indicator. The
selector switch can be set to:
) UP (fully up) 0° ± 1°
) APP (approach) 20° ± 2°
) LDG (landing) 42° ± 1°
The flap position indicator has three light emitting diodes. The top diode lights when the flaps are
in the UP position. The middle diode lights when the flaps rare in the APP position. The bottom
diode lights when the flaps are in the LDG position.
The switch board attaches to the body of the flap actuator. The switch board has five micro
switches. It also has solid state logic board.
The logic circuits monitor the outputs from the selector switch and the micro switches on the switch
board. They control four power transistors. Two of the power transistors can connect the power
supply to the flap motor. The other two can connect the motor to ground.
Two screws attach each micro switch to the switchboard. You can adjust the position of the switch
board with three worm drive clamps. The micro switches have these functions:
) Micro switch 1 - UP position.
) Micro switch 2 - UP indication and APP position moving down.
) Micro switch 3 - APP indication.
) Micro switch 4 - LDG position.
) Micro switch 5 - LDG indication APP position moving up.
Cable harnesses with multi pin connectors connect the components.
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Bolt
Bonding Wire
Washer
Toothed Lockwasher
Worm-Drive
Clamps
Actuator Control Rod
Circuit Board
Actuator Motor
Cam Adjusting Nuts
Cam
Actuator
Idler Lever Swivel
Micro-Switches Block
Micro-Switch Base Plate

Bush
Base Plate Mounting Bracket
Micro-Switch Cam Rear Closing Rib
TYPICAL ATTACHMENT
OF MICRO-SWITCH
Figure 3: Flap Actuator Installation
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3. Operation
If you operate the flap selector switch these things happen:
) The switch energizes the related logic circuit.
) The logic circuit switches on the related transistors to supply power/ground to the flap motor.
) The flap motor turns the reduction gear and spindle. This moves the actuator pushrod towards the
new set position.
) The push rod turns the idler lever around its axis.
) The idler lever moves the flap operating pushrods in the fuselage and the wings.
) The push-rods move the flap bellcranks in the left and right wings.
) The short pushrods move the flaps.
When the flap position reaches the position set by the flap selector:
) The cam on the flap actuator operates the related flap position and indication micro switches.
) The logic circuit switches off the related transistors to de-energize the flap motor.
) The flap position indicator shows the new flap position.
4. Fail-Safe Operation
The flap control system has these fail-safe properties:
) If the LDG position micro switch fails closed the flap actuator pushrod will continue to travel for
about 5 mm (0.2 in) until it reaches an internal stop. This prevents damage to the flaps. The FLAP
circuit breaker opens and breaks the flap operating circuit.
) If the UP position micro switch fails closed, the actuator pushrod contacts the end of the actuator
body after about 5 mm (0.2 in) of movement. This prevents damage to the flaps. The FLAP circuit
breaker opens and breaks the flap operating circuit.
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UP LED
Flaps
UP
APP LED APP

LDG LED LDG
Flap Position Indicator Flap Selector Switch

FLAP CONTROL UNIT IN THE INSTRUMENT PANEL
(View Looking Forward)
Closed Open UP Position

Micro-Switch
S4 S1
UP POSITION
S5 S3 S2
Open Open Closed
UP Indication and
APP Position Moving Down
Micro-Switch
Closed Closed
S4 S1
APP POSITION
S5 S3 S2
LDG Indication and Open Closed Open
APP Position Moving Up UP Indication and
Micro-Switch APP Position Moving Down
APP Indication Micro-Switch
Micro-Switch
LDG Position
Micro-Switch Open Closed
S4 S1
LDG POSITION
S5 S3 S2
LDG Indication and Closed Open Open
APP Position Moving Up
Micro-Switch
MICRO-SWITCH BOARD
(View Looking Down)
Figure 4: Flap Electrical Control System
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Trouble-Shooting
1. General
The table below lists the defects you could have in the flap control system. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair in the
Repair column.
Flaps do not operate. Circuit breaker not set. Set the flap circuit breaker.
Airplane electrical system Do a test of the airplane

voltage low. electrical system voltage.
Flap selector switch defective. Replace the flap electronic

control unit.
Flap circuit breaker will not Short to ground in the wires to Do an insulation test between
stay closed. the electrical control unit or the each wire and ground. Repair
micro switches. or replace defective wires.
Short to ground in the electrical Replace the electrical control

control unit. unit.
Short to ground in a Replace the micro switch.

micro switch.
Short to ground in a wire Do an insulation test between

between a closed micro switch each wire and ground. Repair
and the control unit. or replace defective wires.
Flap circuit breaker opens Short to ground in a motor Do an insulation test between
when flap selector switch supply wire. each wire and ground. Repair
moved to any down position. or replace defective wires.
Flap circuit breaker opens Short to ground in a motor Do an insulation test between
when flap selector switch supply wire. each wire and ground. Repair
moved to any up position. or replace defective wires.
Flap circuit breaker opens Short to ground in the wires to Do an insulation test between
when the flaps stop at the the electrical control unit from each wire and ground. Repair
chosen position. the related indication micro or replace defective wires.
switch.
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when the flaps have moved the electrical control unit from each wire and ground. Repair
only a short distance from the micro switch 1. or replace defective wires.
UP setting.
when the flaps have moved the electrical control unit from each wire and ground. Repair
only a short distance from the micro switch 4. or replace defective wires.
LDG setting.
Flaps move slowly. Airplane electrical system Do a test of the airplane

voltage low. electrical system voltage.
Flap motor defective. Do a test for 24 V at the motor

with flaps selected. If there is
24 V at the motor, replace the
actuator.
Flap actuator defective. Examine the actuator. If you

find damage, then replace the
flap actuator.
Flaps do no not align with the Flaps extended at too high Examine the flap system.
wing trailing edge. airspeed. Replace damaged parts.
Adjust the system.
Flaps will not move to LDG Micro switch 4 defective. Replace the micro switch.
position. Flaps move to APP
Open circuit in the Do a continuity test of the
and UP correctly.
micro switch 4 wiring. wiring. Repair or replace the
defective wire.
Flaps will not move to UP Micro switch 1 defective. Replace the micro switch.
position. Flaps move to APP
and LDG correctly.
defective wire.
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No LDG indication when the Micro switch 5 defective. Replace the micro switch.
flaps are in the LDG position.
Flaps will not move from LDG
to APP. Flaps move from LDG
defective wire.
to UP correctly.
No UP indication when the Micro switch 2 defective. Replace the micro switch.
flaps are in the UP position.
Flaps will not move from UP to
APP. Flaps move from UP to
defective wire.
LDG correctly.
No APP indication when the Micro switch 3 defective. Replace the micro switch.
flaps are in the APP position.
Flaps move to all positions
correctly.
defective wire.
Flap circuit breaker opens at Micro switch 4 defective. Replace the micro switch.
the end of down movement.
Flap circuit breaker opens at Micro switch 1 defective. Replace the micro switch.
the end of up movement.
LDG LED stays on when the Micro switch 5 defective. Replace the micro switch.
flaps are not in the LDG
position. The other indications
operate correctly.
UP LED stays on when the Micro switch 2 defective. Replace the micro switch.
flaps are not in the UP
operate correctly.
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APP LED stays on when the Micro switch 3 defective. Replace the micro switch.
flaps are not in the APP
operate correctly.
Flaps move to LDG when APP Micro switch 2 defective. Replace the micro switch.
set from UP.
Flaps move to UP when APP Micro switch 5 defective. Replace the micro switch.
set from LDG.
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1. General
These Maintenance Practices tell you how to remove and install components of the flap control
system. They also tell you hot to test and adjust the system. See Section 57-50 for data about
removing and installing the flaps.

SURFACES CAN OCCUR.

2. Remove/Install the Flap Actuator
Refer to Figures 1 and 3.
A. Remove the Flap Actuator
(1) If possible set the flaps to the APP position.
(3) Remove the passenger seat. Refer to Section 25-10.
(4) Disconnect the electrical supply connector to At the flap motor.

the flap motor.
(5) Disconnect the control harness plug from the

switch board.
(6) Remove the bolt which attaches the actuator At the rear main bulkhead. Support the
pushrod to the idler lever. flaps.
(7) Lower the flaps by hand until they stop.
(8) Remove the bolt which attaches the actuator At the left rear closing rib.
body to the mounting bracket.
(9) Remove the actuator from the airplane.
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B. Install the Flap Actuator
(1) Put the flap actuator into position in the

fuselage.
(2) Install the bolt which attaches the actuator At the left rear closing rib. Make suer
body to the mounting bracket. that the bush is in the correct position in
the actuator swivel block.
Torque 6.4 Nm (4.7 lbf.ft.).
(3) Install the bolt which attaches the actuator At the rear main bulkhead. Hold the
push-rod to the idler lever. flaps.
Torque 6.4 Nm (4.7 lbf.ft.).
(4) Connect the control harness plug for the

switch-board.
(5) Connect the electrical supply connector to the

flap motor.
(7) Do the flap adjustment procedure. See Paragraph 4.

connected. If necessary for your Airworthiness
Authority do a duplicate inspection of the
controls.
(9) Install the passenger seat. Refer to Section 25-10.
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3. Test the Flap Control System
A. Equipment
Inclinometer. 1 Commercial.
Spring balance. 1 Commercial.
B. Test the Flap Control System

Adjustment Report. Use it to record the measurements.
(2) Make sure that the flaps are fully UP:
S Set the flaps to APP.
S When the flaps stop moving, set the flaps to

UP.
S When the flaps stop moving, set the ELECT.

MASTER switch to OFF.
(3) Do a test for the correct pre-load in the flap UP

position:
S Build a loop with strong (durable) tape and The UP position limit stop at the
bond both ends side by side on top of the outboard end of the inner flap is the
left inner flap. reference point for measurements.
S Use the loops of tape for the spring balance Pull vertical downwards.
until the flap just moves from the lower
surface of the wing.
S Record the value in the Control Surfaces The values must be as shown in the
Adjustment report. Control Surfaces Adjustment Report.
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(4) If the preload is not correct, adjust the control Refer to Section 27-00.
rod between the bellcrank in the wing and the
flap horn for the flap you tested. Repeat steps 3
and 4 as necessary until you measure the
correct pre-load value.
(5) Repeat steps 3 and 4 for the right inner flap.
(6) Zero the inclinometer to the left outer flap:
S Put the inclinometer on the left outer flap

close to the flap horn.
S Zero the inclinometer.
S Remove the inclinometer.
(7) Set the flaps to APP:
S Set the flap selector switch to APP.

(8) Measure the angle of the left outer flap. Use the inclinometer.
Record the value in the Control Surfaces The value must be as shown in the
Adjustment Report. Control Surfaces Adjustment Report.
(9) Set the flaps to LDG:
S Set the flap selector switch to LDG.

(10) Measure the angle of the left outer flap. Use the inclinometer.
Record the value in the Control Surfaces The value must be as shown in the
Adjustment Report. Control Surfaces Adjustment Report.
(11) Repeat steps 6 to 10 for the right outer flap.
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22 Dec 2021 27-50-00 Rev. 5
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(12) Set the flaps to UP:
S Set the flap selector switch to UP.

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4. Adjust the Flap Control System
If you cannot get the correct range of movement of the flap control system, use this procedure to adjust
the system.
A. Equipment
Deflection gauge. 2 D60 5753 00 PL.
B. Adjust the Flap Control System

Adjustment Report. Record the measurements.
(2) Remove these items for access:
S The passenger seat. Refer to Section 25-10.
S The flap bellcrank access panels in both Refer to Section 53-40.

wings.
(4) Remove the bolt, spacer, washer and nut At the rear main bulkhead.
which attach the actuator push-rod to the idler Hold the flaps.
lever.
(5) Put a rigging pin in the idler lever. Refer to Figure 3.

At the rear main bulkhead.
(6) Put a rigging pin in the left inner bellcrank in Refer to Section 27-00.
the left wing. If necessary adjust the push-rod
between the idler lever and the bellcrank.
(7) Repeat step 6 for the left outer flap and both
the right wing inner and outer flaps.
(8) Remove the rigging pins from the flap idler

lever and the bellcranks in the wings.
CAUTION: MAKE SURE THAT ALL THE RIGGING PINS ARE REMOVED!
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WARNING: DO NOT TOUCH THE ACTUATOR WHEN YOU OPERATE IT. THE
MOVING PARTS CAN CAUSE INJURY.
(10) Check actuator extension:
S Hold the actuator rod end clear of the Use a piece of a string through the eye
structure. end.
S When the actuator stops moving, set the

flap switch to UP.
S When the actuator stops moving, set the

ELECT. MASTER switch to OFF.
(11) Measure the extension of the actuator push-rod. The distance between the center of the
eye-end of the actuator rod and the
center of the actuator swivel block
mounting must be 379.7 mm (14.87 in).
(12) If the actuator pushrod extension is not Refer to Figure 3.
correct, adjust the cam rod:
S Loosen the nuts which attach the cam rod to

the plate at the eye end.
S Turn the nuts to move the cam rod. One turn clockwise decreases the
extension by 1 mm (0.04 in).
S Tighten the nuts. Torque 6.4 Nm (4.7 lbf.ft.).
(13) Repeat steps 11 and 12 as necessary to get the

correct extension.
(14) Disconnect the rod end on flap attachment on At the flap.

all 4 flap connections.
(15) Set the flap actuator to flap UP.
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(16) Connect the flap actuator:
S Install the bolt, spacer, washer and nut Torque 6.4 Nm (4.7 lbf.ft.).
which attaches the eye end to the idler
lever.
(17) Install the deflection gauge on the wing.
(18) Connect the outer flap rod end LH and RH on

flap lever and adjust it to 0°.
(19) Connect the inner flap LH and RH on flap lever

and adjust it to the flap stop.
(20) Measure flap deflection: Record the value in the Control Surfaces
Adjustment Report.
Set the flap selector switch to LDG.
S Set the flap selector switch to UP.
(21) Make sure that all the flaps hit the stops at the
same time. If necessary, adjust the rod Refer to Section 27-00.
between the bellcrank in the wing and the
related flap.
(22) Do a test and adjust flap pre-load. Refer to Paragraph C.

(24) Install these items:
S The passenger seat. Refer to Section 25-10.
S The flap bellcrank panels in both wings. Refer to Section 53-40.
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C. Adjust the Flap Preload

Adjustment Report.
(2) Connect external power source.
(4) Check flap deflection for UP, APP, LDG position If deflection out of limit refer to
with deflection gauge according to the Control Paragraph B.
Surfaces Adjustment Report.
(5) Disconnect LH and RH outer flap push rods.
(6) Install reinforced tape loop on outer end of inner Refer to Figure 5.
flap, bond both ends side by side on top of the
inner flaps.
Do not place loop ends over the flap stop.
(7) Put paper slip between inner flap outer end and
flap stop.
(8) Set flaps to 0°.
(9) Connect scale to the reinforced tape loop.
(10) Pull on scale and paper slip until the paper slip Pull vertical downwards.
is released.
(11) If the paper slip release-force is out of limits,

disconnect inner flap push rod and twist rod end
half a revolution. Connect push rod and try
again until limits are reached.
(12) Repeat steps 6 to 11 on other side.
(13) Disconnect LH and RH inner flap push rods.
(14) Connect LH and RH outer flap push rods.
(15) Put paper slip in outer flap stop fairing between

flap stop and flap stop lever.
(16) Set flaps to 0°.
(17) Position scale on screw head on outer end of

flap.
(18) Pull on scale and paper slip until paper slip is

released.
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(19) If the paper slip release-force is too small bond

inserts into the outer flap stop fairing until force
is above minimum. If release force is too high,
remove layers from the outer flap stop fairing
until force is below maximum.
(20) Connect the inner flap push rods.
(21) Do an inspection of all controls that you have

adjusted. If necessary for your Airworthiness
Authority, do a duplicate inspection if the
controls.
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Paper Slip
Reinforced Tape Loop Scale
Figure 5: Flap Preload Adjustment
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5. Flap Push-Rod Access
Flap Pushrod Remove/Install Access References
Between the idler lever at the rear bulkhead Passenger seat. Section 25-10.
and the center section closing ribs.
Center section access Section 52-40.
panels.
Between the center section closing ribs and Passenger seat. Section 25-10.
the inner flap bellcranks. Inner flap bellcrank
access panels under Section 52-40.
each wing.
Between the center section closing ribs and Passenger seat. Section 25-10.
the outer flap bellcranks. Outer flap bellcrank
access panels under Section 52-40.
each wing.
Between the inner flap bellcranks and the Inner flap bellcrank Section 52-40.
inner flap horns. access panels under
each wing.
Between the outer flap bellcranks and the Outer flap bellcrank Section 52-40.
outer flap horns. access panels under
each wing.
6. Flap Bellcrank and Lever Access
Flap Pushrod Remove/Install Access References
Idler lever at the rear main bulkhead. Passenger seat. Section 25-10.
Bellcranks in wings. Inner and outer Section 52-40.

bellcrank access panels
under each wing.
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CHAPTER 28
FUEL
Doc # 7.02.15 Page 1

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Page 2
22 Dec 2021 28-TITLE Doc # 7.02.15
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TABLE OF CONTENTS
CHAPTER 28
FUEL
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Section 28-10
Fuel Storage System
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Main Fuel Tank Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Auxiliary Fuel Tank Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Auxiliary Fuel Tank Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Disassemble a Main Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . 201
3. Assemble/Install a Main Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4. Remove/Install an Auxiliary Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Section 28-20
Fuel Distribution
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Fuel Distribution System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Fuel Transfer/Shut-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/ Install the Fuel Selector Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4. Remove/Install the Fuel Filter Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
5. Remove/Install the Fuel Pre-Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
6. Remove/Replace/Install the Fuel Pressure Pulsation Damper . . . . . . . . . . . . . . 217
7. Remove/Install the Low Pressure Fuel Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . 220
8. Test the Solenoid Valve/Check Valve in the Fuel Transfer Line (If Auxiliary Tanks
Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
9. Remove/Install a Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
10. Test the Crossfeed Position of a Fuel Selector Valve . . . . . . . . . . . . . . . . . . . . . 227
11. Remove/Install an Inline Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
12. Test the Auxiliary Fuel Transfer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Section 28-21
Fuel Distribution (if MÄM 42-600 is installed)
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Fuel Distribution System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Fuel Transfer/Shut-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Fuel Selector Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4. Remove/Install the Fuel Filter Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
5. Remove/Install the Fuel Pre-Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
6. Remove/Replace/Install the Fuel Pressure Pulsation Damper . . . . . . . . . . . . . . 214
7. Remove/Install the Low Pressure Fuel Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . 218
8. Test the Solenoid Valve/Check Valve in the Fuel Transfer Line (If Auxiliary Tanks
Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
9. Test the Crossfeed Position of a Fuel Selector Valve . . . . . . . . . . . . . . . . . . . . . 222
10. Remove/Install an Inline Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
11. Test the Auxiliary Fuel Transfer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
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Section 28-40
Fuel Indicating
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Fuel Quantity Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install a Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Remove/Install a Fuel Low-Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5. Remove/Install a Fuel High-Level Shut-Off Sensor . . . . . . . . . . . . . . . . . . . . . . 207
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Page 4 Doc # 7.02.15

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CHAPTER 28
FUEL
1. General
This Chapter describes the DA 42 NG fuel system. It tells you about the fuel system from the fuel tanks
to the engine fuel filter. For more data on the engine fuel system refer to Chapter 73 and the
AE Operation Manual, latest revision and the AE Maintenance Manual, latest revision.
The DA 42 NG has a fuel tank assembly in each wing. Each fuel tank assembly has an approximate
capacity of 26 US gal (100 liter). Each engine has two parallel installed independent electrically
powered low pressure pumps and a high pressure fuel pump which supply the engine with fuel. Each
engine is protected against contaminated fuel by two pre-filters located in front of the low pressure
pumps and a fine fuel filter after the low pressure fuel pumps. The pre-filters, fine filter, and low
pressure fuel pumps are located in the engine nacelles. A fuel selector/shut-off valve in each engine
nacelle can be operated by the pilot to shut-off the fuel supply to each engine.
Auxiliary fuel tanks are optional equipment (OÄM 42-056). The auxiliary fuel tanks consist of a single
fuel chamber in each engine nacelle. The additional fuel capacity is 13.7 US gal (52 liter) per side. The
total fuel capacity (main fuel tank and auxiliary fuel tank) is 39.6 US gal (150 liter) per side. Each
auxiliary tank has its own fuel tank filler and an auxiliary electric fuel pump which transfers fuel into the
main fuel tank.
Fuel level sensors in the inboard and outboard chambers of each fuel tank assembly provide fuel
quantity data which are displayed on the multi-function display (MFD) screen of the integrated cockpit
system (ICS). Refer to these Sections for more data on these systems:
– Section 28-10. Fuel storage.

– Section 28-20. Fuel distribution.
– Section 28-21. Fuel distribution (if MÄM 42-600 is installed).
– Section 28-40. Fuel indication.
– Section 73-00. Engine fuel system.
Service Bulletin.
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Rev. 5 28-00-00 22 Dec 2021
Fuel DA 42 NG AMM
AIRCRAFT
27
26
25
01 07
LH Wing shown M
24
RH Wing similar
M
23
02 03 04 05 06 07
22
1 Return Line
2 Fuel Supply 19 21
3 Firewall
4 Fuel Filter with Sediment Trap & Drain 20
5 Low Pressure Fuel Pumps
6 Prefilter 18
7 Fuel Selector Valves
8 Wing 17
9 Fuel Level Switch
10 Fuel Filler
11 Pressure Relief Valve
12 Main Fuel Tank Vent Line
13 Check Valve with Capilare
14 Outboard Fuel Level Sensor
15 Outboard Chamber Main Tank
16 Middle Chamber Main Tank 16
17 Inboard Fuel Level Sensor 08
18 Inboard Chamber Main Tank
19 Fuel Temperature Sensor
09
20 Low Level Fuel Sensor
21 Drain 15
22 Finger Filter
23 Nacelle 10 14
24 Fuel Cooler
11 13
25 Fuselage
26 Crossfeed Lines 12
27 Fuel Selector
Figure 1: Fuel System Schematic Diagram without Auxiliary Tanks
Page 2 Doc # 7.02.15

22 Dec 2021 28-00-00 Rev. 5
DA 42 NG AMM Fuel
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27
26
25
24 28 07
01
23
02 03 04 05 06 07
21
01 Return Line
02 Fuel Supply
03 Firewall 19 22
04 Fuel Filter with Sediment
Trap & Drain 20
06 Prefilter
07 Fuel Selector Valves 18
08 Wing
09 Fuel Level Switch 17
10 Fuel Filler
11 Pressure Relief Valve LH Wing shown
12 Main Fuel Tank Vent Line RH Wing similar
16 Middle Chamber Main Tank
17 Inboard Fuel Level Sensor
19 Fuel Temperature Sensor 16
21 Drain 08
22 Finger Filter
23 Nacelle 09
24 Fuel Cooler
25 Fuselage 15
26 Crossfeed Lines
27 Fuel Selector 10 14
28 Fuel Bypass Valve
11 13
12
Figure 2: Fuel System Schematic Diagram without Auxiliary Tanks (if MÄM 42-600 is installed)
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Rev. 5 28-00-00 22 Dec 2021
Fuel DA 42 NG AMM
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2. Description
Figure 1 shows the fuel system schematic diagram of the DA 42 NG airplane. Figure 2 shows the fuel
system schematic diagram of the DA 42 NG airplane, if MÄM 42-600 is installed. The DA 42 NG has
a fuel tank assembly in each wing.
Figure 3 shows the auxiliary fuel tank system schematic diagram of the DA 42 NG airplane. Figure 4
shows the auxiliary fuel tank system schematic diagram of the DA 42 NG airplane, if MÄM 42-600 is
installed. The auxiliary fuel tank system is optional equipment (OÄM 42-056). It has an additional fuel
chamber in each engine nacelle.
A. Main Fuel Tanks
Each wing tank assembly has three separate chambers. The chambers are connected by large
diameter flexible hoses. Smaller hoses interconnect the chambers at the top to provide a vent
system for the fuel tank assembly.
The inboard chamber has a fuel level sensor, fuel temperature sensor, low fuel level switch, fuel
supply and return connections. The fuel supply connection attaches to a finger filter mounted on
the fuel chamber. A fuel drain valve is located at the lowest point of the inner fuel chamber.
The middle fuel chamber is a plain chamber and has no installed components.
The outer fuel chamber has a fuel level sensor, high fuel level switch, and the fuel filler assembly.
In addition a fuel tank vent system, consisting of a check valve, and pressure relief valve, is
installed on the outboard fuel chamber. The high fuel level switch is only used when the optional
auxiliary fuel tanks (OÄM 42-056) are installed.
The fuel level sensors go from the bottom inboard corner to the top outboard corner of the fuel
chambers. The sensors detect the level of fuel in the fuel tank assemblies and display the
information on the MFD (multi-functional display) of the integrated cockpit system.
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B. Auxiliary Fuel Tanks
The auxiliary fuel tank system is optional equipment (OÄM 42-056). The auxiliary fuel tanks consist
of a single fuel chamber in each engine nacelle. Each auxiliary fuel tank has an auxiliary electrically
powered pump which transfers fuel into the collocated main fuel tank. Between the fuel pump and
return line a solenoid valve and a check valve are installed. The solenoid valve is operated via the
fuel transfer pump switch in parallel with the fuel transfer pump.
Each auxiliary fuel tank has a shut-off switch which turns the auxiliary electric pump off in case the
fuel level in the auxiliary fuel tank is low. The fuel supply connection attaches to a finger filter
mounted at the rear of the auxiliary fuel tank. A fuel drain valve is located at the lowest point of the
auxiliary fuel tank. A vent line with check valve and capillary is connected at the forward wall of the
auxiliary fuel tank. A drain line is connected to the filler drip tray.
Prior to the auxiliary fuel pump an inline filter protects the connected fuel pump and electrically
operated solenoid valve from contamination. The function of the solenoid valve is to isolate main
and auxiliary fuel tanks during normal operation. In the event of fuel transfer from the auxiliary to
the main tank, the solenoid valve opens. To prevent fuel from flowing back into the auxiliary tank,
a check valve is mounted to the exit of the solenoid valve. If MÄM 42-600 is installed, the solenoid
valve and a check valve (if installed) are installed aft of the electrically driven auxiliary fuel pump.
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Fuel DA 42 NG AMM
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38
37
36
35
34
33
01 07 32
01 Return Line 31
02 Fuel Supply
03 Firewall 30
M
04 Fuel Filter with Sediment 29
Trap & Drain
M
M
28
06 Prefilter
26
07 Fuel Selector Valves
02 03 04 05 06 07 25
08 Wing
10 Fuel Filler 23 24
11 Pressure Relief Valve 21
13 Check Valve with Capilare 19 22
15 Outboard Chamber Main Tank 20
20 Low Level Fuel Sensor LH Wing shown
21 Drain RH Wing similar
22 Finger Filter
23 Nacelle
24 Check Valve
25 Inline Filter
26 Auxiliary Pump
27 Solenoid Valve 16
28 Finger Filter 08
29 Fuel Cooler
30 Drain 09
31 Fuel Level Switch
32 Auxiliary Fuel Filter 15
33 Auxiliary Tank
10 14
34 Check Valve with Capillare
35 Auxiliary Fuel Tank Vent Line
11 13
36 Fuselage
37 Crossfeed Lines 12
38 Fuel Selector
Figure 3: Auxiliary Fuel System Schematic Diagram (OÄM 42-056 implemented)
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Figure 4: Auxiliary Fuel System Schematic Diagram (OÄM 42-056 and MÄM 42-600 is installed)
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3. Operation
A. Normal Operation
With an engine running and the fuel selector/shut-off valve set to OPEN, fuel to the engine is
supplied from the related fuel tank. Fuel flows through a finger filter of the main tank to the fuel
selector/shut-off valve. From the valve the fuel flows through the two parallel installed pre-filters and
then through the two parallel installed independent electrically powered low pressure fuel pumps.
The low pressure fuel pumps feed the fuel through the fuel filter assembly to the engine. The fuel
filter assembly has a sediment trap and a fuel drain valve.
The low pressure fuel pumps always supply more fuel than the engine fuel injection system can
use. The unused fuel flows back from the engine fuel system through the fuel selector/shut-off
valve. From the fuel selector/shut-off valve the fuel flows through a flexible hose to the fuel cooler.
The fuel cooler is located at the rear of the engine nacelle. Fuel from the fuel cooler flows through
another flexible hose back into the related main fuel tank.
If MÄM 42-600 is installed, the unused fuel flows back to the main fuel tank through the fuel cooler
(located in the engine nacelle) and the fuel selector/shut-off valve. From the fuel selector/shut-off
valve the fuel flows through another flexible hose back into the related main fuel tank.
As the engine uses fuel the fuel level decreases in the related main fuel tank. Air flows through the
vent system in the main fuel tank which prevents the fuel tank pressure from decreasing below
atmospheric pressure. This allows the low pressure fuel pumps to continue taking fuel from the
main fuel tank.
Auxiliary fuel tanks are optional equipment (OÄM 42-056). For each auxiliary tank there is an AUX
PUMP switch in the cockpit, in the center console behind the elevator trim wheel. When this switch
is set to ON, the solenoid valve is opened and fuel is transferred from the auxiliary fuel tank into the
related main fuel tank. The pump is automatically turned off when the main fuel tank is full, or when
the auxiliary fuel tank is empty. If the pump is switched off, the solenoid valve is closed
automatically.
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(1) Fuel Pumps
Each engine is feed by two parallel installed independent low pressure fuel pumps. During
normal operation one of the two fuel pumps is working. In case of a low fuel pressure detection
ECU switches automatically to the second fuel pump. During landing and take-off, or in case of
a low fuel pressure both low pressure fuel pumps can be activated by the FUEL PUMP LH/RH
ENGINE switch. If both fuel pumps are activated the fuel pressure increases.
If MÄM 42-600 is NOT installed:
WARNING: SWITCHING ON THE FUEL PUMP IN COMBINATION WITH

CROSSFEED MAY CAUSE DAMAGE TO THE HIGH-PRESSURE PUMP
DUE TO THE HIGH FUEL PRESSURE. AFTER SWITCHING ON THE
FUEL PUMP IN COMBINATION WITH CROSSFEED IN CASE OF AN
EMERGENCY SPECIAL MAINTENANCE OF THE HIGH PRESSURE
PUMP IS REQUIRED.
Each fuel pump is electrically connected to the LH/RH ECU BUS and protected by a 7.5 A circuit
breaker.
Note: By switching between ECU A and B the two independent electrical fuel pumps are
switched over as well. In case of an emergency both pumps can be activated
simultaneously by using the FUEL PUMP LH/RH ENGINE switch.
B. Fuel Transfer
With an engine running and the fuel selector/shut-off valve set to CROSSFEED the fuel supply and
return lines to the related fuel tank are shut-off. If MÄM 42-600 is NOT installed: Before crossfeed
operation verify FUEL PUMP LH/RH ENGINE switch is OFF. Now the low pressure fuel pumps take
the fuel from the opposite engine main fuel tank through the related fuel crossfeed line. The fuel
returning from the engine leads back to the crossfeed tank where it was taken from.
For example, if the left engine fuel selector/shut-off valve is set to CROSSFEED the left low
pressure fuel pumps will take fuel from the right main fuel tank via the related fuel crossfeed lines
through the fuel selector shut off valve and the independent pre-filters. The electrically powered low
pressure fuel pumps feed then the engine fuel system through the fuel filter assembly. The fuel that
is returned from the left engine will be returned to the right fuel tank. If the right fuel selector/shut-off
valve is set to CROSSFEED the right low pressure fuel pumps will take fuel from the left main fuel
tank via the related fuel crossfeed lines through the fuel selector shut off valve and the independent
pre-filters. The electrically powered low pressure fuel pumps feed then the engine fuel system
through the fuel filter assembly. The fuel returning from the engine leads back to the crossfeed tank
where it was taken from.
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C. Emergency Operation
In an emergency (for example, an engine failure) you can set the related engine fuel
selector/shut-off valve to SHUT-OFF. The fuel selector/shut-off valve has a safety gate to prevent
accidental selection of the SHUT-OFF position. You must turn and hold the gate in the open
position to set a fuel selector/shut-off to SHUT-OFF. When the engine fuel selector/shut-off valve
is set to SHUT-OFF no fuel can flow to the related engine. The engine can not run.
The pilot can set the working engine fuel selector/shut-off valve to CROSSFEED and use the fuel
from the opposite main fuel tank to supply the engine. Thus it is possible for the pilot to keep fuel
balance between main fuel tanks.
D. Refueling
Add fuel to the tanks through the fuel fillers in the top of each wing. Fuel flows through the filler
caps into the main fuel tank assembly. Air in the tank can escape back past the fuel. As the fuel
tank becomes full the air can also escape through the vent system.
E. Fuel Drains
You can use the fuel drains in each fuel tank, each auxiliary fuel tank (if installed) and each
sediment trap to defuel the airplane. As part of the pre-flight inspection use these drains to drain
a small quantity of fuel into a transparent container to test for water or other contamination. Push
the bottom part of the valve up to release fuel. A spring inside the drain valve closes the valve
automatically when you release the bottom part. Always make sure that the drain valves close
correctly and does not leak.
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Section 28-10
Fuel Storage System
1. General
This Section describes the fuel storage system of the DA 42 NG airplane. It talks the following
components:
) Main fuel tanks.
) Fuel filler assembly.
) Fuel tank vents.
) Auxiliary fuel tanks (optional equipment).
Refer to Section 28-00 for a general description and schematic of the fuel system. Refer to Section
28-20 for data about the fuel distribution system and Section 28-40 for data about the fuel indicating
system.
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Fuel Quantity Probe

Temperature Sensor
4
2
Rubber Band
Inboard Fuel Chamber

Outlet Hose
Finger Filter
Rubber Band
Balance/Vent Hoses
Rubber Band
Rubber Band
Flexible Coupling
Middle Fuel Chamber
Fuel Quantity Probe
Rubber Band
Tank Filler
Pressure
Balance/Vent Hoses Relief Valve
Flexible Coupling
LH Installation Shown
Outboard Fuel Chamber
RH Installation Similar
Check Valve
Rubber Band
Figure 1: Main Fuel Tank Installation
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2. Main Fuel Tank Description
A. Main Fuel Tank
Figure 1 shows the fuel tank installation. The airplane has two fuel tank assemblies. One in the left
wing and one in the right wing. Three chambers connected by flexible couplings make the fuel tank
assembly. The three chambers are outboard of the engine nacelles and are located between the
main spars of each wing.
Each chamber is a welded aluminum structure. Each chamber has an oval cross section and flat
end plates. Baffles in the chambers prevent the fuel from moving quickly from one end of the tank
to the other. The chambers have bosses welded into the end plates to make connections for the
flexible hoses and other components that attach to the end plates of the chambers.
A tank outlet is located at the inboard end plate of the inner chamber. A finger filter at the tank
outlet prevents debris from entering the engine fuel systems. A drain valve is located at the lower
surface of the inner chamber. You can use this drain valve to check for fuel contamination and for
draining the fuel tanks.
A fuel temperature sensor and a low fuel sensor are also mounted on the inboard end plate of the
inner fuel tank chamber. The fuel return/transfer line also connects to the inboard end plate. The
outer end plate of the inner chamber has mountings for the flexible connecting hose and a fuel high
level switch.
The end plates of the middle chamber have fittings attached for the flexible connecting hoses that
join the middle chamber to the inner and outer chambers.
The inboard end plate of the outer fuel chamber has fittings attached for the flexible connecting
hose and a fuel high level switch. The inboard end plate also has fittings attached for the fuel tank
vents. The top surface of the outboard fuel tank has an attachment for the fuel filler assembly.
Fuel level sensors are installed in both the inner and outer chambers. The sensors go from the
lower inboard corner to the upper outboard corner of each chamber. The signals from the sensors
are displayed on the MFD of the integrated cockpit system. Refer to Section 28-40 for more data
about the fuel indicating system.
Ribs and the two main spars of the wings hold the fuel tank chambers in position. Rubber strips go
between the tank chambers and the ribs. The filler cap assembly is attached to the upper surface
of the wing with screws which holds the tank assembly in position.
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%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
Figure 2: Fuel Filler Assembly LH
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B. Fuel Filler Assemblies
The fuel filler assembly is a welded aluminum tubular structure, approximately 75 mm (3 in)
diameter. The filler has a flange that attaches to the top skin of the wing. It also has slots to engage
the fuel filler cap.
The filler cap has a locking lever. You pull the locking lever up and turn the filler cap counter-
clockwise to release it. You turn the cap clockwise to install it and push down the locking lever to
secure it. The area just below the flange has adapters where the flexible hoses of the vent system
connect (see Figure 2).
Bonding strips connect the tank to the fuel filler assembly and the airplane bonding system.
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3. Auxiliary Fuel Tank Description
Figure 3 shows the auxiliary fuel tank installation. The airplane has two auxiliary fuel tank
assemblies (optional equipment, OÄM 42-056). A single chamber makes the auxiliary fuel tank
assembly. The chamber is located in the rear section of each engine nacelle.
The chamber is a welded aluminum structure. Baffles in the chamber prevent the fuel from moving
quickly from one end of the tank to the other. The chamber has bosses welded into the forward and
rearward end plates to make connections for the flexible hoses and other components that attach
to the end plates of the chamber.
A tank outlet is located at the inboard rear corner of the chamber. A finger filter at the tank outlet
prevents debris from entering the main fuel tank. A drain valve is located at the lower surface at the
rear end of the chamber. You can use this drain valve during pre-flight inspection to check fuel
contamination and for draining the auxiliary fuel tank assembly. A fuel low level sensor is also
mounted on the rearward end plate of the chamber.
The forward end plate of the fuel chamber has a fitting to attach the auxiliary fuel tank vent line. The
top surface has the fitting to attach the fuel filler assembly.
The auxiliary fuel tank has no fuel quantity indicating system.
Two ribs in the nacelle hold the fuel chamber in position. The rearward rib is open on the bottom
side. A stainless steel strap closes the rear rib.
Rubber strips go between the tank chamber and the nacelle ribs. The filler cap assembly is
attached to the upper surface of the nacelle.
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Fuel Level Sensor

Finger Filter
Auxiliary Tank
Fuel Filler Cap

Check Valve
Figure 3: Auxiliary Fuel Tank Installation
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4. Auxiliary Fuel Tank Filler
Refer to Figure 4 for the auxiliary tank fuel filler installation.
The auxiliary fuel tank filler has a flange that attaches to a drip tray in the top skin of the nacelle. It also
has slots that engage the fuel filler cap. Turn the filler cap counterclockwise to release it. Turn the cap
clockwise to install it.
A drain line is connected to the drip tray.
Bonding strips connect the tank to the airplane bonding system.
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Auxiliary Tank
Filler Cap
O-Ring
Cover Plate
Connecting Pipe
LH shown, Drip Tray

O-Rings
RH similar
Figure 4: Auxiliary Fuel Tank Filler Installation
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Trouble-Shooting
1. General
The table below list the defects you could have with the fuel storage system. If you have the trouble
Filler cap leaking. Filler cap damaged. Replace filler cap gasket.
Filler cap does not have a tight Tighten nut on lower side of
fit. cap.
Fuel drain valve leaking. Drain valve damaged. Replace fuel drain valve.
Contamination in drain valve. Open and close drain valve to

flush contaminant. Do this until
the drain seals. If the drain will
not seal then replace the drain
valve.
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1. General
These Maintenance Practices tell you how to remove/install the fuel tanks. Obey the safety precautions
for fuel at all times.
WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE.
WARNING: DO NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN CAUSE
INJURY TO PERSONS AND DAMAGE TO EQUIPMENT.
WARNING: DO NOT BREATHE FUEL VAPOR. FUEL VAPOR CAN MAKE YOU ILL.
2. Remove/Disassemble a Main Fuel Tank Assembly
A. Remove a Main Fuel Tank Assembly
(1) Make sure that the fuel tank that you will remove Defuel and drain the fuel tank.
is empty.
(2) Remove the outer wing that has the fuel tank Refer to Section 57-10.
that you will remove and support the wing on
trestles.
(3) Remove the fuel tank assembly access panels Refer to Section 52-40.
from the lower surface of the wing.
(4) Remove the fuel drain valve:
S Cut the lockwire.
S Remove the drain valve from its mounting.
(5) Remove the fuel tank access panel from the

wing root rib:
S Remove the 11 nuts and washers that

attach the access panel to the wing root.
S Move the access panel clear of the wing

root.
(6) Disconnect the electrical connector for the fuel

quantity probe at the inboard end of the outer
fuel chamber.
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(7) Release the bonding strip from the inboard end

of the tank assembly:
S Remove the nut and washer from the bolt.
S Remove the bonding strip from the bolt and

move it clear of the tank.
S Remove the bolt.
(8) Disconnect the 2 vent hoses from the adapters Near the outboard end of the lower
on the fuel tank access panel: wing.
S Remove the access panel from the outer Refer to Section 52-40.
lower surface of the wing.
S Remove the clamps that hold the vent hoses

to the adapters on the access panels.
S Disconnect the vent hoses from the

adapters on the access panels.
(9) Disconnect the bonding wire cable from the fuel

tank access panel:
S Remove the nut and washer from the bolt.
S Remove the bonding strip from the bolt and

move it clear of the tank.
S Remove the bolt.
(10) Remove the fuel filler assembly:
S Remove the fuel filler cap.
% S Remove the 8 screws that attach the filler Note the location of the retaining cable.
flange to the to the fixing ring in the outer
fuel chamber.
S Remove the filler flange, the O-ring seal, the Discard the O-ring seal.
spacer ring and the fixing ring.
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(11) Remove the fuel tank assembly:
S Remove the nut, washer and bolt that

attaches the outer fuel chamber to the
retaining bracket in the wing.
S Gently pull the fuel tank assembly out of the

wing through the wing root rib. Move the
tank clear of the wing and support the tank
on a clean workbench.
B. Disassemble a Main Fuel Tank Assembly
(1) Remove the fuel tank assembly that you will Refer to Paragraph 2A.
disassemble and support on a clean workbench.
(2) Remove the connecting link that attach the

inboard fuel chamber to the middle fuel
chamber:

attach each end of the link to the fuel
chambers.
S Move the link clear of the fuel chambers.
(3) Remove the connecting link that attach the

middle fuel chamber to the outboard fuel
chamber:

attach each end of the link to the fuel
chambers.
S Move the link clear of the fuel chambers.
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(4) Remove the vent connector hoses that connect

the inboard fuel chamber to the middle fuel
chamber:
S Remove the hose clips from the 2 hoses.
S Pull the hoses off the fuel chamber

connectors and clear of the fuel chambers.
(5) Remove the vent connector hoses that connect

the middle fuel chamber to the outboard fuel
chamber:
S Remove the hose clips from the 2 hoses.
S Pull the hoses off the fuel chamber

connectors and clear of the fuel chambers.
(6) Remove the flexible coupling that connects the

chamber:
S Remove the worm drive clamps from the

flexible coupling.
S Pull the flexible coupling off the fuel

chamber connectors and clear of the fuel
chambers.
(7) Remove the flexible coupling that connects the

chamber:
S Remove the worm drive clamps from the

flexible coupling.
S Pull the flexible coupling off the fuel

chamber connectors and clear of the fuel
chambers.
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3. Assemble/Install a Main Fuel Tank Assembly
A. Preparation
(1) Examine the fuel chambers. Look specially for:
S Damage to the skins and welded seams of Use a x 10 magnifying glass.

the chambers.
S Corrosion.
S Damage/wear to the rubber mounting bands

which go around the outside of the fuel
chambers.
(2) Examine all the flexible hoses and couplings

which connect the fuel chambers together. Look
specially for:
S Cuts or damage, specially at the ends where

the clips and worm drive clamps locate.
S Distortion or cracking.
(3) Examine the fuel filler flange on the outer fuel

chamber. Look specially for:
S Corrosion on the mating surfaces. Use a strong light and x 10 magnifying

glass.
S Cracking around the flange.
(4) Make sure that the insides of all the fuel

chambers are clean.
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B. Assemble a Main Fuel Tank Assembly
(1) Lay the fuel chambers on a clean workbench in

the order in which you will assemble them.
(2) Install the flexible coupling that connects the

outboard fuel chamber to the middle fuel
chamber:
S Push a flexible coupling over the large

connector on the outboard fuel cell.
S Move the middle fuel chamber towards the

outer fuel chamber until the large connector
engages with the open end of the flexible
coupling.
S Push the fuel chambers together until the

flexible coupling is fully located of the fuel
chamber connectors.
S Install the worm drive clamps onto the

flexible couplings.
(3) Install the flexible coupling that connects the

chamber:
S Push a flexible coupling over the large

connector on the middle fuel chamber.
S Move the inboard fuel chamber towards the

middle fuel chamber until the large
connector engages with the open end of the
flexible coupling.
S Push the fuel chambers together until the

flexible coupling is fully located of the fuel
chamber connectors.

flexible couplings.
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(4) Install the flexible vent hoses that connect the

chamber:
S Install 2 flexible hoses over the vent

connectors on the outboard fuel chamber.
S Install the other end of the 2 flexible hoses

on the vent connectors of the middle fuel
chamber.
S Install the worm-drive-clamps onto the

flexible hoses.
(5) Install the flexible vent hoses that connect the

chamber:
S Install 2 flexible hoses over the vent

connectors on the middle fuel chamber.
S Install the other end of the 2 flexible hoses

on the vent connectors of the inboard fuel
chamber.

flexible hoses.
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(6) Install the connecting links that connect the fuel

chambers together:
S Move the link into position between the

outboard fuel chamber and the middle fuel
chamber.

attach the connecting link to the fuel
chambers.
S Move the link into position between the

middle fuel chamber and the inboard fuel
chamber.

attach the connecting link to the fuel
chambers.
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C. Install a Main Fuel Tank Assembly
(1) Move the fuel tank assembly into position in the Make sure that the tank assembly is
wing. correctly located in the wing.
% (2) Install the fuel filler assembly:

% If necessary, move the tank assembly to
% S Make sure that the mounting in the outboard
% give the correct alignment.
% fuel chamber is correctly aligned with the
% hole in the top surface of the wing.
% Use Hylomar Aerograde PL32M or
% S Apply a thin layer of sealant to the contact
% Hylomar Aerograde Ultra PL32A.
% area between spacer ring and tank filler
% mounting.
%
% S Install the spacer ring onto the tank filler
%
% mounting.
%
% S Install a new O-ring seal in position on the
% top surface of the wing.
% Use Hylomar Aerograde PL32M or
% S Apply a thin layer of sealant to the contact
% Hylomar Aerograde Ultra PL32A.
% area between the ring for filler cap and the
%
% spacer ring.
%
%
% S Put the ring for filler cap in position over the
% filler flange.
% At the position noted in
% S Install the retaining wire cable.
% Paragraph 2 A, step 10.
%
% S Install the 8 screws which attach the fuel Finger tight only.
% filler to the outboard fuel chamber.
%
%
% S When all 8 screws are installed, then Tighten opposite screws.
%
% tighten the screws.
% S Remove any excess sealant squeeze-out CAUTION: FAILURE TO
% from the fuel filler assembly. DO SO COULD LEAD TO
% FUEL CONTAMINATION
%
(3) Install the bolt, washer and nut that attaches the
bracket at the outboard end of the outboard fuel
chamber to the bracket in the wing.
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(4) Install the bonding strip at the inboard end of the

tank assembly:
S Install the bolt through the bracket on the

fuel chamber and the bonding strip.
S Install the washer and nut onto the bolt.
(5) Connect the 2 vent hoses to the adapters on the

fuel tank access panel:
S Push the vent hoses onto the adapters on

the access panels.
S Install the hose clips that hold the hoses.
(6) Connect the bonding cable to the fuel tank

access panel:
S Install the bolt through the bonding cable

and the bonding bracket.
S Install the washer and nut onto the bolt.
(7) Connect the electrical connector for the fuel At the inline connector.
quantity probe at the inboard end of the outer
fuel chamber.
(8) Install the fuel tank access panel at wing root

rib:
S Move the access panel into position over the

studs.
S Install the 11 washers and nuts that attach

the panel to the wing root rib.
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(9) Install the fuel drain valve on the lower surface

of the inboard fuel chamber:
S Install a new seal onto the fuel drain.
S Install the drain valve into the lower surface Torque: 1 - 3 Nm (0.73 - 2.21 lbf.ft).
of the fuel chamber.
S Secure the drain valve with lock-wire.
(10) Install the wing assembly onto the airplane. Refer to Section 57-10.
(11) Refuel or transfer fuel into the wing tank Refer to Section 12-10.
assembly that you removed and do a test for
fuel leaks. Look specially at the hose
connections and around the fuel filler assembly.
(12) Install all the fuel tank access panels in the Refer to Section 52-40.
lower surface of the wing.
(13) Do an engine ground run up. Make sure that: Refer to Chapter 71-00.
S Both engines can be supplied with fuel from

the fuel tank assembly that you installed.
S Make sure that the fuel quantity and

temperature indications operate correctly.
S Make sure that the L/R FUEL LOW caution

on the integrated cockpit system display
panel operates at the correct fuel level.
4. Remove/Install an Auxiliary Fuel Tank
A. Remove an Auxiliary Fuel Tank
(1) Make sure that the auxiliary fuel tank that you Defuel and drain the auxiliary fuel tank.
will remove is empty.
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(2) Remove the auxiliary fuel tank access panel

from the engine nacelle:

panel to the nacelle.
S Disconnect the vent line and the drain line

(coming from the drip tray) from the
connectors on the access panel.
S Move the access panel clear of the nacelle.
(3) Disconnect the electrical connector for the fuel

level switch at the rearward end of the fuel
chamber.
(4) Disconnect the fuel line from the tank outlet.
(5) Disconnect the bonding strip from the cooler

bracket.
(6) Remove the fuel filler assembly:
S Open the access door to the fuel filler cap.
S Remove the fuel filler cap.
S Remove the 3 screws that attach the cover

plate to the drip tray.
S Remove the cover plate with the connection

pipe.
(7) Remove the bolt, washer and nut which closes Hold the tank.
the metal strap on the rear attachment rib.
(8) Disconnect the front bonding cable at the Accessible through the inspection cover
connection point, in the chamber below the tank below the tank filler.
compartment.
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(9) Disconnect the 2 vent hoses at the front wall of

the auxiliary fuel tank:
S Gently move the tank rearward a small

distance.
S Pull the vent lines off the connectors on the Through the hole for the drip tray.
tank.
(10) Remove the fuel tank assembly:
S Gently pull the auxiliary fuel tank assembly

out of the nacelle in a rearward and
downward direction.
S Move the tank clear of the nacelle and

support it on a clean workbench.
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B. Install an Auxiliary Fuel Tank
(1) Install the fuel tank assembly:
S Gently move the auxiliary fuel tank Do not move the tank fully forward (see
assembly into the nacelle in an upward and next item).
forward direction.
(2) Connect the 2 vent hoses at the front wall of the

auxiliary fuel tank:
S Connect the vent lines to the connectors on Through the hole for the drip tray.
the tank.
S Gently move the tank fully forward.
(3) Connect the front bonding cable at the Accessible through the inspection cover
connection point, in the chamber below the tank below the tank filler.
compartment.
(4) Install the bolt, washer and nut which closes the
metal strap on the rear attachment rib.
% (5) Install the fuel filler assembly:
% S Lubricate thread of connection pipe. Use EZ-Turn (Fuel Lube).

%
% S Assemble the cover plate with the
%
% connection pipe.
%
% S Lubricate outer surface of connection pipe. Use EZ-Turn (Fuel Lube).
%
% S Seal the flange of the cover plate to the drip Use Dow Corning 732.
% tray.
% S Install cover plate connection pipe

% assembly.
% S Install the 3 screws that attach the cover

% plate to the drip tray.
% S Install the fuel filler cap.
% S Close the access door to the fuel filler cap.

%
(6) Connect the bonding strip to the cooler bracket.
(7) Connect the fuel line to the tank outlet.
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(8) Connect the electrical connector for the fuel

level switch at the rearward end of the fuel
chamber.
(9) Install the auxiliary fuel tank access panel to the

engine nacelle:
S Move the access panel in place on the

nacelle.
S Connect the vent line and the drain line

(coming from the drip tray) to the connectors
on the access panel.

(10) Refuel the auxiliary fuel tank.
(11) Check auxiliary fuel tank assembly for leakage.
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Section 28-20
Fuel Distribution
1. General
This Section describes the fuel distribution system for the DA 42 NG airplane. The fuel distribution
system supplies fuel from the fuel tanks to the engines. The components of the fuel distribution system
are:
) Flexible fuel hoses.
) Fuel transfer/shut-off valves.
) Fuel filters.
) Low pressure fuel pump assembly.
) Fuel coolers.
) Fuel pressure pulsation damper.
Refer to Section 28-00 for a general description of the fuel system and for the schematic diagram of
the fuel system.
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27
26
25
01 07
LH Wing shown M
24
RH Wing similar
M
28
23
02 03 04 05 06 07
1 Return Line 21
2 Fuel Supply
3 Firewall 19 22
4 Fuel Filter with Sediment Trap & Drain
5 Low Pressure Fuel Pumps 20
6 Prefilter
8 Wing
10 Fuel Filler
11 Pressure Relief Valve
18 Inboard Chamber Main Tank 08
20 Low Level Fuel Sensor 09
21 Drain
22 Finger Filter 15
23 Nacelle
10 14
24 Fuel Cooler
25 Fuselage
11 13
26 Crossfeed Lines
27 Fuel Selector 12
28 Fuel Pressure Pulsation Damper
Figure 1: Fuel Distribution System Schematic Without Auxiliary Tanks
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2. Description
A. Normal Operation
Figure 1 shows the schematic diagram of the fuel distribution system for the DA 42 NG airplane,
auxiliary tanks not installed. Figure 2 shows the schematic diagram with the auxiliary fuel tanks
installed. Figure 3 shows the items connecting the auxiliary fuel tank to the main fuel tank.
A flexible hose connects the main fuel tank outlet to the fuel transfer/shut-off valve. The fuel
transfer/shut-off valve is located in the related engine nacelle, aft of the engine firewall. A lever in
the cockpit center console controls the fuel transfer/shut-off valve via a mechanical drive system.
The fuel transfer/shut-off valve connects to the parallel installed independent pre-filters and the low
pressure fuel pumps. The electrically powered fuel pumps connect then to the fuel filter assembly.
A drain valve is located at the bottom of the fuel filter assembly. The bottom of the fuel filter
assembly forms the sediment trap.
The fuel filter assembly connects via flexible hose to a fuel bulkhead fitting on the engine firewall.
From there a flexible hose connects the bulkhead fitting to a fuel pressure pulsation damper and
then to the engine driven high pressure fuel pump.
A flexible hose connects the engine fuel system return line to the return bulkhead fitting located on
the engine firewall. A flexible fuel hose connects on the nacelle side to the return line of the fuel
transfer/shut-off valve. Another flexible hose connects the return of the fuel transfer/shut-off valve
to the related main fuel tank return system.
During normal operation the fuel returning from the left engine will flow through the left fuel cooler
back into the left fuel tank. Flexible hoses connect the fuel cooler into the fuel return system. The
fuel cooler is located in the rear of the engine nacelle. A NACA duct in the lower surface of the rear
engine nacelle supplies air for the fuel cooler. A shroud around the fuel cooler guides the air from
the NACA duct through the matrix of the fuel cooler. The air from the cooler exits from the nacelle
through air outlets at the rear of the nacelle.
If the optional auxiliary fuel tank is installed (OÄM 42-056), a flexible hose runs from the outlet of
the auxiliary fuel tank to the auxiliary fuel pump. Another flexible hose runs from the outlet of the
auxiliary fuel pump via an inline filter, a solenoid valve and a check valve to a T-fitting which feeds
the auxiliary fuel into the return fuel circuit.
The check valve and the solenoid valve prevent a backflow of the cooled return fuel from the engine
into the auxiliary fuel tank. To protect the solenoid valve from contamination an inline filter is
installed in the fuel transfer line directly at the outlet of the auxiliary fuel pump.
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38
37
36
01 Return Line 35
02 Fuel Supply 34
03 Firewall 33
04 Fuel Filter with Sediment 01 07 32
Trap & Drain 31
06 Prefilter M
30
08 Wing M
28
09 Fuel Level Switch 39 M
10 Fuel Filler 26
11 Pressure Relief Valve 02 03 04 05 06 07 25
13 Check Valve with Capilare 27
14 Outboard Fuel Level Sensor 23 24
15 Outboard Chamber Main Tank 21
17 Inboard Fuel Level Sensor 19 22
21 Drain 18
22 Finger Filter
23 Nacelle 17
24 Check Valve LH Wing shown
25 Inline Filter RH Wing similar
26 Auxiliary Pump
27 Solenoid Valve
28 Finger Filter
29 Fuel Cooler
30 Drain
16
32 Auxiliary Fuel Filter 08
33 Auxiliary Tank
34 Check Valve with Capillare 09
35 Auxiliary Fuel Tank Vent Line
36 Fuselage 15
37 Crossfeed Lines 10 14
38 Fuel Selector
39 Fuel Pressure Pulsation 13
Damper 11
12
Figure 2: Fuel Distribution System Schematic With Auxiliary Tanks (OÄM 42-056)
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B. Fuel Transfer Operation
When the left engine fuel transfer/shut-off valve is set to CROSSFEED the fuel for the left engine
is taken from the right fuel tank. A flexible hose from the left fuel transfer/shut-off valve connects
to the supply system of the right fuel tank. Another flexible hose connects the return port of the left
fuel transfer/shut-off valve to the right return system of the right fuel tank. The right engine fuel
transfer system is designed similar.

PUMP IS REQUIRED.
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Solenoid Valve
Check Valve
Fuel Cooler
Fuel Pump
Auxiliary Tank
Return Fuel Line

from Engine
Inline Filter
To Exterior
Fuel Feed Line

to Main Fuel Tank
Drain Line
Vent Line
Figure 3: Auxiliary Fuel Supply to the Main Fuel Tank
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3. Fuel Distribution System Components
A. Flexible Hoses
The fuel system uses synthetic flexible hoses. The flexible hoses in the engine bay have integral
fire-protection sleeves.
You must only use approved flexible hoses in the fuel system which have been pressure tested.
B. Fuel Transfer/Shut-Off Valves
Figure 4 shows a fuel transfer/shut-off valve installation. A fuel transfer/shut-off valve is located in
each engine nacelle, aft of the engine firewall. A long shaft connects the valve to a drive unit
located under the cockpit floor. A lever connects the drive unit to a fuel selector lever. The selector
levers for both fuel transfer/shut-off valves are mounted in the cockpit center console. Each lever
has the positions:
(1) ON
If you set the engine fuel selector levers to the ON position both engines will be take fuel from
their related fuel tanks. For example, the left engine will take fuel from the left main fuel tank and
the right engine will take fuel from the right main fuel tank.
(2) CROSSFEED
If you set an engine fuel selector lever to the CROSSFEED position the engine will take fuel
from the opposite main fuel tank. For example, if you set the left fuel selector lever to
CROSSFEED and the right fuel control lever to ON then both engines will take fuel from the
right main fuel tank. If you set the right fuel selector lever to CROSSFEED and the left selector
lever to ON then both engines will take fuel from the left main fuel tank.
(3) SHUT-OFF
If you set an engine fuel selector to the SHUT-OFF position then the fuel supply to that engine
will be shut-off and the engine will not run. Each lever has a safety guard located on the lever
console to prevent accidental selection of the SHUT-OFF position. You must turn the safety
guard before you can move the related fuel selector lever to the SHUT-OFF position. The other
engine fuel selector lever is independent and will operate based on the selected position.
For example, if you set the left fuel selector lever to SHUT-OFF and the right fuel selector lever
to ON the left engine takes no fuel and the right engine takes fuel from the right main fuel tank.
If the right selector lever is moved to CROSSFEED then the right engine will take fuel from the
left main fuel tank.
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PUMP IS REQUIRED.
C. Fuel Filter Assembly
Figure 5 shows a fuel filter assembly. The fuel filter assembly is installed in the engine nacelle and
is accessible through the inspection panel on the lower inboard side.
The fuel filter assembly consists of a cap which distributes the fuel into the fuel filter body. The body
is an integral part which acts as fine filter and sediment trap. A drain is installed at the bottom of the
sediment trap. Use this drain to drain fuel from the fuel distribution system or for drain fuel when
you do a test for fuel contamination.
You can remove the filter element for replacement.
D. Low Pressure Fuel Pump Assembly
Figure 6 shows a low pressure fuel pump assembly. The low pressure fuel pump assembly is
installed in the engine nacelle and is accessible through the nacelle inspection panel on the lower
outboard side.
Flexible hoses connect a fuel distribution bridge which leads into two independent pre-filters. The
pre-filters prevent the low pressure fuel pumps from contamination. Figure 8 shows the pre-filter
assembly. The pre-filters are screwed into independent electrically powered low pressure fuel
pumps. By turning the FUEL PUMP LH/RH ENGINE switch on the instrument panel the fuel pumps
can be powered without switching the ENGINE MASTER. Check that the fuel transfer/shut-off
valves are turned to position ON before switching the fuel pumps to ON. At the pressure side the
fuel pumps are connected through a bridge banjo into a flexible hose.
E. Fuel Cooler
Figure 9 shows the fuel cooler. The fuel cooler for each fuel return system is located in the rear of
each engine nacelle. Flexible hoses connect the fuel cooler to the fuel return line and the related
fuel tank. Air to the cooler inlet is channeled through a NACA duct in the lower surface of the
nacelle. The outlet for the cooling air is on the rear face of the engine nacelle.
F. Fuel Pressure Pulsation Damper
A fuel pressure pulsation damper is installed in the fuel supply line firewall forward between the
bulkhead fitting and the engine driven high pressure fuel pump (LH and RH engine). See Figure 8.
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Trouble-Shooting
1. General
The table below lists the trouble you could have with the fuel distribution system. If you have the
trouble detailed in the Trouble column then read across to the Possible Cause column. Then do the
repair given in the Repair column.
The airplane smells of fuel. Hose/pipe leaking. Examine all hoses and pipes.
Replace damaged or defective
components.
Loose connection. Examine all connections.

Tighten loose connections.
Component leaking. Examine all components.

Replace defective
components.
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1. General
This Section gives you the Maintenance Practices for the fuel distribution system. The procedures are
limited to the removal/installation of the main components of the system.
Obey the safety precautions for fuel at all times.
2. Remove/Install a Fuel Transfer/Shut-Off Valve
A. Remove a Fuel Transfer/Shut-Off Valve
(1) Defuel the airplane. Refer to Section 12-10.
(2) Remove the access panels from the related Refer to Section 52-40.
engine nacelle, aft of the bulkhead that give
access to the fuel transfer/shut-off valve.
(3) Remove the engine cowlings for the related Refer to Section 71-10.
engine.
(4) Drain the fuel from the fuel distribution system: Use a suitable container. Use the drain
valve on the fuel sediment bowl.
S Set the related FUEL SELECTOR lever in
the cockpit to the related engine until fuel
stops draining from the fuel sediment bowl
drain.

the cockpit to the CROSSFEED position
until fuel stops draining from the fuel
sediment bowl drain.

the cockpit to the SHUT-OFF position.
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(5) Disconnect these fuel connections at the fuel Refer to Figure 4. Put caps on all the
transfer/shut-off valve: open fuel connections.
S The fuel supply to the engine.
S The fuel return from the engine.
S The fuel supply from the related fuel tank.
S The fuel supply from the opposite fuel tank.
S The fuel return to the related fuel tank.
S The fuel return to the opposite fuel tank.
(6) Remove the fuel transfer/shut-off valve from the

bulkhead:
S Remove the cotter pin from the universal

joint.
S Remove the 4 bolts and washers that attach

the valve to the mounting bracket.
S Remove the bonding wire.
S Move the valve clear of the mounting

bracket and pull the valve off the valve
drive-tube assembly.
S Move the fuel transfer/shut-off valve clear of

the engine nacelle.
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Fuel Selector Lever

Safety Guards
Fuel Selector
Rod Assy, RH
Fuel Selector
Fuel Selector
Rod Assy, LH Gearbox
LH details shown,
RH details similar
Fuel Selector
Lever, RH
Fuel Selector
Lever, LH Pin
Universal Joint
Connecting Rod Universal Joint
Pin
Fuel Transfer/Shut-Off Valve
Figure 4: Fuel Transfer/Shut-Off Valve Installation
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B. Install a Fuel Transfer/Shut-Off Valve
(1) Make sure that the related FUEL SELECTOR In the cockpit.
lever in the cockpit is set to SHUT-OFF.
(2) Set the fuel transfer/shut-off valve to the shut-off

position.
(3) Install the fuel transfer/shut-off valve:
S Hold the valve in the shut-off position and

move the valve into position over the valve
S Install cotter pin (of universal joint).
S Locate the fuel transfer/shut-off valve on the

mounting bracket.
S Install the 4 bolts and washers that attach

the fuel transfer/shut-off valve to the
bracket.
S Install the bonding wire. Seal the connection with bonding

lacquer.
(4) Connect these fuel connections at the fuel Make sure that all the caps are removed
transfer/shut-off valve: from the connections. Make sure that all
the fuel hoses are connected to the
correct transfer/shut-off valve
S The fuel return from the engine. connectors.
(5) Refuel the airplane. Refer to Section 12-10.
(6) Bleed both engine fuel distribution systems. Refer to Paragraph 7.
(7) Do a test for fuel leaks at these connections:
S The inlet from the related fuel tank.
S The inlet from the opposite fuel tank.
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(8) Do a test for correct operation of the fuel Refer to Paragraph 9.

transfer/shut-off valve.
(9) Install the access panels that you removed. Refer to Section 52-40.
(11) Do an engine ground run up. Make sure that the

fuel system operates correctly.
3. Remove/ Install the Fuel Selector Gearbox
A. Remove the Fuel Selector Gearbox
Refer to Figure 2.
(1) Remove pilot’s and co-pilot’s seat. Refer to Section 25-10.
(2) Remove center console between pilot’s and

co-pilot’s seat.
(3) Remove knobs from the fuel selector levers.
(4) Remove fuel selector cover plate.
(5) Push LH fuel selector lever into ON position. Make sure that the fuel selector valve is
engaged in the ON position.
(6) Mark the ON position on the outer

connecting rod (splined tube, which connects
the fuel selector gearbox with the fuel
selector valve) directly at the bushing in the
fuselage wall.
(7) Pull fuel selector lever into CROSSFEED Make sure that the fuel selector valve is
position. engaged in the CROSSFEED position.
(8) Mark the CROSSFEED position on the outer

connecting rod directly at the bushing in the
fuselage wall.
(9) Pull the fuel selector lever into the OFF Make sure that the fuel selector valve is
position. engaged in the OFF position.
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(10) Mark the OFF position on the outer

fuselage wall.
(11) Repeat steps 5 to 10 for the RH fuel selector

lever.
(12) Push both fuel selector levers into the ON Make sure that the fuel selector valves are
position. engaged in the ON position. This is the
necessary position for adjustment when the
new fuel selector valve will be installed.
(13) Remove crash element above the fuel

selector gearbox.
(14) Disconnect the fuel selector push rods (rods

between fuel selector levers and fuel selector
gearbox) directly at the fuel selector gear
box.
(15) Disconnect the LH inner connecting rod from Open the three bolts at the connection
the outer connecting rod. element below the outer crash element.
(16) Disconnect the RH inner connecting rod from Open the three bolts at the connection
(17) Disconnect both inner connecting rods from Open the bolts at the universal joint.
the fuel selector gearbox.
(18) Remove the fuel selector gearbox. Open both bolts of the attachment brackets
and the two countersunk bolt which attach
the fuel selector gearbox to the main spar.
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DA 42 NG AMM Fuel
AIRCRAFT
B. Install the Fuel Selector Gearbox
Refer to Figure 4.
(1) Bring fuel selector gearbox in position

between the attachment brackets.
(2) Attach the fuel selector gearbox to both

brackets with the bolts on the bottom of the
gearbox.
(3) Attach the gearbox to the main spar.
(4) Connect the fuel selector push rods to the

fuel selector gearbox.
(5) Install fuel selector cover.
(6) Push both fuel selector levers fully forward Make sure that the length of the push rods
into the ON position. is proper to reach the most forward position
at the fuel selector gearbox.
If necessary adjust the length of the push

rods at the designated point. Old push rods
are not adjustable. If necessary, exchange
these push rods with new ones.
Make sure that the fuel selector valve is

engaged in the ON position. For reference
use marking on the outer push rod directly
at the bushing in the fuselage wall.
(7) Exchange the drilled part of the connection For adjustment of the fuel selector valve
element between the connecting rods with a positions in accordance with the fuel
new undrilled part. selector lever positions new holes must be
drilled.
(8) Connect the inner connecting rods to the fuel

selector gearbox.
(9) Bring both parts of the LH connection

element between the connecting rods into
position.
(10) Mark the position of both parts of the

connection element in relation to each other.
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(11) Remove both parts of the connection

element.
(12) Drill holes in the undrilled part of the Use drilled part of the connection element
connection element. in the marked position as template.
(13) Install both parts of the connection element.
(14) Connect both parts of the connection

element with the three bolts.
(15) Repeat steps 9 to 14 for the RH connection

element.
(16) Do a functional test of the fuel selector valve. Pull fuel selector levers into all positions.
engaged in the respective positions using
the marking at the bushing in the fuselage
wall as reference.
(17) Bond new crash element onto the fuel Refer to Section 51-20.
selector gearbox using bonding paste.
(18) Install center console between pilot’s and

co-pilot’s seat.
(19) Install pilot’s and co-pilot’s seat. Refer to Section 25-10.
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Fitting
Screw
Plug Screw
Sealing Ring Sealing Ring
Washer
Fuel Filter Cap
Fitting
Fuel Filter Body
Lock Wire
Rubber
Worm Drive Clamp
Fuel Filter Drain Adapter
Drain
Figure 5: Fuel Filter Assembly
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4. Remove/Install the Fuel Filter Body
A. Remove the Fuel Filter Body
lever is set to SHUT-OFF.
(2) Remove the fuel filter element: Refer to Figure 5.
S Drain the fuel from the fuel distribution From the fuel sediment bowl drain. Use
system. a suitable container to catch spilt fluid.
S Remove the safety wire from the filter bowl.
S Unscrew the filter body together with the

drain valve assembly from the filter
assembly.
S Unscrew the drain valve and the drain valve

adapter from the fuel filter body.
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B. Install the Fuel Filter Body
(1) Install the fuel filter drain adapter and the drain Refer to Figure 5.
valve into the new filter body. Use Loctite 243 on adapter to fuel filter
body connection.
(2) Install the filter body assembly into the fuel filter Make sure that the integral sealings at
cap. the new fuel filter body are not
damaged.
(3) Secure the filter body assembly via the drain

valve to the filter assembly with lockwire.
(4) Do a test for leaks of the filter assembly:
S Make sure that there is fuel in the related

fuel tank.
S Set the FUEL SELECTOR lever to the

related tank.
S Examine the filter assembly for leaks.
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Hollow Bolt
Sealing Ring
Worm Drive Clamp
Electrical Fuel Pump
Worm Drive Clamp

Solid Bridge M14
Sealing Ring
Fuel Pre-Filter
Screw
Washer
Screw Hollow Bolt
Washer
Fuel Pump Bracket Sealing

Solid Bridge M14 Ring
Fuel Hose OUT

Lock Nut
90° Fitting
Lock Nut
Fuel Pump Upper Plate LH
IN Fuel Hose
Connector Bracket Assy
Fuel Pump Lower Plate LH
Figure 6: Fuel Pumps Assembly
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DA 42 NG AMM Fuel
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Figure 7: Fuel Pumps Assembly (if MÄM 42-480 is installed)
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5. Remove/Install the Fuel Pre-Filters
A. Remove the Fuel Pre-Filters
(2) Pull the appropriate circuit breaker of electrically

driven fuel pumps.
(3) Remove the fuel pre-filters: Refer to Figure 6.
S Drain the fuel from the fuel distribution From the fuel filter drain. Use a suitable
system. container to catch spilt fluid.
S Disconnect the fuel hose on the pre-filter

side.
S Remove the safety wire from the hollow

bolts next to the pre-filters.
S Remove the hollow bolts and the solid

bridge next to the pre-filters.
S Remove the pre-filter assemblies. The assemblies will contain fuel!
B. Clean the Pre-Filters
(1) Disassemble the pre-filters. Refer to Figure 8.
(2) Flush the filter mesh with clean fuel.
(3) Replace the O-ring.
(4) Assemble the pre-filters. Torque: 15 ± 2 Nm (11.1 ± 1.5 lbf.ft.).
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Fuel Filter Casing (Female)

IN
Filter Mesh
O-Ring
Fuel Filter Casing (Male)
OUT
Figure 8: Fuel Pre-Filter Assembly
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C. Install the Fuel Pre-Filters
(1) Install the pre-filters: Refer to Figure 6.
S Replace all aluminium washers of the fuel

pump assembly on the pre-filter side.
S Install the pre-filter assembly.
S Install the solid bridge and the hollow bolts. Torque: 18 ± 2 Nm (13.3 ± 1.5 lbf.ft.).
S Connect the fuel hose on the pre-filter side.
S Secure the hollow bolts with safety wire.

fuel tank.
S Reset the circuit breaker of the fuel pumps.

related tank.
S Examine the filter assembly for leaks while

both low pressure fuel pumps are running.
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6. Remove/Replace/Install the Fuel Pressure Pulsation Damper
A. Remove the Fuel Pressure Pulsation Damper (LH or RH Engine)

(1) Make sure that the engine is safe:
(2) Remove the upper cowlings.
(3) Remove the P-clamp which positions the fuel

pressure pulsation damper installation.
(4) Remove the lock wires at the lines on the fuel

pressure pulsation damper housing.
(5) Disconnect the two fuel lines which are

connected to the fuel pressure pulsation damper
housing.
(6) Remove the fuel pulsation damper.
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Pulsation Damper
Element
Damper Housing
Damper Housing
O-Rings
Note: Installation Direction as shown
O-Rings
Pulsating Damper Assy
Fuel Supply Line
Fuel Return Line
Engine Driven High

Pressure Fuel Pump
Figure 9: Fuel System Components Firewall Forward LH and RH Engine
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B. Replace the Fuel Pressure Pulsation Damper
(1) Remove the wire locking of the fuel pressure

pulsation damper housing.
(2) Open the fuel pressure pulsation damper housing

by turning the cover counterclockwise.
(3) Remove and discard the fuel pressure pulsation

damper and the four O-rings.
(4) Clean the inside of the fuel pressure pulsation Flush with fuel approved for the
damper housing. airplane.
No contamination allowed.
(5) Install the four new O-rings.
(6) Apply 09-25300 ‘Fuelube EZTurn 1LB’ to the

outside thread and sealing surface of the fuel
(7) Install the new fuel pressure pulsation damper in Refer to Figure 9.
the housing. Watch out for the installation
direction of the fuel pressure pulsation damper in
the housing.
(8) Tighten the fuel pressure pulsation damper Torque 80 ± 4 Nm (59.0 ± 2.9 lbf.ft).
housing.
(9) Secure the fuel pressure pulsation damper

housing with locking wire.
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C. Install the Fuel Pressure Pulsation Damper Housing Assy
(1) Flush the fuel pressure pulsation damper assy

with fuel approved for the airplane.
(2) Connect the fuel pressure pulsation damper

housing to the fuel supply lines and secure with
locking wire. Watch out for the flow direction
(arrow).
(3) Install the P-clamp and mount the fuel pressure

pulsation damper assy to the engine.
(4) Install the upper cowlings.
(5) Conduct an engine ground run.
(6) Inspect the airplane for fuel leakage.
7. Remove/Install the Low Pressure Fuel Pumps
A. Remove/Replace the Low Pressure Fuel Pumps

driven fuel pumps.
(3) Remove the low pressure fuel pumps: Refer to Figure 6.
S Remove the fuel hoses from the fuel filter

assembly.
S Disconnect the electric wires from the

electric fuel pumps.
S Remove the fuel pump assembly from the

bracket.
S Remove the hollow bolts, solid bridge, and

pre-filters.
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(4) If MÄM 42-480 is carried out: Refer to Figure 7.

Remove the low pressure fuel pumps:

assembly.


bracket.
S Remove the two hollow bolts, the solid

bridge, and the two pre-filters from the
bottom of the fuel pump assembly.
S Remove safety wire from plug nuts.
S Remove the two plug nuts, the solid bridge

and two check valves from the top of the
fuel pump assembly.
(5) Replace fuel pumps and pre-filters. Refer to Chapter 05.
(6) Replace aluminium washers.
(7) Check hollow bolts and bridges for damage. Replace damaged items!
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B. Install Low Pressure Fuel Pumps
(1) Install the low pressure fuel pump assembly: Refer to Figure 6.
S Install the aluminum washers, the two pre- Hollow bolts torque:
filters, the solid bridges, and the hollow D-08: 18 ± 2 Nm (13.3 ± 1.5 lbf.ft.)
bolts. D-06: 18 ± 2 Nm (13.3 ± 1.5 lbf.ft.)
S Install the fuel pumps assembly to the

bracket.
S Connect the electric wires to the fuel pumps.
S Connect the fuel hoses to the solid bridges.
S Secure hollow bolts with safety wire.
(2) If MÄM 42-480 is carried out: Refer to Figure 7.

Install the low pressure fuel pump assembly:
S Install the aluminum washers, the two pre- Hollow bolts torque:
filters, the solid bridge, and the two hollow 18 ± 2 Nm (13.3 ± 1.5 lbf.ft.)
bolts.
S Install the washers, the two check valves, Plug nuts torque:
the solid bridge, and the two plug nuts. 18 ± 2 Nm (13.3 ± 1.5 lbf.ft.)
S Secure plug nuts with safety wire.

bracket.
S Connect the fuel hoses to the solid bridges.
S Secure hollow bolts with safety wire.
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fuel tank.

related tank.

8. Test the Solenoid Valve/Check Valve in the Fuel Transfer Line (If Auxiliary Tanks Installed)
CAUTION: YOU MUST REPLACE THE CHECK VALVE IF THE TEST FAILS.
(1) Make sure that there is no fuel in the related

main fuel tank.
(2) Top off the auxiliary fuel tank.
(3) Disconnect the fuel transfer line from the Put a cap on the T-fitting.
Tee-fitting of the fuel return line.
(4) Check for any leakage from the solenoid If leakage is observed: replace solenoid
valve/check valve. valve/check valve.
(5) Disconnect cap from the T-fitting and reconnect

the fuel transfer line to the T-fitting.
(6) Check for leakage while operating the auxiliary If leakage is observed replace relevant
fuel pump. fittings and hoses.
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9. Remove/Install a Fuel Cooler
A. Remove a Fuel Cooler
(2) Remove the access panel for the fuel cooler: At the rear of the engine nacelle. On the
lower surface of the nacelle. Support the
S Remove the screws that attach the panel to
panel.
the lower surface of the engine nacelle.
(3) Disconnect the flexible hoses that connect to Refer to Figure 10. Use a suitable
the fuel cooler. container to catch spilt fuel. Put caps on
all open connections.
(4) Remove the fuel cooler:
S Remove the 4 bolts and washers that attach Support the cooler.
the fuel cooler to the mounting brackets.
S Lower the cooler from the mounting Take care! The cooler will contain fuel!
brackets and clear of the engine nacelle.
S Empty the fuel from the cooler into a

suitable container.
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LH shown,
RH similar
Flexible Hose
Flexible Hose
Fuel Cooler
Figure 10: Fuel Cooler Installation
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B. Install a Fuel Cooler
(1) Install the fuel cooler:
S Move the fuel cooler into position in the

engine nacelle.
S Align the cooler with the mounting brackets

and install the 4 bolts and washers that
attach the fuel cooler to the brackets.
(2) Connect the flexible hoses to the fuel cooler. Make sure that you remove all the
blanking caps.
(3) Bleed the related fuel distribution system. Refer to Paragraph 9.
(4) Do a test for leaks. Specially at the flexible hose

connections to the fuel cooler.
Install the fuel cooler access panel:

rear of the engine nacelle, lower surface.
S Install the screws that attach the access

panel to the engine nacelle.
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10. Test the Crossfeed Position of a Fuel Selector Valve

PUMP IS REQUIRED.
(1) Do the preparation for an engine test. Refer to Section 71-00.
(2) Start the related engine. On the side of the fuel selector valve
that you want to test.

in the ON position.
(3) Set the fuel selector valve that you want to test
in the CROSSFEED position.
(4) Let the engine idle for 1 minute. Refer to Section 71-00.
(5) Set the related power lever to 100% after Keep the engine temperature in view.
engine warm up and keep this position for Do not continue the test if the engine
1 minute. temperature rises too high.
(6) Make sure that the engine does not stop. If the engine stops, then the
CROSSFEED system is defective.
Correct the fault and do the test again.
(7) Shut down the engine. Refer to Section 71-00.
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11. Remove/Install an Inline Filter
A. Remove an Inline Filter
(1) Make sure that the auxiliary fuel tank is empty. Defuel and drain the auxiliary fuel tank.



(3) Disconnect the fuel transfer line from the

auxiliary fuel pump outlet.
(4) Remove the inline filter. Filter is inserted in the fuel transfer line.
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B. Install an Inline Filter
(1) Insert the inline filter into the fuel transfer line. Directly at the auxiliary fuel pump outlet
connection fitting.
(2) Connect the fuel transfer line to the auxiliary fuel

pump outlet.
(3) Refuel the auxiliary fuel tank. Fill more than 2 US gal (7.6 l) of fuel into
the auxiliary tank.
(4) Perform a test of the auxiliary fuel transfer Refer to Paragraph 11.
system.

engine nacelle:

nacelle.

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12. Test the Auxiliary Fuel Transfer System
A. Equipment
Ground power supply. 1 -
Stopwatch. 1 Commercial.
B. Procedure
CAUTION: YOU MUST REPLACE THE INLINE FILTER IF THE TEST FAILS.
(1) Connect the airplane to ground power.
(2) Defuel the auxiliary tank using the auxiliary fuel On the side of the auxiliary fuel system
transfer pump. that you want to test.
Make sure that the corresponding main

tank is empty enough to hold the
auxiliary fuel.
The auxiliary fuel pump must stop due to

the auxiliary tank empty switch.
(3) Fill 2 US gal (7.6 l) of fuel into the auxiliary fuel

tank.
(4) Measure transfer time for transferring the The auxiliary fuel pump must stop due to
2 US gal (7.6 l) of fuel from the auxiliary tank the auxiliary tank empty switch. Measure
into the main tank. time from switching on the fuel pump
until the fuel transfer stops due to the
auxiliary tank empty switch.
The transfer time must not be more than

4 min.
Check if the corresponding main tank

fuel quantity indication increases.
(5) Repeat steps 2 thru 4 for the other auxiliary fuel

transfer system.
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Section 28-21
Fuel Distribution (if MÄM 42-600 is installed)
1. General
This Section describes the fuel distribution system for the DA 42 NG airplane with MÄM 42-600
installed. The fuel distribution system supplies fuel from the main fuel tanks to the engines. The
components of the fuel distribution system are:
) Flexible fuel hoses.
) Fuel transfer/shut-off valves.
) Fuel filters.
Low pressure fuel pump assembly. Refer to Section 28-00 for a general description of the fuel system
and for the schematic diagram of the fuel system.
Refer to Chapter 73-00 for information about the fuel cooler installation.
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27
26
25
24 28 07
01
23
02 03 04 05 06 07
21
01 Return Line
02 Fuel Supply
03 Firewall 19 22
Trap & Drain 20
06 Prefilter
08 Wing
10 Fuel Filler
21 Drain 08
22 Finger Filter
23 Nacelle 09
24 Fuel Cooler
25 Fuselage 15
26 Crossfeed Lines
11 13
12
Figure 1: Fuel Distribution System Schematic Without Auxiliary Tanks (if MÄM 42-600 installed)
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2. Description
A. Normal Operation
Figure 1 shows the schematic diagram of the fuel distribution system for the DA 42 NG airplane,
auxiliary tanks not installed. Figure 2 shows the schematic diagram with the auxiliary fuel tanks
installed. Figure 3 shows the items connecting the auxiliary fuel tank to the main fuel tank.
A flexible hose connects the main fuel tank outlet to the fuel transfer/shut-off valve. The fuel
transfer/shut-off valve is located in the related engine nacelle, aft of the engine firewall. A lever in
the cockpit center console controls the fuel transfer/shut-off valve via a mechanical drive system.
The fuel transfer/shut-off valve connects to the parallel installed independent pre-filters and the low
pressure fuel pumps. The electrically powered fuel pumps connect then to the fuel filter assembly.
A drain valve is located at the bottom of the fuel filter assembly. The bottom of the fuel filter
assembly forms the sediment trap.
The fuel filter assembly connects via flexible hose to a fuel bulkhead fitting on the engine firewall.
From there a flexible hose connects the bulkhead fitting to a fuel pressure pulsation damper and
then to the engine driven high pressure fuel pump.
A flexible hose connects the engine fuel system return line to the return bulkhead fitting located on
the engine firewall via the fuel cooler. A flexible fuel hose connects on the nacelle side to the return
line of the fuel transfer/shut-off valve. Another flexible hose connects the fuel transfer/shut-off valve
to the related main fuel tank return system.
During normal operation the fuel returning from the left engine will flow through the left fuel cooler
back into the left main fuel tank via the fuel transfer / shut -off valve. The fuel cooler is located in
the engine compartment. An opening in the left sidewall of the air inlet diffusor of the radiator
supplies cooling air to the fuel cooler via a duct system. The cooling air from the fuel cooler exits
through cowling air outlets.
If the optional auxiliary fuel tank is installed (OÄM 42-056), a flexible hose runs from the outlet of
the auxiliary fuel tank to the electrically driven auxiliary fuel pump via an inline fuel filter. Another
flexible hose runs from the outlet of the auxiliary fuel pump via a solenoid valve and a check valve
to a Y-adapter which feeds the auxiliary fuel into the return fuel circuit.
The check valve and the solenoid valve prevent fuel backflow into the auxiliary fuel tank. To protect
the fuel pump and the solenoid valve from contamination an inline filter is installed in the fuel
transfer line prior to the auxiliary fuel pump.
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38
37
36
35
34
29 39 07 33
01 32
01 Return Line
02 Fuel Supply
31
03 Firewall
M
30
Trap & Drain
05 Low Pressure Fuel Pumps M
28
06 Prefilter
07 Fuel Selector Valves M
25
08 Wing 26
09 Fuel Level Switch 02 03 04 05 06 07
10 Fuel Filler
11 Pressure Relief Valve 27
23 24
14 Outboard Fuel Level Sensor 21
16 Middle Chamber Main Tank 19
20
21 Drain 18
22 Finger Filter
23 Nacelle
24 Check Valve
17
25 Inline Filter
26 Auxiliary Pump
LH Wing shown
27 Solenoid Valve RH Wing similar
28 Finger Filter
29 Fuel Cooler
30 Drain
32 Auxiliary Fuel Filter
33 Auxiliary Tank 16
34 Check Valve with Capillare
35 Auxiliary Fuel Tank Vent Line 08
36 Fuselage
37 Crossfeed Lines
38 Fuel Selector 09
15
10 14
11 13
12
Figure 2: Fuel Distribution System Schematic With Auxiliary Tanks

(OÄM 42-056 and MÄM 42-600 installed)
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B. Fuel Transfer Operation
When the left engine fuel transfer/shut-off valve is set to CROSSFEED the fuel for the left engine
is taken from the right main fuel tank. A flexible hose from the left fuel transfer/shut-off valve
connects to the supply system of the right main fuel tank. Another flexible hose connects the return
port of the left fuel transfer/shut-off valve to the right return system of the right main fuel tank. The
right engine fuel transfer system is designed similar.
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Inline Filter
Fuel Pump
Check Valve
(if installed)
Solenoid Valve
Auxiliary Tank
To Exterior
Fuel Line to
Main Fuel Tank
Drain Line
Vent Line
Figure 3: Auxiliary Fuel Supply to the Main Fuel Tank (if MÄM 42-600 is installed)
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3. Fuel Distribution System Components
A. Flexible Hoses
The fuel system uses synthetic flexible hoses. The flexible hoses in the engine compartment have
integral fire-protection sleeves.
Only use approved flexible hoses in the fuel system.
B. Fuel Transfer/Shut-Off Valves
Figure 4 shows a fuel transfer/shut-off valve installation. A fuel transfer/shut-off valve is located in
each engine nacelle, aft of the engine firewall. A long shaft connects the valve to a drive unit
located under the cockpit floor. A lever connects the drive unit to a fuel selector lever. The selector
levers for both fuel transfer/shut-off valves are mounted in the cockpit center console. Each lever
has the positions:
(1) ON
If you set the engine fuel selector levers to the ON position both engines will take fuel from their
related main fuel tanks. For example, the left engine will take fuel from the left main fuel tank
and the right engine will take fuel from the right main fuel tank.
(2) CROSSFEED
If you set an engine fuel selector lever to the CROSSFEED position the engine will take fuel
from the opposite main fuel tank. For example, if you set the left fuel selector lever to
CROSSFEED and the right fuel control lever to ON then both engines will take fuel from the
right main fuel tank. If you set the right fuel selector lever to CROSSFEED and the left selector
lever to ON then both engines will take fuel from the left main fuel tank.
(3) SHUT-OFF
If you set an engine fuel selector to the SHUT-OFF position then the fuel supply to that engine
will be shut-off and the engine will not run. Each lever has a safety guard located on the lever
console to prevent accidental selection of the SHUT-OFF position. You must turn the safety
guard before you can move the related fuel selector lever to the SHUT-OFF position. The other
engine fuel selector lever is independent and will operate based on the selected position.
For example, if you set the left fuel selector lever to SHUT-OFF and the right fuel selector lever
to ON no fuel is provided to the left engine and the right engine takes fuel from the right main
fuel tank.
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C. Fuel Filter Assembly
Figure 5 shows a fuel filter assembly. The fuel filter assembly is installed in the engine nacelle and
is accessible through the inspection panel on the lower inboard side.
The fuel filter assembly consists of a cap which distributes the fuel into the fuel filter body. The body
is an integral part which acts as fine filter and sediment trap. A drain is installed at the bottom of the
sediment trap. Use this drain to drain fuel from the fuel distribution system or for drain fuel when
you do a test for fuel contamination.
The filter element can be removed for replacement.
D. Low Pressure Fuel Pump Assembly
Figure 8 shows a low pressure fuel pump assembly. The low pressure fuel pump assembly is
installed in the engine nacelle and is accessible through the nacelle inspection panel on the lower
outboard side.
Flexible hoses connect a fuel distribution bridge which leads into two independent pre-filters. The
pre-filters prevent the low pressure fuel pumps from contamination. Figure 6 shows the pre-filter
assembly. The pre-filters are screwed into independent electrically powered low pressure fuel
pumps. By turning the FUEL PUMP LH/RH ENGINE switch on the instrument panel to ON the fuel
pumps can be powered without switching the ENGINE MASTER to ON. Check that the fuel
transfer/shut-off valves are turned to position ON before switching the fuel pumps to ON. At the
pressure side the fuel pumps are connected through a bridge banjo into a flexible hose.
E. Fuel Cooler
Refer to Chapter 73-00 for information about the fuel cooler installation.
F. Fuel Pressure Pulsation Damper
A fuel pressure pulsation damper is installed in the fuel supply line firewall forward between the
bulkhead fitting and the engine driven high pressure fuel pump (LH and RH engine). See Figure 7.
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Trouble-Shooting
1. General
The table below lists the trouble you could have with the fuel distribution system. If you have the
trouble detailed in the Trouble column then read across to the Possible Cause column. Then do the
The airplane smells of fuel. Hose / pipe leaking. Examine all hoses and pipes.
Replace damaged or defective
components.
Loose connection. Examine all connections.

Tighten loose connections.
Examine all components.

Replace defective
components.
Component leaking.
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1. General
This Section gives you the Maintenance Practices for the fuel distribution system. The procedures are
limited to the removal/installation of the main components of the system.
2. Remove/Install a Fuel Transfer/Shut-Off Valve
A. Remove a Fuel Transfer/Shut-Off Valve
(2) Remove the access panels from the related Refer to Section 52-40.
engine nacelle, aft of the bulkhead that give
access to the fuel transfer/shut-off valve.
(3) Remove the engine cowlings for the related Refer to Section 71-10.
engine.
(4) Drain the fuel from the fuel distribution system: Use a suitable container. Use the drain
valve on the fuel sediment bowl.
the cockpit to the related engine until fuel
stops draining from the fuel sediment bowl
drain.

the cockpit to the CROSSFEED position
until fuel stops draining from the fuel
sediment bowl drain.

the cockpit to the SHUT-OFF position.
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(5) Disconnect these fuel connections at the fuel Refer to Figure 4. Put caps on all the
transfer/shut-off valve: open fuel connections.
S The fuel return from the engine.
(6) Remove the fuel transfer/shut-off valve from the

bulkhead:
S Remove the cotter pin from the universal

joint.

the valve to the mounting bracket.
S Remove the bonding wire.
S Move the valve clear of the mounting

bracket and pull the valve off the valve
S Move the fuel transfer/shut-off valve clear of

the engine nacelle.
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Fuel Selector Lever

Safety Guards
Fuel Selector
Rod Assy, RH
Fuel Selector
Fuel Selector
Rod Assy, LH Gearbox
LH details shown,
RH details similar
Fuel Selector
Lever, RH
Fuel Selector
Lever, LH Pin
Universal Joint
Connecting Rod Universal Joint
Pin
Fuel Transfer/Shut-Off Valve
Figure 4: Fuel Transfer/Shut-Off Valve Installation (if MÄM 42-600 is installed)
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B. Install a Fuel Transfer/Shut-Off Valve
lever in the cockpit is set to SHUT-OFF.
(2) Set the fuel transfer/shut-off valve to the shut-off

position.
(3) Install the fuel transfer/shut-off valve:
S Hold the valve in the shut-off position and

move the valve into position over the valve
S Install cotter pin (of universal joint).
S Locate the fuel transfer/shut-off valve on the

mounting bracket.

the fuel transfer/shut-off valve to the
bracket.
S Install the bonding wire. Seal the connection with bonding

lacquer.
(4) Connect these fuel connections at the fuel Make sure that all the caps are removed
transfer/shut-off valve: from the connections. Make sure that all
the fuel hoses are connected to the
correct transfer/shut-off valve
S The fuel return from the engine. connectors.
(5) Refuel the airplane. Refer to Section 12-10.
(6) Bleed both engine fuel distribution systems. Refer to Paragraph 7.
(7) Do a test for fuel leaks at these connections:
S The inlet from the related fuel tank.
S The inlet from the opposite fuel tank.
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(8) Do a test for correct operation of the fuel Refer to Paragraph 9.

transfer/shut-off valve.
(9) Install the access panels that you removed. Refer to Section 52-40.
(11) Do an engine ground run up. Make sure that the

fuel system operates correctly.
3. Remove/Install the Fuel Selector Gearbox
A. Remove the Fuel Selector Gearbox
Refer to Figure 2.
(1) Remove pilot’s and co-pilot’s seat. Refer to Section 25-10.
(2) Remove center console between pilot’s and

co-pilot’s seat.
(3) Remove knobs from the fuel selector levers.
(4) Remove fuel selector cover plate.
(5) Push LH fuel selector lever into ON position. Make sure that the fuel selector valve is
engaged in the ON position.
(6) Mark the ON position on the outer

connecting rod (splined tube, which connects
the fuel selector gearbox with the fuel
selector valve) directly at the bushing in the
fuselage wall.
(7) Pull fuel selector lever into CROSSFEED Make sure that the fuel selector valve is
position. engaged in the CROSSFEED position.
(8) Mark the CROSSFEED position on the outer

fuselage wall.
(9) Pull the fuel selector lever into the OFF Make sure that the fuel selector valve is
position. engaged in the OFF position.
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(10) Mark the OFF position on the outer

fuselage wall.
(11) Repeat steps 5 to 10 for the RH fuel selector

lever.
(12) Push both fuel selector levers into the ON Make sure that the fuel selector valves are
position. engaged in the ON position. This is the
necessary position for adjustment when the
new fuel selector valve will be installed.
(13) Remove crash element above the fuel

selector gearbox.
(14) Disconnect the fuel selector push rods (rods

between fuel selector levers and fuel selector
gearbox) directly at the fuel selector gear
box.
(15) Disconnect the LH inner connecting rod from Open the three bolts at the connection
(16) Disconnect the RH inner connecting rod from Open the three bolts at the connection
(17) Disconnect both inner connecting rods from Open the bolts at the universal joint.
the fuel selector gearbox.
(18) Remove the fuel selector gearbox. Open both bolts of the attachment brackets
and the two countersunk bolt which attach
the fuel selector gearbox to the main spar.
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B. Install the Fuel Selector Gearbox
Refer to Figure 4.
(1) Bring fuel selector gearbox in position

between the attachment brackets.
(2) Attach the fuel selector gearbox to both

brackets with the bolts on the bottom of the
gearbox.
(3) Attach the gearbox to the main spar.
(4) Connect the fuel selector push rods to the

fuel selector gearbox.
(5) Install fuel selector cover.
(6) Push both fuel selector levers fully forward Make sure that the length of the push rods
into the ON position. is proper to reach the most forward position
at the fuel selector gearbox.
If necessary adjust the length of the push

rods at the designated point. Old push rods
are not adjustable. If necessary, exchange
these push rods with new ones.

engaged in the ON position. For reference
use marking on the outer push rod directly
at the bushing in the fuselage wall.
(7) Exchange the drilled part of the connection For adjustment of the fuel selector valve
element between the connecting rods with a positions in accordance with the fuel
new undrilled part. selector lever positions new holes must be
drilled.
(8) Connect the inner connecting rods to the fuel

selector gearbox.
(9) Bring both parts of the LH connection

element between the connecting rods into
position.
(10) Mark the position of both parts of the

connection element in relation to each other.
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(11) Remove both parts of the connection

element.
(12) Drill holes in the undrilled part of the Use drilled part of the connection element
connection element. in the marked position as template.
(13) Install both parts of the connection element.
(14) Connect both parts of the connection

element with the three bolts.
(15) Repeat steps 9 to 14 for the RH connection

element.
(16) Do a functional test of the fuel selector valve. Pull fuel selector levers into all positions.
engaged in the respective positions using
the marking at the bushing in the fuselage
wall as reference.
(17) Bond new crash element onto the fuel Refer to Section 51-20.
selector gearbox using bonding paste.
(18) Install center console between pilot’s and

co-pilot’s seat.
(19) Install pilot’s and co-pilot’s seat. Refer to Section 25-10.
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Fitting
Screw
Plug Screw
Washer
Fuel Filter Cap
Fitting
Fuel Filter Body
Lock Wire
Rubber
Worm Drive Clamp
Fuel Filter Drain Adapter
Drain
Figure 5: Fuel Filter Assembly (if MÄM 42-600 is installed)
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4. Remove/Install the Fuel Filter Body
A. Remove the Fuel Filter Body
(2) Remove the fuel filter element: Refer to Figure 5.
S Drain the fuel from the fuel distribution From the fuel sediment bowl drain. Use
system. a suitable container to catch spilt fluid.
S Remove the safety wire from the filter bowl.
S Unscrew the filter body together with the

drain valve assembly from the filter
assembly.
S Unscrew the drain valve and the drain valve

adapter from the fuel filter body.
B. Install the Fuel Filter Body
(1) Install the fuel filter drain adapter and the drain Refer to Figure 5.
valve into the new filter body. Use Loctite 243 on adapter to fuel filter
body connection.
(2) Install the filter body assembly into the fuel filter Make sure that the integral sealings at
cap. the new fuel filter body are not
damaged.
(3) Secure the filter body assembly via the drain

valve to the filter assembly with lockwire.
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fuel tank.

related tank.
S Examine the filter assembly for leaks.
5. Remove/Install the Fuel Pre-Filters
A. Remove the Fuel Pre-Filters

driven fuel pumps.
(3) Remove the fuel pre-filters: Refer to Figure 8.
S Drain the fuel from the fuel distribution From the fuel filter drain. Use a suitable
system. container to catch spilt fluid.
S Disconnect the fuel hose on the pre-filter

side.
S Remove the safety wire from the hollow

bolts next to the pre-filters.
S Remove the hollow bolts and the solid

bridge next to the pre-filters.
S Remove the pre-filter assemblies. The assemblies will contain fuel!
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B. Clean the Pre-Filters
(1) Disassemble the pre-filters. Refer to Figure 6.
(2) Flush the filter mesh with clean fuel.
(3) Replace the O-ring.
(4) Assemble the pre-filters. Torque: 15 ± 2 Nm (11.1 ± 1.5 lbf.ft.).
C. Install the Fuel Pre-Filters
(1) Install the pre-filters: Refer to Figure 8.
S Replace all aluminium washers of the fuel

pump assembly on the pre-filter side.
S Install the pre-filter assembly.
S Install the solid bridge and the hollow bolts. Torque: 18 ± 2 Nm (13.3 ± 1.5 lbf.ft.).
S Install the T-fitting, bypass valve and bypass

fuel line.
S Connect the fuel hose on the pre-filter side.
S Secure the hollow bolts with safety wire.

fuel tank.

related tank.

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Fuel Filter Casing (Female)

OUT
O-Ring
Filter Mesh
Fuel Filter Casing (Male)
Retaining Ring
IN
Figure 6: Fuel Pre-Filter Assembly (if MÄM 42-600 is installed)
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6. Remove/Replace/Install the Fuel Pressure Pulsation Damper
A. Remove the Fuel Pressure Pulsation Damper (LH or RH Engine)

1. Make sure that the engine is safe:
2. Remove the upper cowlings.
3. Remove the P-clamp which positions the fuel

pressure pulsation damper installation.
4. Remove the lock wires at the lines on the fuel

5. Disconnect the two fuel lines which are

connected to the fuel pressure pulsation damper
housing.
6. Remove the fuel pulsation damper.
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Pulsation Damper
Element
Damper Housing
Damper Housing
O-Rings
Note: Installation Direction as shown
O-Rings
Pulsating Damper Assy
Fuel Supply Line
Engine Driven High

Pressure Fuel Pump
Fuel Return Line
Firewall
Figure 7: Fuel System Components Firewall Forward LH and RH Engine

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B. Replace the Fuel Pressure Pulsation Damper
1. Remove the wire locking of the fuel pressure

pulsation damper housing.
2. Open the fuel pressure pulsation damper housing

by turning the cover counterclockwise.
3. Remove and discard the fuel pressure pulsation

damper and the four O-rings.
4. Clean the inside of the fuel pressure pulsation Flush with fuel approved for the
damper housing. airplane.
5. Install the four new O-rings.
6. Apply 09-25300 ‘Fuelube EZTurn 1LB’ to the

outside thread and sealing surface of the fuel
7. Install the new fuel pressure pulsation damper in Refer to Figure 7.

the housing. Watch out for the installation
direction of the fuel pressure pulsation damper in
the housing.
8. Tighten the fuel pressure pulsation damper Torque 80 ± 4 Nm (59.0 ± 2.9 lbf.ft).
housing.
9. Secure the fuel pressure pulsation damper

housing with locking wire.
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C. Install the Fuel Pressure Pulsation Damper Housing Assy
1. Flush the fuel pressure pulsation damper assy

with fuel approved for the airplane.
2. Connect the fuel pressure pulsation damper

housing to the fuel supply lines and secure with
locking wire. Watch out for the flow direction
(arrow).
3. Install the P-clamp and mount the fuel pressure

pulsation damper assy to the engine.
4. Install the upper cowlings.
5. Conduct an engine ground run.
6. Inspect the airplane for fuel leakage.
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7. Remove/Install the Low Pressure Fuel Pumps
A. Remove/Replace the Low Pressure Fuel Pumps

driven fuel pumps.
(3) Remove the low pressure fuel pumps: Refer to Figure 8.

assembly.
S Remove the bypass valve, the bypass fuel

line and the T-fitting.


bracket.
S Remove the hollow bolts, the solid bridge,

and the two pre-filters from the bottom of the
fuel pump assembly.
S Remove the safety wires from plug nuts.
S Remove the two plug nuts, the solid bridge

and two check valves from the top of the
fuel pump assembly.
(4) Replace fuel pumps and inspect / clean pre- Refer to Chapter 05.
filters.
(5) Replace aluminium washers.
(6) Check hollow bolts and bridges for damage. Replace damaged items!
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B. Install Low Pressure Fuel Pumps
(1) Install the low pressure fuel pump assembly: Refer to Figure 8.
S Install the aluminum washers (new), the two Hollow bolts torque:
pre-filters, the solid bridge, and the two 18 ± 2 Nm (13.3 ± 1.5 lbf.ft.)
hollow bolts.
S Install the washers, the two check valves, Plug nuts torque:
the solid bridge, and the two plug nuts. 18 ± 2 Nm (13.3 ± 1.5 lbf.ft.)
S Secure plug nuts and hollow bolts with

safety wire.
S Install the T-fitting, the bypass valve and the

bypass fuel line.

bracket.
S Connect the fuel hoses to the bypass valve

and the T-fitting.

fuel tank.

related tank.

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Plug Nut Check Valve

Worm Drive Clamp
Electrical Fuel Pump
Solid Bridge M12 Worm Drive Clamp
Sealing Ring
Fuel Filter
Screw
Washer
Screw Hollow Bolt
Washer
Fuel Pump Bracket Sealing
Solid Bridge M14 Ring
Fuel Hose
Bypass Valve
OUT
Lock Nut
Bypass Hose
Fuel Pump T-Fitting
Upper Plate LH
Lock Nut
Fuel Hose IN
Connector Bracket
Assy Fuel Pump Lower Plate LH
Figure 8: Fuel Pumps Assembly (if MÄM 42-600 is installed)
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8. Test the Solenoid Valve/Check Valve in the Fuel Transfer Line (If Auxiliary Tanks Installed)
CAUTION: YOU MUST REPLACE THE CHECK VALVE IF THE TEST FAILS.
(1) Make sure that there is no fuel in the related

main fuel tank.
(2) Top off the auxiliary fuel tank.
(3) Disconnect the fuel transfer line from the check Put a cap on the fuel line.
valve.
(4) Check for any leakage from the check valve. If leakage is observed: replace solenoid
valve and check valve.
(5) Disconnect cap from the check valve and

reconnect the fuel transfer line to the check
valve.
(6) Check for leakage while operating the auxiliary If leakage is observed replace relevant
fuel pump. fittings and hoses.
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9. Test the Crossfeed Position of a Fuel Selector Valve
(1) Do the preparation for an engine test. Refer to Section 71-00.
(2) Start the related engine. On the side of the fuel selector valve
that you want to test.

in the ON position.
(3) Set the fuel selector valve that you want to test
in the CROSSFEED position.
(4) Let the engine idle for 1 minute. Refer to Section 71-00.
(5) Set the related power lever to 100% after Keep the engine temperature in view.
engine warm up and keep this position for Do not continue the test if the engine
1 minute. temperature rises too high.
(6) Make sure that the engine does not stop. If the engine stops, then the
CROSSFEED system is defective.
Correct the fault and do the test again.
(7) Shut down the engine. Refer to Section 71-00.
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10. Remove/Install an Inline Filter
A. Remove an Inline Filter
(1) Make sure that the auxiliary fuel tank is empty. Defuel and drain the auxiliary fuel tank.



(3) Disconnect the fuel transfer line from the inline

fuel filter.
(4) Remove the inline filter from the auxiliary fuel

pump.
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B. Install an Inline Filter
(1) Install the fuel filter to the auxiliary fuel pump

inlet.
(2) Connect the fuel transfer line to the auxiliary fuel

filter.
(3) Refuel the auxiliary fuel tank. Fill more than 2 US gal (7.6 l) of fuel into
the auxiliary tank.
(4) Perform a test of the auxiliary fuel transfer Refer to Paragraph 11.
system.

engine nacelle:

nacelle.

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11. Test the Auxiliary Fuel Transfer System
A. Equipment
Ground power supply. 1 -
Stopwatch. 1 Commercial.
B. Procedure
CAUTION: YOU MUST REPLACE THE INLINE FILTER IF THE TEST FAILS.
(1) Connect the airplane to ground power.
(2) Defuel the auxiliary tank using the auxiliary fuel On the side of the auxiliary fuel system
transfer pump. that you want to test.
Make sure that the corresponding main

tank is empty enough to hold the
auxiliary fuel.
The auxiliary fuel pump must stop due to

the auxiliary tank empty switch.
(3) Fill 2 US gal (7.6 l) of fuel into the auxiliary fuel

tank.
(4) Measure transfer time for transferring the The auxiliary fuel pump must stop due to
2 US gal (7.6 l) of fuel from the auxiliary tank the auxiliary tank empty switch. Measure
into the main tank. time from switching on the fuel pump
until the fuel transfer stops due to the
auxiliary tank empty switch.
The transfer time must not be more than

4 min.
Check if the corresponding main tank

fuel quantity indication increases.
(5) Repeat steps 2 thru 4 for the other auxiliary fuel

transfer system.
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Section 28-40
Fuel Indicating
1. General
This Section tells you about the fuel indicating systems of the DA 42 NG. Refer to Section 28-00 for
the general data on the fuel system.
2. Description
Figure 1 shows the main components of the fuel indicating systems. The DA 42 NG has these fuel
system indications which are displayed on the integrated cockpit system (ICS) display.
) Fuel quantity. Fuel level probes are installed in the inboard and outboard fuel chambers of both the
left and right main fuel tank assemblies.
) Fuel temperature. Fuel temperature probes are installed on the inboard end of each inboard fuel
chamber.
) Fuel low-level. Fuel low-level sensors are installed on the inboard end of each inboard fuel
chamber.
The fuel quantity in the auxiliary fuel tanks (optional equipment, OÄM 42-056) is not indicated.
3. Operation
A. Fuel Quantity
As the fuel level in the fuel tanks decreases, the area of the fuel probes which are ‘wetted’ with fuel
also decreases. The amount of ‘wetted’ area of each tank probe is converted into electrical signals
which set the fuel quantity indication which is displayed on the ICS. The fuel quantity indication
shows the amount of fuel in the left fuel tank and the right fuel tank. The display shows the fuel
quantities in US gallons.
Electrical cables connect the fuel probes to the ICS. Refer to Section 31-40 for more data about
the ICS.
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B. Fuel Temperature
The electrical resistance of the fuel temperature probes change with temperature. This change of
electrical resistance is used to set the fuel temperature indications shown on the ICS. Electrical
cables connect the fuel temperature probes to the ICS.
The display shows the temperature of the fuel in the left main fuel tank and in the right main fuel
tank. The temperature is given in °C.
C. Fuel Low-Level
The fuel low-level sensors are float-type switches. When the fuel in the fuel tank falls to 11 to
15 liter (3 to 4 US gal) the float operates a micro-switch. The micro-switch operates an electrical
circuit which gives a L/R FUEL LOW caution on the ICS.
Electrical cables connect the fuel low-level switches to the ICS. Refer to Section 31-40 for more
data about the ICS.
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B
A
Outboard Fuel Tank
Fuel Contents Probe

VIEW ON INBOARD END OF LEFT OUTBOARD FUEL TANK
LH Tank Shown,
RH Tank Similar
Low Fuel Switch
Inboard Fuel Tank
Fuel Temperature Sensor
Fuel Contents Probe
VIEW ON INBOARD END OF LEFT INBOARD FUEL TANK
Figure 1: Fuel Indicating System Components
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Trouble-Shooting
1. General
The table below lists the defects you could have with the fuel indicating systems of the DA 42 NG. If
you have the trouble detailed in the Trouble column read across to the Possible Cause column. Then
do the repair given in the Repair column.
Fuel quantity for one tank Fuel probe unit in fuel tank Defuel/refuel the related fuel
incorrect, other tank reads defective/contaminated. tank to flush the fuel probe.
correctly. Rock the wings during
defueling several times. This
will flush the water out of the
fuel quantity probe. Repeat
defueling / refueling until the
fuel quantity probe indicates
correct values. If the indication
is still incorrect after the third
attempt, replace the fuel
probe(s).
Do a test of the fuel quantity

Fuel quantity indicating system indicating system wiring. Refer
wiring defective. to Chapter 92-00 for the wiring
diagrams.
Fuel quantity indication on both Fuel quantity display on ICS Refer to the ICS
tanks incorrect. defective. manufacturer’s manual.
Fuel temperature indication in Temperature probe defective. Replace the temperature probe
one tank incorrect. in the related fuel tank.
Fuel temperature wiring Do a test of the fuel

defective. temperature indicating system
wiring. Refer to Chapter 92-00
for the wiring diagrams.
Fuel temperature indication in Fuel temperature display on Refer to the ICS

both fuel tanks incorrect. ICS defective. manufacturer’s manual.
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Fuel low level warning fails to Fuel low level switch defective. Replace the related fuel low-
operate in one fuel tank. level switch.
Fuel low level warning wiring Do a test of the fuel low-level

defective. warning system wiring. Refer
to Chapter 92-00 for the wiring
diagrams
Fuel low-level warning fails to Fuel low level caution on ICS Refer to the ICS
operate in both fuel tanks. defective. manufacturer’s manual.
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1. General
The Maintenance Practices in this Section tell you how to replace a fuel tank probe, a fuel tank
temperature sensor and a fuel tank low-level warning switch.
Refer to Section 31-40 for more data about the related indicator.
2. Remove/Install a Fuel Quantity Probe
The inboard and outboard chambers of each main fuel tank assembly has a fuel quantity probe.
A. Remove a Fuel Quantity Probe
(1) Remove the outer wing section that has the fuel Refer to Section 57-10.
quantity probe(s) that you will remove, and
support the wing on trestles.
(2) Remove the access panel from the wing root

rib.
(3) Remove the fuel tank assembly from the outer Refer to Section 28-10.
wing section.
(4) Remove the fuel quantity probe from it

mounting:
S Remove the lockwire from the probe.
S Unscrew the probe from the fuel tank.
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B. Install a Fuel Quantity Probe
(1) Install the fuel quantity probe into the fuel

chamber:
S Apply sealant to the thread of the fuel Use Loctite 243 similar.
quantity probe.
S Install a new O-ring seal.

Make sure that the fuel quantity probe is
S Carefully move the probe into position into
correctly located.
the guide tube in the fuel chamber and
engage the screw thread.
S Turn the probe clockwise, by hand, until the

fuel quantity probe is fully engaged in its
mount.
S Tighten the fuel quantity probe until the

O-ring seals.
(2) Install the fuel tank assembly into the outer wing Refer to Section 28-10.
section.
(3) Install the outer wing section onto the airplane. Refer to Section 57-10.
(4) Refuel the airplane and examine the fuel

quantity probe installation for leaks.
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3. Remove/Install a Fuel Temperature Sensor
A. Remove a Fuel Temperature Sensor
(1) Remove the outer wing section that has the fuel Refer to Section 57-10.
temperature sensor that you will remove, and
support the wing on trestles.

rib:

attach the access panel to the root rib.
S Move the access panel clear of the root rib.
(3) Unscrew the temperature sensor from the Install a blank on the open tank
mounting boss and pull the sensor clear of the connector.
tank.
(4) Remove and discard the seal from the sensor.
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B. Install a Fuel Temperature Sensor
(1) Install a new seal onto the temperature sensor.
(2) Screw the temperature sensor into the mounting Remove the blanking cap. Make sure
boss on the fuel tank. that the seal is seated correctly.
(3) Install the access panel in the wing root rib:

studs in the wing root rib.

the access panel to the wing root rib.
(4) Install the wing onto the airplane. Refer to Section 57-10.
(5) Refuel/transfer fuel into the fuel tank assembly

for which you installed the temperature sensor.
(6) Bleed the fuel system. Refer to Section 28-20.
(7) Do a test for fuel leaks at the temperature

sensor that you replaced.
(8) Do a test for the correct operation of the related

fuel temperature sensor:
S Set the ELECT. MASTER switch to ON. Monitor the multi function display screen
of the ICS. The fuel temperature
indications must both indicate the
ambient temperature.
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4. Remove/Install a Fuel Low-Level Sensor
A. Remove a Fuel Low-Level Sensor
(1) Defuel the main fuel tank related to the fuel low Refer to Section 12-10.
level switch that will be removed.
(2) Remove the wing. Refer to Section 57-10.

rib:

attach the access panel to the root rib.
S Move the access panel clear of the root rib.
(4) Unscrew the fuel low-level sensor from the inner

tank chamber.
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B. Install a Fuel Low-Level Sensor
(1) Screw the low-level sensor into the inner tank Make sure the arrow on the wrench face
chamber. Use Loctite 243. of the low-level sensor is pointing
DOWN.
(2) Install the access panel in the wing root rib:

studs in the wing root rib.

the access panel to the wing root rib.
(3) Install the wing. Refer to Section 57-10.

for which you installed the low-level sensor.
Monitor the ICS alert panel and:
S Note the fuel level indication at which the If the L/R FUEL LOW caution is on.
related L/R FUEL LOW caution goes out.
S Stop the refuel/transfer.
S Transfer fuel out from the related fuel tank.
S Note the fuel level indication at which the The level at which the caution comes on
related L/R FUEL LOW caution comes ON. must be at the level given in the Airplane
Flight Manual.
(5) Make sure there are no fuel leaks, especially

around the replaced fuel low-level sensor.
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5. Remove/Install a Fuel High-Level Shut-Off Sensor
Obey the safety precautions for fuel at all times
A. Remove a Fuel High-Level Shut-Off Sensor
(1) Defuel the main fuel tank related to the fuel Refer to Section 12-10.
high-level shut-off sensor that will be removed.
(2) Remove the wing. Refer to Section 57-10.
(3) Remove the main fuel tank assembly. Refer to Section 28-10.
(4) Unscrew the fuel high-level shut-off sensor from

the outer tank chamber.
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B. Install a Fuel High-Level Shut-Sensor
(1) Install a new seal onto the fuel high-level

shut-off sensor.
(2) Screw the high-level shut-off sensor into the Remove the blanking cap. Make sure
mounting boss on the fuel tank. that the seal is seated correctly and that
the arrow on the wrench face of the
high-level shut-off sensor is pointing
DOWN.
(3) Secure the high-level shut-off sensor with

lock-wire.
(4) Install the main fuel tank assembly. Refer to Section 28-10.
(5) Install the wing onto the airplane. Refer to Section 57-10.
(6) Bleed the fuel system. If necessary refuel or Refer to Section 28-20.
transfer a small amount of fuel into both fuel
tanks.

for which you installed the low-level sensor.
Monitor the ICS alert panel and:
S Note the fuel level indication at which the If the L/R FUEL LOW caution is on.
related L/R FUEL LOW caution goes out.
S Stop the refuel/transfer.
S Transfer fuel out from the related fuel tank.
S Note the fuel level indication at which the The level at which the caution comes on
related L/R FUEL LOW caution comes ON. must be at the level given in the Airplane
Flight Manual.
(8) Do a test for fuel leaks. Specially around the

fuel high-level shut-off sensor that you replaced.
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CHAPTER 29
HYDRAULIC POWER
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TABLE OF CONTENTS
CHAPTER 29
HYDRAULIC POWER
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 29-10
Main Hydraulic Power
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Check the Hydraulic Fluid Level of the Hydraulic System . . . . . . . . . . . . . . . . . 201
2. Fluid Change of the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3. Depressurize the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4. Bleed the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5. Drain Fluid from the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
6. Remove/Install the Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
7. Remove/Install the Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
8. Remove/Install the Hydraulic Supply and Control Assembly . . . . . . . . . . . . . . . 215
9. Remove/Install Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
10. First Fill/Replenishment of the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . 222
11. Tests of the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
12. Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
13. Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
14. Remove/Install/Disassemble/Assemble Hydraulic Control Block . . . . . . . . . . . . 249
15. Bleed/Remove/Install the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
16. Check the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
17. Charge the Hydraulic Accumulator with Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . 260
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CHAPTER 29
HYDRAULIC POWER
1. General
This Chapter tells you about the hydraulic system of the DA 42 NG. It gives you the system description.
It also gives you the trouble-shooting data and tells you how to remove and install the main components
of the hydraulic system.
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Section 29-10
Main Hydraulic Power
1. General
Use these procedures to maintain the hydraulic system of the DA 42 NG. The Trouble-Shooting section
provides information about possible causes and repair procedures.
2. Description
The hydraulic main unit contains all components which are necessary to produce the hydraulic power
for the DA 42 NG. It consists of the hydraulic pump, the hydraulic fluid tank, the hydraulic main control
block and the hydraulic accumulator.
The hydraulic main unit is shown in Figure 1.
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Trouble-Shooting
1. General
Trouble Possible Cause Repaired Items/References
Landing gear is not retracting. Dump valve is not closed Close the dump valve. Tighten
(hydraulic short circuit). the hexagon socket with
6 - 10 Nm (4.4 - 7.4 lbf.ft.).
Tighten counter nut with 8 Nm
(5.9 lbf.ft.).
See Figure 1.
CAUTION: DO NOT OPERATE THE HYDRAULIC MAIN PUMP WITH LOW FLUID
LEVEL IN THE HYDRAULIC PUMP.
Fill quantity of hydraulic Check the fill quantity of the

reservoir is too low. Pump hydraulic reservoir. Replenish
draws air and runs with high the hydraulic reservoir with
speed. fluid. Refer to Section 29-10
(check reason of fluid leakage).
Bottom solenoid valve is not

switching.
S No voltage supply on the Check fuses, power supply and

solenoid valve. cables.
S Solenoid valve does not Replace solenoid valve. Refer

switch, power is switched to Section 29-10.
on and off.
Solenoid valves are not fully High rate of re-pump cycles or

closing. permanent operation of the
pump.
Leakage caused by dirt or low Check power supply and

supply voltage. solenoid valves.
Replace solenoid valve. Refer

to Section 29-10.
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Hydraulic pump is not working

(landing gear is moving until
the accumulator is empty).
S Relay is damaged. Check if Replace the relay.

relay is switching correctly.
S Landing gear switch Replace landing gear switch.

damaged. Check fuses,
electric power supply and
cables.
S Hydraulic pump defect. Check hydraulic pump and

replace if damaged.
Landing gear is retracting too Dump valve is not fully closed Close dump valve. Tighten
slow. (high re-pump cycles). hexagon socket with 6 - 10 Nm
(4.4 - 7.4 lbf.ft.). Tighten
counter nut with 8 Nm
(5.9 lbf.ft.).
See Figure 1.
Poor motor/pump performance.
S Power supply low. Check power supply.
Top solenoid valve is switched

ON (i.e. differential pressure
mode is OFF).
S Electrical fault. Check cables, connectors and

power supply of the solenoid
valve.
S Mechanical fault. Replace solenoid valve or main

control block. Refer to Section
29-10.
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pump.


to Section 29-10.
Landing gear is not fully Dump valve is not fully closed Close dump valve. Tighten
retracting. (high re-pump cycles). hexagon socket with 6 - 10 Nm
(4.4 - 7.4 lbf.ft.). Tighten
(5.9 lbf.ft.).
See Figure 1.
Pressure limitation valve is not Check pressure limitation

working properly. Wrong valve. Refer to Section 29-10.
system pressure.
Replace pressure limitation
valve. Refer to Section 29-10.
Level of hydraulic fluid in the Check the level of the hydraulic

hydraulic reservoir is too low. reservoir. Replenish hydraulic
Pump draws air and runs with reservoir, if necessary. Refer to
high speed. Section 29-10 (check reason of
fluid leakage).
Landing gear is not extending. Bottom solenoid valve is not

switching.
S Landing gear switch defect. Check power supply and

cables.
S Mechanical fault. Replace solenoid valves. Refer

to Section 29-10.
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Landing gear is extending slow Dump valve is not fully closed Open up the dump valve fully,
and erratic. (high re-pump cycles). then close the dump valve.
Tighten hexagon socket with
6 - 10 Nm (4.4 - 7.4 lbf.ft.).
Tighten counter nut with 8 Nm
(5.9 lbf.ft.).
See Figure 1.
Motor/Pump is not pumping

enough hydraulic fluid.
S Power supply low. Check power supply.
Hydraulic pump does not Dump valve is not fully closed Close dump valve. Tighten
switch off after (high re-pump cycles). hexagon socket with 6 - 10 Nm
extending/retracting the (4.4 - 7.4 lbf.ft.). Tighten
landing gear. counter nut with 8 Nm
(5.9 lbf.ft.).
See Figure 1.

pump.


to Section 29-10.
Pump pressure switch is Check switching points (refer to

damaged. pump pressure switch
operation test).
Replace pump pressure switch.

system pressure.
valve. Refer to Section 29-10.
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Charging time of the Dump valve is not fully closed Close dump valve. Tighten
completely empty accumulator (high re-pump cycles). hexagon socket with 6 - 10 Nm
is too long (more than 25 sec). (4.4 - 7.4 lbf.ft.). Tighten
(5.9 lbf.ft.).
See Figure 1.
Pre-fill pressure in hydraulic Check accumulator pressure.

accumulator too low. Refer to Section 29-10.
Charge accumulator to
appropriate pressure.

system pressure.
valve.
Leakage of the emergency Check Bowden cables.

extension block. Occurs only
Replace the emergency
when retracting the landing
extension block. Refer to
gear.
Section 29-10.
Re-pump time of the pump is Pre-fill pressure in hydraulic Check accumulator pressure.
too short (less than 2 sec). accumulator too low. Refer to Section 29-10.
Pump pressure switch is Check switching points (refer to

damaged. pump pressure switch
operation test).
Replace pump pressure switch.

Refer to Section 29 -10.
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Re-pump cycles are too high Dump valve is not fully closed Close dump valve. Tighten
(more than 1 cycle per (high re-pump cycles). hexagon socket with 6 - 10 Nm
45 min). (4.4 - 7.4 lbf.ft.). Tighten
(5.9 lbf.ft.).
See Figure 1.
Pre-fill pressure in hydraulic Check accumulator pressure.

accumulator is too low. Refer to Section 29-10.

pump.


to Section 29-10.
Emergency extension slow or High stream resistance in the Check hydraulic hoses for
not completed. hydraulic system. damage.
Note: Emergency extension does not fully extend on the ground because of missing
aerodynamic forces. Pull the gear backwards to extend it fully!
Pressure in the hydraulic Open FILL plug on the

reservoir. hydraulic reservoir to check if
pressurized.
Send reservoir to vendor.
High friction on landing gear Send hydraulic actuators to

legs and/or actuators. vendor (Rev. B of main gear
and Rev. A of nose gear have
Remove hydraulic actuators
friction optimized piston
and move the landing gear
sealings). Refer to Section
manually.
32-20.
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1. Check the Hydraulic Fluid Level of the Hydraulic System
(1) Get access to the hydraulic system:
S Fold the rear passenger seat-backs forward. Refer to Section 25-10.
S Remove the rear baggage compartment Refer to Section 25-60.

lower access panel.
(2) Charge the hydraulic accumulator:
S The hydraulic pump must operate until the

system pressure stabilizes.
S The hydraulic pump must stop operating. Approx. 16 (+4/-3) sec with a
completely empty accumulator.
(3) Check the fluid level on the hydraulic reservoir:
S The accumulator must be fully charged and

the landing gear has to be fully extended.
S The airplane must be even on the ground and

the fluid level should be in the middle of the
inspection glass.
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Figure 1: Hydraulic Supply and Control Assembly
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2. Fluid Change of the Hydraulic System
A. Equipment
Pump (for emptying the reservoir). 1 Commercial.
B. Fluid Change of the Hydraulic System
WARNING: TAKE PRECAUTIONS BY SECURING THE AREA AROUND THE

AIRPLANE BEFORE YOU PERFORM MAINTENANCE ON THE
LANDING GEAR. THE LANDING GEAR RETRACTION SYSTEM CAN
CAUSE SERIOUS INJURY TO PERSONS IF OPERATED
ACCIDENTALLY.
WARNING: DO NOT GET HYDRAULIC FLUID ON YOU. HYDRAULIC FLUID CAN

CAUSE SKIN DISEASE. IT CAN ALSO DAMAGE CLOTHING.
CAUTION: CLEAN OFF SPILT HYDRAULIC FLUID IMMEDIATELY. HYDRAULIC

FLUID CAN DAMAGE THE AIRPLANE STRUCTURE. IT CAN ALSO
REMOVE THE PAINT FROM SOME COMPONENTS.
CAUTION: DO NOT OPERATE THE HYDRAULIC PUMP WITH LOW FLUID LEVEL.
THE PUMP WILL HEAT UP AND GETS DAMAGED.
Details Steps/Work Items Key Items/References
(1) Connect an external power supply to the Refer to Section 24-40.

airplane.
and rear fuselage trestles into position to support
the airplane.
(3) Retract the landing gear. Refer to Section 32-30.
(4) Pull the GEAR circuit breaker. Right side of instrument panel.
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Details Steps/Work Items Key Items/References
(5) Extend the landing gear with the emergency

extension switch.
(6) Set the landing gear handle down.
(7) Set the emergency gear lever up.
S Fold the rear passenger seat backs forward. Refer to Section 25-10.

lower access panel.
(9) Remove the fluid from the hydraulic reservoir

using a pump to suck it out.
(10) Replace the high pressure filter. Refer to Section 29-10.
(11) Maintain the hydraulic reservoir filter. Refer to Section 29-10.
(12) First fill / replenish the hydraulic system. Refer to Section 29-10.
(13) Bleed the accumulator. Refer to Section 29-10.
(14) Bleed the hydraulic system. Refer to Section 29-10.
(15) Reset the GEAR circuit breaker. Right side of instrument panel.
(16) Do the normal operation test for the hydraulic Refer to Section 29-10.
system.
(17) Replenish the hydraulic system, if necessary. Refer to Section 29-10.
(18) Check level of the hydraulic reservoir. Refer to Section 29-10.
(19) Repeat the last two steps until the level of the
hydraulic reservoir is correct.
(20) Lower the airplane with the jacks. Make sure that the area around the
airplane is clear.
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C. Fluid Change of the Hydraulic System from Aero Shell Fluid 41 to AMG-10
(1) Repeat the Fluid Change of the Hydraulic Refer to Paragraph B.

System procedure 3 times.
(2) Apply the hydraulic fluid placard and mark the Refer to Figure 2.
used fluid. Mark hydraulic fluid type by punching.
Hydraulic
Reservoir
Hydraulic Fluid
AeroShell Fluid 41
AMG-10
Figure 2: Position of the Hydraulic Fluid Placard
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3. Depressurize the Hydraulic System
(1) Pull the GEAR circuit-breaker. Right side of instrument panel.
(2) Remove the protection cap from the If the hydraulic system is an old revision
MiniMess 1215 plug. without MiniMess 1215 contact the
vendor to get it installed.
(3) Install a test manometer on the MiniMess 1215 Located on the hydraulic control block.
plug. The normal pressure should be between Refer to Figure 4.
95 and 120 bar (1378 to 1740 PSI).
(4) Operate the dump valve:
S Remove the lock wire from the dump valve.
S Loosen the counter nut. Wrench size 19 mm.
S Loosen the hexagon socket to open the dump Wrench size 1/4 in.
valve.
S After emptying wait 10 to 15 min until the

accumulator is thermally balanced.
(5) Operate the pressure button on the upper See Figure 4.

solenoid valve. Located on the top of the
Use a little metal pin or ball pen to
hydraulic control block.
operate the button.
(6) Check the drop in pressure on the manometer. There should be no pressure left.
(7) Close the dump valve:
S Tighten the hexagon socket to close the 6 - 10 Nm (4.4 - 7.4 lbf.ft.),

dump valve. wrench size 1/4 in.
S Tighten the counter nut.
S Install the lock wire onto the dump valve. 8 Nm (5.9 lbf.ft.), wrench size 19 mm.
(8) Disconnect the test manometer from the

MiniMess 1215 plug.
(9) Install the protection cap onto the

MiniMess 1215 plug.
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4. Bleed the Hydraulic System
A. Equipment
B. Bleed the Hydraulic System
Detail Steps/Work Items Key Items/Reference

ACCIDENTALLY.
CAUTION: MAKE SURE THAT THE AREA AROUND THE AIRPLANE IS CLEAR.
IF THE LANDING GEAR HITS AN OBJECT THE LANDING GEAR CAN
BE DAMAGED.
(1) Pull the GEAR circuit-breaker. Right side of instrument panel
the airplane.

airplane.
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Detail Steps/Work Items Key Items/Reference
(4) Extend and retract the landing gear to bleed the Refer to Paragraph 7 in Chapter 32-30.
system: (Landing Gear Extension and
Retraction Test).
S Retract and extend the landing gear 2 to Check the times of extending and
4 times with short breaks in between. retracting the landing gear.
S Between the extension/retraction the dump Refer to Section 29-10.

valve should be operated 3 to 4 times to
release possible air pockets.
(5) Operate the emergency extension of the landing Refer to Section 29-10.
gear (repeat this step 1 to 2 times).
(6) Move the wing and rear fuselage trestles clear of

the airplane.
airplane is clear.
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5. Drain Fluid from the Hydraulic System

CAUTION:: CLEAN OFF SPILT HYDRAULIC FLUID IMMEDIATELY. HYDRAULIC

CAUTION: DO NOT OPERATE THE HYDRAULIC PUMP WITH LOW FLUID LEVEL.
THE PUMP WILL HEAT UP AND GETS DAMAGED.
(2) Getting access to the hydraulic system:

lower access panel.
(3) Prepare the drain hose: Use a drain hose which can be
connected to the MiniMess 1215 plug
S Put a container under the drain hose to
Refer to Figure 4.
collect spilt hydraulic fluid.
(4) Install the drain hose: The MiniMess 1215 plug is situated on
the hydraulic control block.
S Remove the protection cap from the
MiniMess 1215 plug. Refer to Figure 4.
S Install the drain hose onto the plug. If your hydraulic system is an old
revision without the MiniMess 1215 plug
contact the vendor to get it installed.
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(6) Drain hydraulic fluid from the hydraulic system: For most Maintenance Practices it's the
best to drain approx. ½ liter of hydraulic
S Turn the ELECT. MASTER switch to ON.
fluid from the fully filled hydraulic
S The hydraulic pump starts pumping and system.
drains hydraulic fluid into the container.
S Turn the ELECT. MASTER switch to OFF.
(7) Remove the drain hose:
S Remove the drain hose from the

MiniMess 1215 plug.
S Install the protection cap back onto the plug.
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6. Remove/Install the Relay
Note: To change the relay on an old hydraulic system contact the customer service of
Diamond Aircraft.

lower access panel.
(3) Disconnect all electric connectors from the relay. Remember how the cables where
connected to the relay.
(4) Remove the 2 bolts which hold the relay onto the
mounting plate.
(5) Install the new relay with two bolts onto the
hydraulic panel.
(6) Reconnect all electric connectors with the relay.
system.
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7. Remove/Install the Hydraulic Reservoir


A. Remove Hydraulic Reservoir

lower access panel.
(2) Depressurize the hydraulic system. Refer to Section 29-10
(3) Remove the hydraulic supply and control Refer to Section 32-30.
assembly.
(4) Draining the hydraulic tank:
S Remove the fill port to put a drain hose into

the hydraulic tank and use a commercial
pump to suck the fluid.
S Remove the fluid from the hydraulic reservoir

until the tank is completely empty.
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(5) Remove the hydraulic reservoir: Refer to Figure 3.
S Remove the intake line and the return line

from the reservoir.
S Put caps onto the open ends of the lines and

the end fittings of the reservoir.
S Remove the 4 bolts from the clamp which

secure the hydraulic tank.
S Then move the tank clear from the hydraulic

system.
B. Install the Hydraulic Reservoir
(1) Install the hydraulic reservoir:
S Move the reservoir into position.
S Install the 4 bolts onto the clamp to secure

the hydraulic tank.
S Install the intake line and the return line onto

the reservoir.
(2) Install the hydraulic supply and control assembly. Refer to Section 32-30.
(3) Replenish the hydraulic reservoir with hydraulic Refer to Section 29-10.
fluid.
system.
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Drain Hose
Filter Fitting
Lid
Fill Port
Hydraulic
Reservoir
Drain Port
Figure 3: DA 42 NG Hydraulic Reservoir Assembly
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8. Remove/Install the Hydraulic Supply and Control Assembly
A. Equipment
WARNING: DO NOT GET HYDRAULIC FLUID ON YOUR SKIN OR YOUR CLOTHES.

HYDRAULIC FLUID CAN CAUSE SKIN DISEASE.
CAUTION: CLEAN UP SPILT HYDRAULIC FLUID IMMEDIATELY. HYDRAULIC

FLUID CAN CAUSE DAMAGE TO AIRPLANE COMPONENTS.
B. Remove the Hydraulic Supply and Control Assembly

ACCIDENTALLY.
(3) Release the hydraulic pressure from the

hydraulic system:

lower access panel.
S Operate the accumulator dump-valve. Hydraulic supply and control assembly.
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(4) Disconnect these hydraulic hoses from the Use a suitable container to catch spilt
hydraulic manifold: fluid.
S Disconnect the 3 return hoses from the Fit blanking caps to all connectors.
hydraulic manifold.
S Disconnect the pressure hose from the Fit blanking caps to all connectors.
hydraulic manifold.
% (5) Disconnect these electrical cables from the

% hydraulic supply and control assembly:
% S Disconnect the electrical cables from the At the in-line connectors.

% 2 solenoid valves.
%
% S Disconnect the electrical cables from the At the in-line connectors.
% hydraulic pump pressure switch.
% S Disconnect the electrical cables from the At the hydraulic pump electric motor.
% hydraulic pump motor.
% Loosen the connection by holding the
%
% lower nut and applying torque to the
% upper nut.
(6) Disconnect the flexible cable from the

emergency extension valve:
S Loosen the bolt on the cable swivel fitting.
S Move the cable clear of the swivel fitting.
S Release the cable clamp and move the

cable clear of the supply and control
assembly.
(7) Remove the hydraulic supply and control

assembly:
S Remove the 4 bolts and washers that attach Note the location of the bonding strip
the mounting tray to the surrounding connection and the earth wire.
structure.
S Lift the complete assembly clear of the Use a suitable container/material to

airplane. Hold the assembly level to catch spilt hydraulic fluid.
minimize hydraulic fluid spillage.
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C. Install the Hydraulic Supply and Control Assembly
(1) Install the hydraulic supply and control

assembly:
S Move the hydraulic supply and control

assembly into position in the fuselage.
S Install the 4 bolts and washers that attach Attach the bonding strip and earth cable
the hydraulic supply and control assembly in the location noted in Paragraph 8 B
mounting to the fuselage structure. step 7.
(2) Connect these flexible hydraulic hoses to the Make sure that all the blanking caps are
hydraulic supply and control assembly: removed.
S The 3 return hoses to the hydraulic

manifold.
S The supply hose to the hydraulic manifold.
% (3) Connect these electrical cables to the hydraulic

% supply and control assembly:
% S Connect the electrical cables to the At the hydraulic pump electric motor.
% hydraulic pump motor. Tighten the connection by holding the
% lower nut and applying torque to the
%
% upper nut.
%
% Torque: 9 - 11 Nm (6.6 - 8.1 Ibf.ft.).
%
%
%
% S Connect the electrical cables to the At the in-line connectors.
% 2 solenoid valves.
%
% S Connect the electrical cables to the At the in-line connector.
% hydraulic pump pressure witch.
%
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(4) Connect the flexible cable to the emergency

extension valve:
S Make sure that the emergency extension

valve is in the fully closed (normal) position.
S Make sure that the emergency extension

control lever in the cockpit is fully forward.
S Attach the flexible cable outer sheath to the

mounting bracket.
S Pass the flexible cable inner through the

swivel fitting in the emergency extension
valve operating lever and tighten the screw.
(5) Do a visual test for the correct adjustment of the

emergency extension valve operating cable:
S Set and hold the lever in the cockpit to the The emergency valve at the supply and
EMERGENCY position. control panel must be in the emergency
position. The hydraulic pump cut-out
micro switch must be open.
S Set the lever in the cockpit to the NORMAL The emergency valve at the supply and
position. control panel must be in the normal
position. The hydraulic pump cut-out
micro switch must be closed.
(6) If necessary, fill the hydraulic reservoir with Refer to Section 29-10.
fluid.
(7) If necessary, charge the hydraulic accumulator

with nitrogen.
(8) Install the rear baggage compartment lower Refer to Section 25-60.
access panel.
(10) Do a test for the correct operation of the landing Refer to Section 32-30.
gear extension and retraction system.
(11) Do a test for the correct operation of the Refer to Section 32-30.
emergency extension system.
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(12) Move the wing and fuselage trestles clear of the

airplane.
airplane is clear.
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9. Remove/Install Hydraulic Pump



lower access panel.
(3) Depressurize the hydraulic system. Refer to Section 29-10.
(4) Drain fluid from the hydraulic system. Refer to Section 29-10.
The fluid level should be lower than the

hydraulic lines of the motor-pump.
% (5) Disconnect the motor-pump: Refer to Figure 1.
% S Disconnect the two hydraulic connectors from

% the pump.
%
% S Put caps onto the hydraulic lines and on the
% pump so that no hydraulic fluid can leak.
% S Disconnect the electric connectors from the Remember which one is the plus and
% motor. minus pole. Loosen the connection by
% holding the lower nut and applying
% torque to the upper nut.
(6) Remove the motor-pump:
S Remove the bolts which hold the motor-pump

on the hydraulic panel.
S Move the motor-pump clear from the

hydraulic system.
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(7) Install the new motor-pump:
S Move the motor-pump into position.
S Install the bolts which hold the motor-pump

onto the hydraulic panel.
% (8) Connect the motor-pump:
% S Connect the electric connectors to the motor. M8 nut. Tighten the connection by
% holding the lower nut and applying
% torque to the upper nut.
%
% Torque: 9 - 11 Nm (6.6 - 8.1 Ibf.ft.).
%
% S Remove the caps from the hydraulic lines and
% the pump.
% S Connect the two hydraulic connectors onto

% the pump.
%
(9) If hydraulic fluid was drained, replenish the Refer to Section 29-10.
hydraulic reservoir with hydraulic fluid.
system.
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AIRCRAFT
10. First Fill/Replenishment of the Hydraulic System
A. Material
CAUTION: DO NOT MIX OR REPLACE HYDRAULIC FLUIDS OF DIFFERENT

TYPES OR MANUFACTURERS.
Note: If MÄM 42-495 is carried out, a placard is installed by the airplane

manufacturer identifying the type of hydraulic fluid. All airplanes with
MÄM 42-495 NOT installed have been manufactured with Aeroshell
Fluid 41 (MIL-PRF-5606 H). The identification placard must be installed
if a hydraulic fluid change to another fluid type is carried out.
Hydraulic fluid. As required. Aeroshell Fluid 41

(MIL-PRF-5606 H) or AMG-10
(GOST 6794-75 Amdt 1-5),
see CAUTION above.
B. Fluid Capacity
Item Capacity
Hydraulic reservoir. 0.9 l (0.24 US gal)

(mid-leve on the inspection glass)
Extended landing gear Both actuators: Approx. 0.5 l (0.13 US gal)

(when hydraulic actuators are retracted).
Accumulator. Approx. 0.09 l (0.02 US gal)
Hoses and misc. components. Approx. 0.25 l (0.07 US gal)
Total hydraulic system. Approx. 1.74 l (0.46 US gal)
Note: If the level of the hydraulic reservoir differs 1 cm (0.4 inch) it equals
approx. 0.12 liter (0.03 US gal) of hydraulic fluid.
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C. Equipment
Hand pump. 1 P/N X11-P004.
D. First Fill/Replenishment of the Hydraulic System

ACCIDENTALLY.
BE DAMAGED.
the airplane.

airplane.

lower access panel.
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(5) ONLY FOR FIRST FILL: See Figure 3.
Fill the hydraulic reservoir with 1.25 liter

(0.33 US gal) using a hand pump which connects
to the FILL port of the hydraulic reservoir.
(6) Reset the GEAR circuit-breaker. Right side of instrument panel.
(7) Charge the hydraulic accumulator: Approx. 16 (+4/-3) sec with a


system pressure stabilizes.
S The hydraulic pump must stop operating.
(8) Check the fluid level of the hydraulic reservoir. Refer to Section 29-10.
CAUTION: DO NOT FILL THE HYDRAULIC TANK FULL BECAUSE IT MAY

OVERFLOW. FILL IT IN SMALL STEPS.
(9) Use the hand pump to replenish the hydraulic

reservoir to adjust the fluid level.
(10) Repeat steps 8 and 9 until the fluid level of the

hydraulic reservoir is correct.
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(13) Do the normal operational test of the hydraulic Refer to Section 29-10.
system.

the airplane.
airplane is clear.
11. Tests of the Hydraulic System
A. Normal Operation Test of the Hydraulic System
(1) Charging Time of the Empty Accumulator

S Fold the rear passenger seat-backs forward.
S Remove the rear baggage compartment
lower access panel.
(5) Measure the charging time of the accumulator:
S Set the ELECT. MASTER switch to ON. 16 (+4/-3) sec.
S Charging time of a completely empty (18 - 20 sec for control blocks before
accumulator until the electronic pump revision D).
pressure switch turns it off.
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Note: The normal refill cycle is shorter (from the lower switching point to the upper
switching point of the pump pressure switch). If the measured time differs
significantly from the actual value, then check the prefill pressure of the
accumulator.
(2) Extending and Retracting Time of the Landing Gear
These values assume that the hydraulic system is fully bled.
Cycle Set-point
Retracting. 7 (+2/-1) sec.
Follow-up time of the pump. 12 (+3/-2) sec,

respectively 15 sec for control blocks rev. D.
Extending. 7 (+2/-1) sec.
Follow-up time of the pump. 12 (+3/-2) sec,

respectively 15 sec for control blocks rev. D.
Note: Make sure to raise the airplane according to Section 07-10 and connect an
external power supply according to Section 24-40 before doing this test. If the
measured values accord to the set-points, the function of the “differential
pressure mode for retracting” is given automatically.
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(3) Differential Pressure Mode for Retracting of the Landing Gear

lower access panel.
S Use a screwdriver or any magnetizable A magnetic testing device

material and hold it close to the solenoid (P/NX11-P005) can also be used to test
valve. the solenoid valve.
S If the tool gets pulled to the valve it means it

is energized and the differential mode is OFF.
(3) In case the solenoid valve is not energized, Refer to Section 32-60.
check the micro switches in the nose landing
gear bay.
(4) Internal Leak Tightness
High re-pump cycles as a result of internal leakage at the fully bled system are usually a
maximum of one cycle in 2 hours.
Re-pump cycles at completely bled and

Set-point
thermally balanced system cycle
Retracted landing gear. Max. 1 cycle per hour.
Extended landing gear. Max. 1 cycle per hour.
Note: When the system is cooling down it starts to re-pump earlier. High re-pump
cycles can be caused by internal leakage in the valves or also by the piston
sealing of the actuator.
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B. Emergency Operation Function Test of the Hydraulic System
(1) Equipment
(2) Emergency Extension Test

ACCIDENTALLY.
BE DAMAGED.
(1) Pull the GEAR circuit-breaker. Right side of the instrument panel.
the airplane.

airplane.
(4) Release the hydraulic pressure from the

hydraulic system:

lower access panel.
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(5) Open the dump valve:
valve.
S After emptying wait 10-15 min until the

S Tighten the hexagon socket to close the 6 - 10 Nm (4.4 - 7.4 lbf.ft.),

dump valve. wrench size 1/4 in.
S Tighten the counter nut. 8 Nm (5.9 lbf.ft.), wrench size 19 mm.
S Install the lock wire onto the dump valve.
(8) Emergency extension:
S Operate the emergency extension micro This causes the solenoid valves to
switch. (Located on the hydraulic main switch off and the landing gear extends.
control block)
See Figure 4.
(10) Extend the landing gear regularity.

the airplane.
airplane is clear.
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C. Leak Tightness Test of the Hydraulic System



ACCIDENTALLY.
BE DAMAGED.
(1) Pull the GEAR circuit-breaker. Right side of the instrument panel.
the airplane.

airplane.
(4) Retract the landing gear. Refer to Section 32-30 (Landing Gear
Extension and Retraction Test).

lower access panel.
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(6) Switch to permanent differential pressure mode: This causes the hydraulic system to
stay in differential pressure mode.
S Remove the electrical plug from the upper
Refer to Figure 4 to see the solenoid
solenoid valve.
valve.
This is important because when testing

the hydraulic system, fluid gets pumped
into the system and can cause an
overflow.
(8) Install the hand pump: The MiniMess 1215 plug is situated on
the hydraulic control block.
S Remove the protection cap from the
MiniMess 1215 plug. Refer to Figure 4.
S Install the hand pump onto the plug. If your hydraulic system is an old
Note: Make sure to use clean hydraulic fluid with the hand pump for testing
the hydraulic system. Don't overfill the hydraulic reservoir by pumping
too much hydraulic fluid with the hand pump into the system.
(9) Adjust the pressure limitation valve of the hand

pump to 190 bar (2775 PSI).
(10) Check for external/internal leakage: The pressure should stay at

170 (+0, -5) bar (2466 [+0, -72] PSI).
S Increase the pressure with the hand pump in If the pressure drops below 165 bar
the hydraulic system to 170 bar (2466 PSI). (2393 PSI) and there is no external
leakage visible it can be assumed that
S Keep this pressure for 5 minutes and check
there is an internal leakage. Please
for any pressure decrease.
contact after sales support at Diamond
Aircraft.
S Use checklist for leakage test. Refer to Paragraph D (Checklist for
external leakage).
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(11) Check operation of the protection valve on the Refer to Figure 4.

main control block:
S Increase the pressure of the hydraulic system

to >180 bar (2610 PSI).
S The protection valve should open and after

the valve closes and the pressure in the
hydraulic system is stabilized the pressure is
steady at 150 bar (2175 PSI).
(12) Move the wings and rear fuselage trestles clear

of the airplane.
(13) Lower the airplane with the jacks.

Make sure that area around the airplane is clear.
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D. Checklist for External Leakage
Note: Check the hydraulic hoses on the hydraulic kit which is installed in the back of the
fuselage. Also check the connections of the hoses on the hydraulic control block
and on the hydraulic actuators visually for leak-tightness.
Checkpoint Set-point
Leakage on the fittings of the hydraulic kit. No leakage.
Leakage on the hose connections of the manifold No leakage.

and control block.
Leakage on the hose connections of the No leakage.

hydraulic actuators.
Leakage on the piston seal of the hydraulic No drop formation allowed.

actuator.
Maximum a little amount of dried fluid on the
cylinder head respectively on the piston rod
end.
Note: After fixing a leakage on the fittings or hose connections a leak tightness test has
to be done.
(1) External Leakage
In general you should check if there is any damage of the piston of the hydraulic actuator when
the landing gear is retracted. (Refer to Section 32-30 Landing Gear Extension and Retraction
Test). Look for scratches, bumps, grooves or any other physical damage. If there are any
damages in the range of the piston seal the hydraulic actuator piston has to be replaced. (Refer
to Section 29-10)
If a hydraulic actuator has a major leakage (drop formation visible) send the hydraulic actuator
to the vendor for a repair.
If a hydraulic actuator has a minor leakage (a little amount of dried fluid, no drop formation)
perform a detailed check.
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(2) Detailed Check
Static (landing gear extended, ELECT. MASTER switch ON / set GEAR circuit breaker):
) Max. leakage 1 drop of fluid in 10 hours.
Dynamic (after 25 extend/retract cycles):
) Max. leakage 1 drop of fluid.
Note: If one of the measurements don’t comply with these set-points send the actuator
to the vendor for a repair. Otherwise you can continue the operation but observe
the situation.
E. Pump Pressure Switch and Pressure Limitation Valve Operation Test
(1) Equipment
Manometer to test hydraulic pressure. 1 X11-P001.
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(2) Testing Procedure

ACCIDENTALLY.
BE DAMAGED.
the airplane.

airplane.

lower access panel.
(5) Remove the protection cap from the test plug See Figure 4.
(MiniMess 1215) located on the main control
If your hydraulic system is an old
block and connect the manometer.
(7) Check of the pressure limitation valve:
S Landing gear fully extended. Set-point: 120 (+5, -0) bar

(1740 [+72, -0] PSI).
S Pump is still running to charge the
accumulator.
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Note: The following 2 steps to test the pump pressure switch are not required if the
system is working properly.
(8) Check closing point of the pump pressure switch:
S Retract the landing gear fully. Refer to Section 32-30, Paragraph 7.
S Operate the emergency extension lever just a See Figure 4.

little bit, so that the micro switch on the
emergency extension doesn't switch but that
the valve is opened a little bit.
S The pressure on the manometer should

decrease.
S When the pump switches on, read the 93 ±1 bar (1349 ± 14.5 PSI).
manometer value.
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(9) Check opening point of the pump pressure

switch:
S Extend the landing gear fully. Refer to Section 32-30.
S Open dump valve until the pump switches

ON:
S Loosen the counter nut.
S Loosen the hexagon socket to open the

dump valve.
S Slowly close the dump valve so that the Adjust the dump valve so that the
pressure on the manometer increases slowly. circulation pressure is at 110 bar
(1595 PSI).
S Now wait approx. 20 sec so that the
accumulator can charge fully.
S Slowly close the dump valve completely and Set-point: 114 ±1 bar (1653 ± 14.5 PSI).
check the pressure with the manometer:
6 - 10 Nm (4.4 - 7.4 lbf.ft.),
S Tighten the hexagon socket to close the wrench size 1/4 in.
dump valve.
8 Nm (5.9 lbf.ft.), wrench size 19 mm.
S Install the lock wire onto the dump valve.

the airplane.
airplane is clear.
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12. Filters
A. Maintain Hydraulic Reservoir Filter


Note: A contaminated filter causes a bad intake performance of the pump,

because it needs a minimum intake pressure of 350 mbar.

lower access panel.
(3) Remove the vent hose by disconnecting the 90° In case you have an old revision
fitting on the top of the hydraulic reservoir. without drain hose skip this step.
Refer to Figure 3.
(4) Maintain the filter assembly (fitting and filter): Use wrench size 27 mm.
S Remove the lock wire from the filter fitting.
S Hold the reservoir lid screw with a wrench Use wrench size 22 mm.
that the lid doesn't turn while removing the
filter.
S Remove the filter fitting while holding the lid.
S Clean the filter by using benzine or other Make sure to blow the filter in the
washing solvent. Blow the filter with correct direction.
compressed-air to remove dirt.
(5) If removed, install vent hose by connecting the

90° fitting on the top of the hydraulic reservoir.
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access panel.
(7) Fold the rear passenger seat-backs backwards. Refer to Section 25-10.
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B. Replace/Maintain the High Pressure Filter



lower access panel.
(3) Replace high pressure filter: Refer to Figure 1.
S Remove filter housing. Put paper towel underneath to avoid

spilling of hydraulic fluid.
S Pull the old filter element clear of the filter
body.
S Push and slightly turn the filter element into Metal/paper filter element.
the filter body until it's secure.
S Install filter housing. Tighten the filter housing with your hand
(approx. 5 Nm, 3.7 lbf.ft.)
access panel.
(5) Fold the rear passenger seat-backs backwards. Refer to Section 25-10.
CAUTION: BECAUSE OF ITS DESIGN THIS FILTER ELEMENT CAN NOT BE

CLEANED. IT HAS TO BE REPLACED IF IT'S CONTAMINATED.
Note: The high pressure filter is located between the pressure pipe of the
hydraulic pump and the hydraulic control unit. It consists of a metal/paper
filter element.
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13. Valves
A. Replace the Dump Valve



lower access panel.
The fluid level of the reservoir should be
lower than the top surface of the main
control block.
(5) Replace the dump valve:
S Remove both lock wires from the valve.
S Remove the dump valve. Use wrench size 22 mm.
S Install the new dump valve. Put Rivolta F.L.A onto the thread and
tighten the valve with 25 Nm
S Install lock wires on the dump valve.
(18.4 lbf.ft.).
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(6) If hydraulic fluid was drained in step 3, replenish Refer to Section 29-10.
the hydraulic reservoir with hydraulic fluid.
system.
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B. Replace the Pressure Relief Valve / Pump Pressure Switch



lower access panel.
The fluid level of the reservoir should be

lower than the top surface of the main
control block.
(5) Remove the pump pressure switch: To get a better access to the pressure
relief valve remove the pump pressure
S Remove the electric connector from the
switch first.
switch.
S Remove the pump pressure switch. Use wrench size 27 mm.
Note: The following 2 steps are not required if only the pump pressure switch should
be replaced.
(6) Install a cap onto the main control block where This is to protect the control block from
the pump pressure switch was installed. dirt/dust. Use a DIN908-G 1/4 size plug.
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(7) Replace the pressure relief valve: Use wrench size 24 mm.
S Remove the valve carefully. Make sure not to damage the backup
ring on the valve.
S Install the pressure relief valve. Apply Rivolta F.L.A onto the thread and
tighten with 25 Nm (18.4 lbf.ft.).
(8) Install the pump pressure switch:
S Install the switch. Use wrench size 27 mm.
S Install the electric connector back onto the Apply Rivolta F.L.A. onto the thread and
switch. tighten with 18 Nm (13.3 lbf.ft.).
(9) If hydraulic fluid was drained in step 3, replenish Refer to Section 29-10.
the hydraulic reservoir with hydraulic fluid.
system.
(13) Reset the GEAR circuit breaker. Right side of the instrument panel.
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C. Replace/Check a Solenoid Valve
Note: In order to replace the bottom solenoid valve, remove the bolts from the metal
plate where the hydraulic system is mounted on. Now lift the plate to get access
to the solenoid valve.
(1) Replace a Solenoid Valve
(2) Remove the electric connector from the solenoid

valve.
(3) Remove the knurled nut on the top of the valve. Use special tool to remove the nut.
(4) Remove the solenoid valve from the shaft. Make sure all the O-rings are removed
from the shaft.
(5) Install the new solenoid valve onto the shaft. Make sure the valve is installed
Tighten the valve by hand (approx. 5 Nm properly otherwise you can damage it.
(3.7 lbf.ft.)).
(6) Plug the electric connector back onto the

solenoid valve.
system.
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(2) Electric States of the Solenoid Valves
Checkpoint Set-Point
Top solenoid valve: energized.

Retracting.
Bottom solenoid valve: not energized.
Top solenoid valve: energized.

Fully retracted.
Bottom solenoid valve: energized.
Top solenoid valve: not energized.

Extending / Fully extended.
Bottom solenoid valve: not energized.
D. Replace the Accumulator Charging Valve
(1) Pull the GEAR circuit breaker. Right side of instrument panel
S Fold the rear passenger seat-backs forward. Refer to Section 25-10

lower access panel.
Note: Make sure when loosening the counter nut that you don’t accidentally loosen
the whole accumulator charging valve.
(3) Releasing the nitrogen from the accumulator: Make sure to release the nitrogen
slowly. The accumulator cools down
S Remove the yellow protection cap from the
while releasing the nitrogen.
accumulator charging valve.
Use wrench size ¾ in.
S Loosen the counter nut on the accumulator
charging valve until you feel a resistance.
Now slowly continue to loosen the nut. This
will cause the valve to open.
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(4) Replace the accumulator charging valve: MS-28889-2 standard valve is used.
Use wrench size ¾ in.
S Remove the accumulator charging valve by
loosening the hexagon head of valve body
(not the counter nut).
S Install the new accumulator charging valve. Apply Rivolta F.L.A onto the thread and
tighten the valve with 25 Nm
(18.4 lbf.ft.).
(5) Charge the accumulator with nitrogen. Refer to Section 29-10.
(6) Test the accumulator charging valve for leak- Apply some leak-finder spray onto the
tightness. valve and look for air bubbles.
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E. Replace the Flow Regulation Valve



lower access panel.
The fluid level should be lower than the

hydraulic control manifold.
(4) Remove the flow regulation valves.
S Remove the valves and two seal rings on Wrench size 22 mm.
each valve.
S Make sure to catch spilt hydraulic fluid.
(5) Install flow regulation valves:
S Install the M1.7 valve in the middle hole of

the hydraulic supply manifold and tighten it
with 25 Nm (18.4 lbf.ft.).
S Install the two M1.5 valves in the top and Put Rivolta F.L.A on both, the thread
bottom hole of the hydraulic supply manifold and the O-rings.
and tighten them with 25 Nm (18.4 lbf.ft.).
(6) Replenish the hydraulic reservoir with hydraulic Refer to Section 29-10.
fluid.
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system.
14. Remove/Install/Disassemble/Assemble Hydraulic Control Block


A. Remove the Hydraulic Control Block

lower access panel.
(2) Depressurize the hydraulic system. Refer to Section 29–10.
(3) Remove all seven hydraulic hoses from the Use a suitable container to catch spilt
hydraulic control block. hydraulic fluid. Fit caps on all open
connections.
(4) Remove all electrical connections from the (Pump pressure switch connector,
hydraulic control block. solenoid valve connections).
(5) Remove the emergency extension micro switch. Refer to Figure 4.
(6) Disconnect the Bowden cable from the Refer to Figure 4.

emergency extension block.
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(7) Remove the control block: Use hexagon socket size 4.
S Remove the three bolts which secure the

S Move the control block clear from the rest of

the hydraulic system.
B. Install the Hydraulic Control Block
(1) Install the control block: Use hexagon socket size 4.
S Move the control block into position onto the

hydraulic system.
S Install the three bolts which secure the

hydraulic control block but don’t tighten them
yet.
(2) Connect the Bowden cable onto the emergency Refer to Figure 4.
extension module.
(3) Install the emergency extension micro switch. Refer to Figure 4.
(4) Install all electrical connections onto the Check polarity of solenoid valve
hydraulic control block (Pump pressure switch connections.
connector, solenoid valve connections).
(5) Install all seven hydraulic hoses onto the Remove the caps from the connections.
(6) Tighten the three bolts which secure the

(7) If hydraulic fluid was drained, replenish the Refer to Section 29-10.
hydraulic reservoir with hydraulic fluid.
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system.
C. Disassemble Hydraulic Control Block


(1) Remove hydraulic control block. Refer to Section 29-10.
(2) Remove the four bolts from the control block

(size 4 hexagon socket head).
(3) Separate the three main blocks. Refer to Figure 4.
(4) Remove the control block: Standard MS28778-4 seal rings are
used.
S Clean the holes and bolts from residues of
the adhesive.
S Remove the seal rings from contact surface

of the blocks.
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D. Assemble Hydraulic Control Block
(1) Prepare the three main blocks: Refer to Figure 4.
S Make sure there is no residues of the So that the plane surface where the
adhesive on the holes and bolts. seals get installed is horizontal.
S Position the three main blocks vertical so that Make sure there is no dirt on the plane
seal rings can be installed easier. surfaces otherwise the control block
may be leaking.
S Install the seal rings onto the blocks.
(2) Install the four bolts to secure the three main

parts:
S Apply some Loctite 243 onto each bolt thread

to secure it.
S Install the bolts and tighten them with 4 Nm

(3 lbf.ft.).
(3) Install the hydraulic control block. Refer to Section 29-10.
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Pump Pressure Switch Cap

(Electric Connector)
Pressure Relief Valve
Protection Valve
Pressure Button
Pump
Pressure
Top Magnetic Valve
Switch
Control Block
Emergency Extension Lever
O-Ring
Emergency Extension Block
Dump Valve Microswitch Hydraulic Supply
Manifold
Mini Mess 1215 O-Ring
Bolts (Remove/Install
Control Block)
Electric Connector
Knurled Nut
Bottom Magnetic Valve
Current
Regulation
Valve
Bolt
Figure 4: Hydraulic Control Block
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AIRCRAFT
15. Bleed/Remove/Install the Accumulator
A. Bleed the Accumulator
(1) Check level of hydraulic reservoir. Refer to Section 29-10.
(2) Replenish hydraulic reservoir if necessary. Refer to Section 29-10.
(3) Set GEAR circuit breaker. Right side of instrument panel.
(4) Set ELECT. MASTER switch to ON.
(5) The hydraulic pump must operate until the system The hydraulic pump must stop
pressure stabilizes. operating.
(7) Open the dump valve:
valve.
S After emptying wait 10-15 min until the

S Tighten the hexagon socket to close the dump 6-10 Nm (4.4 - 7.4 lbf.ft.),
valve. wrench size 1/4 in.
S Install the lock wire onto the dump valve. 8 Nm (5.9 lbf.ft.), wrench size 19 mm.
(9) Pull GEAR circuit breaker. Right side of instrument panel.
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B. Remove the Accumulator


(2) Open the dump valve: Wrench size 19 mm.
S Remove the lock wire from the dump valve. Wrench size 1/4 in.
S Loosen the hexagon socket to open dump

valve.
S After emptying wait 10-15 min. until the

(3) Operate the pressure button on the upper solenoid See Figure 4.
valve on the top of the hydraulic control block.
Use a little metal pin or ball pen to
operate the button.
(4) Remove the accumulator:
S Remove the hydraulic hose from the

accumulator.
S Open the bolts which hold the accumulator in

place and open the clamp
S Move the accumulator clear from the hydraulic

system.
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C. Install the Accumulator
(2) Install the accumulator:
S Move the accumulator in position.
S Close the clamps and install the bolts which Apply Rivolta F.L.A for corrosion
hold the accumulator in place. protection. Tighten with 5 - 6 Nm
(3.7 - 4.4 lbf.ft.).
S Install the hydraulic hose from the
accumulator.
(3) Check the hydraulic fluid level of the hydraulic Refer to Section 29-10.
reservoir.
system.
16. Check the Accumulator
The accumulator should be tested every 200 hours of operation respectively once a year if there is any
inner leakage and the correct pre-fill pressure.
A. Equipment
Adapter MS28889-2 / MiniMess 1615. 1 Commercial.
Manometer to test pressure on the 1 X11-P002.

accumulator.
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Hydraulic Hose
Accumulator
Fitting
Bolt
Fitting
Clamp
Screw Protection Cap

Washer
Charging Valve
Figure 5: Hydraulic Accumulator Installation
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AIRCRAFT
B. Testing Procedure
S Remove the rear baggage compartment lower Refer to Section 25-60.

access panel.
Note: Make sure when loosening the counter nut on the accumulator that you don’t
accidentally loosen the whole high pressure valve.
WARNING: IF THE HOSE OF THE MANOMETER IS NOT CONNECTED

PROPERLY TO THE HIGH PRESSURE VALVE, NITROGEN CAN
LEAK FROM THE ACCUMULATOR. IF THAT IS THE CASE, CLOSE
THE COUNTER NUT IMMEDIATELY AND CHECK ALL
CONNECTIONS AGAIN. THE ACCUMULATOR HAS TO BE REFILLED
ACCORDING TO SECTION 29-10 PARAGRAPH 17.
(3) Connecting the test manometer:

high pressure valve on the accumulator.
S Screw the Adapter (MS28889-2 /

MiniMess 1615) onto the valve as far as it will
go (sealing face).
S Screw the swivel nut from the manometer onto

the adapter.
S Loosen the counter nut on the valve until it

reaches the end face. Now slowly continue to
loosen the nut -> this will cause the valve to
open.
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(4) Check the pressure on the manometer: If the measured pressure differs a lot
compared to the set-point, see the
The required pressure is 80 bar (1160 PSI) at
Troubleshooting section.
15°C, (82.8 bar [1200 PSI] at 25°C).
(5) Disconnecting the test manometer:
S Tighten the counter nut on the valve with

10 Nm (7.4 lbf.ft.).
S Remove the manometer from the adapter.
S Remove the Adapter (MS28889-2 /

MiniMess 1615) from the valve.
S Put the yellow protection cap back onto the

high pressure valve.
(7) Check for correct charging time of the hydraulic

accumulator:

system pressure stabilizes. Approx. 16 (+4/-3) seconds with a
S The hydraulic pump must stop operating.
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17. Charge the Hydraulic Accumulator with Nitrogen
A. Equipment
Adapter MS28889-2 / MiniMess 1615. 1 Commercial.
Nitrogen bottle with pressure reducer. 1 X11-P003.
B. Charge Accumulator with Nitrogen
S Remove the rear baggage compartment lower Refer to Section 25-60.

access panel.
Note: Make sure when loosening the counter nut on the accumulator that you don’t
accidentally loosen the whole high pressure valve.
WARNING: IF THE HOSE OF THE MANOMETER IS NOT CONNECTED

PROPERLY TO THE HIGH PRESSURE VALVE, NITROGEN CAN
LEAK FROM THE ACCUMULATOR. IF THAT IS THE CASE, CLOSE
THE COUNTER NUT IMMEDIATELY AND CHECK ALL
CONNECTIONS AGAIN.
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(4) Connecting the nitrogen bottle:
S First, check that the pressure reducer on the

nitrogen bottle is set to 90 bar (1305 PSI).

accumulator charging valve.
S Screw the Adapter (MS28889-2 /

MiniMess 1615) onto the valve as far as it will
go (sealing face).
S Screw the swivel nut of the charging hose onto

the adapter.
S Loosen the counter nut on the high pressure

valve until it reaches the end face. Now slowly
continue to loosen the nut -> this will cause the
valve to open.
(5) Charge the accumulator:
S Read the pressure on the manometer of the

pressure reducer.
S Charge the accumulator to a pressure of

85 - 90 bar (1233 - 1305 PSI).
S Close the valve on the nitrogen bottle and wait

10 min until the accumulator is thermally
balanced.
S Check the pressure of the accumulator again Set-point:

and fine tune the pressure with the pressure 80 bar, 1160 PSI (15°C)
reducer on the nitrogen bottle until the 82.8 bar, 1200 PSI (25°C)
set-point is reached.
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(6) Disconnect the nitrogen bottle:
S Tighten the counter nut on the valve with

10 Nm (7.4 lbf.ft.).
S Close the valve on the nitrogen bottle and

release the remaining pressure with the
pressure reducer.
S Remove the nitrogen bottle from the adapter.
S Remove the Adapter (MS28889-2 /

MiniMess 1615) from the valve.
S Put the yellow protection cap back onto the

high pressure valve.
(8) Check operation of the hydraulic accumulator. Refer to Section 29-10.
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DA 42 NG Series
Ice Protection System
AMM AIRCRAFT
CHAPTER 30
ICE PROTECTION SYSTEM
Doc # 7.02.15 Page 1

DA 42 NG Series
AIRCRAFT AMM
Page 2
22 Dec 2021 30-TITLE Doc # 7.02.15
Rev. 5
DA 42 NG Series
AMM AIRCRAFT
TABLE OF CONTENTS
CHAPTER 30
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4. Handling of Porous Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Drain the Ice Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4. Remove/Install the De-Icing Fluid Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5. Remove/Install the De-Icing Fluid Inlet Strainer . . . . . . . . . . . . . . . . . . . . . . . . . 208
6. Remove/Install a De-Icing Metering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
7. Replace the Filter Cartridge or Windshield Pump or Solenoid Valve . . . . . . . . . 211
8. Bleed the De-Icing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
9. Purge the De-Icing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
10. Remove/Install a Proportioning Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
11. Replace an Ice Protection Porous Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
12. Replace De-Icing Fluid Nylon Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
13. Replace Ice Protection Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
14. Remove/Install the High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
15. Remove/Install the Low Pressure Switch Proportioning Unit . . . . . . . . . . . . . . . 220
16. Remove/Install a Low Pressure Switch in the Horizontal Tail . . . . . . . . . . . . . . 222
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AMM AIRCRAFT
CHAPTER 30
1. General
WARNING: DO NOT GET DE-ICING FLUID ON YOUR SKIN OR ON YOUR

CLOTHES. DE-ICING FLUID IS HARMFUL AND CAN CAUSE INJURIES
TO PERSONS AND CAN DAMAGE YOUR CLOTHING.
CAUTION: HANDLE DE-ICING FLUID WITH CARE. DE-ICING FLUID IS

FLAMMABLE AND CAN CAUSE DAMAGE TO EQUIPMENT.
This Section explains the fluid based ice protection system of the DA 42 NG airplane. It gives you
general data and the trouble-shooting data on the system. Refer to CAV Aerospace Ltd. for data on the
ice protection system.
The ice protection system prevents accumulation of ice by distributing a thin film of a special de-icing
fluid on the wings, horizontal stabilizer, vertical stabilizer, propellers and canopy. The area on the
panels at which de-icing fluid weeps out through many fine holes is called the 'active area.'
The airframe and propellers are grouped and operate together. Windshield de-icing is a separate
system and operates independently. All systems draw fluid from a common tank.
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DA 42 NG Series
AIRCRAFT AMM
Spray Nozzle
De-ice Propeller
with Slinger Ring
and Blade Nozzle
Proportioning Unit
Metering Pumps
Horizontal Tail Panel
De-icing
Fluid Tank
Filler Neck with Vertical Fin Panel
Inlet Strainer
T-Fitting
for Drain
HP Switch
Tail Unit for Distribution
Filters Spraybar
Windshield
Pumps
Solenoid
Valves
Proportioning Unit
Inner Wing Panel
Outer Wing Panel
Figure 1: Ice Protection System - Mechanical Schematic
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AMM AIRCRAFT
Spray Nozzle
De-ice Propeller
with Slinger Ring
and Blade Nozzle
Proportioning Unit
Metering Pumps
De-icing Fluid Tank

if OÄM 42-160 and OÄM 42-203
are carried out
Vertical Fin Panel
Tail Unit for

HP Switch Distribution
Filters Spraybar Filler Neck with Inlet Strainer
Windshield if OÄM 42-160 and
Pumps OÄM 42-203 are
Solenoid carried out
Valves Horizontal Tail Panel
Proportioning Unit
Inner Wing Panel
Outer Wing Panel
Figure 2: Ice Protection System - Mechanical Schematic (if OÄM 42-203 is installed)
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DA 42 NG Series
AIRCRAFT AMM
Ice Light
De-ice Control Panel

Low Level Switch
Main Pumps
De-Ice Fluid
Low Pressure Switch
Level Gauge
High Pressure
Switch Low Pressure Switch
De-Ice Low Pressure Switch
Control Box
Windshield
Pumps
Solenoid
Valves
Ice Light
Figure 3: Ice Protection System - Electrical Schematic
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AMM AIRCRAFT
Ice Light
De-Ice
Low Pressure
Control Panel
Switch
Main Pumps De-icing Fluid

Level Gauge
High Pressure Switch Low Pressure
Switch
De-Ice Low Pressure

Control Box Switch
Low Level Switch
Windshield
if OÄM 42-160 and OÄM 42-203
Pumps
are carried out
Solenoid
Valves
Ice Light
Figure 4: Ice Protection System - Electrical Schematic (if OÄM 42-203 is installed)
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DA 42 NG Series
AIRCRAFT AMM
2. Description
Figures 1 and 2 show the schematic diagram for the mechanical parts of the fluid based ice protection
system on the DA 42 NG. The mechanical part of the ice protection system consists of:
) Porous panels on the leading edge of the horizontal tail.
) Porous panel on the leading edge of the vertical tail.
) Porous panels on the leading edge of the outer wings.
) De-icing fluid tank with integrated level sensor, level switch and inlet strainer.
) De-icing fluid main pumps.
) De-icing fluid filters.
) Drain hose connector in nose landing gear bay.
) Proportioning units in each engine nacelle.
) Nozzles and slinger rings on the LH and RH propeller.
) Proportioning unit in the vertical tail.
) Low pressure sensors in the vertical tail.
) High pressure sensor.
) Windshield pumps with solenoid valves.
) Spraybar in front of the canopy.
These system components are connected with nylon tubing. For the ice protection of the propeller
Teflon lines through the engine nacelles to the slinger rings of the propeller are used.
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Figures 3 and 4 show the schematic diagram for the electrical parts of the fluid based ice protection
system on the DA 42 NG. The electrical part of the ice protection system consists of:
) De-ice control box.
) De-ice control panel.
) Low level sensor.
) De-ice fluid level gauge.
) Low pressure sensor.
) High pressure sensor.
) Main pumps.
) Windshield pumps.
) Solenoid valves.
) Ice lights.
The ice protection system is electrically operated. It is supplied with power via the XFR PUMP/DE-ICE
circuit breaker. Refer to Chapter 92 for wiring diagrams.
A. De-Icing Fluid Tank
The de-icing fluid tank is installed in the nose baggage compartment of the airplane on the RH side.
It consists of a single polyamide chamber with a usable capacity of 30 liter (7.9 US gal). If
OÄM 42-203 is installed, the de-icing fluid tank is installed behind the baggage compartment and
the optional short baggage extension. The tank filler is located in the fuselage nose on the RH side,
aft of the nose baggage door. If OÄM 42-203 is installed, the tank filler is located on the LH side of
the fuselage, aft of the passenger door.
A fluid level sensor provides the signal for the fluid level indication on the G1000. A level switch in
the tank provides indication of the minimum quantity for dispatch (45 minutes) via a caution
message on the G1000.
The tank has an inlet with an integrated strainer. From the outlet, nylon tubing feeds the fluid to the
inlet of the main pump assembly.
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AIRCRAFT AMM
B. Main Pump Assembly
The main pump assembly consists of two electrical pumps which are connected in series. These
pumps are mounted to the bottom side of a lid in the floor of the nose baggage compartment on the
RH side.
The main pump assembly has two outlets. One outlet supplies the airframe ice protection system
(see Paragraph C). The other outlet supplies the windshield de-icing system (see Paragraph D).
C. Airframe Ice Protection System
(1) High Pressure Sensor
A high pressure sensor is situated between the main pump assembly and the filter. It is attached
to the LH inspection hole cover in the nose baggage compartment.
When the resistance of the filters becomes too high, the sensor activates a caution message
("DEIC PRES HI") on the Garmin G1000 PFD. The system remains operative, but the filter
cartridges must be replaced at the next scheduled inspection.
(2) De-Icing Fluid Filters
Two filters protect the capillaries in the proportioning units from fouling . The filters are connected
in parallel for redundancy purposes. The outlets of the filters are merged with a T-fitting and then
the fluid runs underneath the cockpit floor to a manifold block in the center of the airplane. Each
filter has a bleeding socket connected to a bleeding hose, which is located in the LH nose
(3) Manifold Block
The manifold block is located under the small center console between the center wing main
spars. It divides the flow of de-icing fluid into three branches. One branch goes to each wing to
feed the wing and propeller ice protection system (see Paragraph 4). One branch goes back to
feed the empennage ice protection system (see Paragraph 5).
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(4) Wing and Propeller Ice Protection System
(a) Proportioning Unit
A proportioning unit is located in each engine nacelle between the center wing spars. It is
accessible after removal of the small inspection panel on the outboard side of the nacelle.
The proportioning unit divides the fluid flow into three sub-branches. For each sub-branch
there is a capillary which ensures that the correct amount of de-icing fluid flows to the related
sub-branch.
One sub-branch goes forward to feed the propeller ice protection system (see Paragraph b).
Two branches go to the outer wing to feed the wing ice protection system (see Paragraph c).
(b) Propeller Ice Protection System
A Teflon tube goes from the proportioning unit forward to a nozzle near the propeller, where
the de-icing fluid drops onto a slinger ring. In the engine compartment of the nacelle the tube
is protected by a fire sleeve. The slinger ring has three notches that allow the de-icing fluid
to be distributed over the propeller blades by centrifugal action.
(c) Wing Ice Protection System
Two porous panels are attached to the leading edge of each outer wing. They discharge the
fluid onto the wing through many fine holes.
The panels are bonded to the wing leading edge. They cannot be removed without damage.
(d) Purging Connections
Near the rearward inspection hole cover on the outboard side of each nacelle an equal tee
for purging of the system is installed.
(e) Filter Bleeding Hose
In the LH nose baggage compartment behind the floor carpet.
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DA 42 NG Series
AIRCRAFT AMM
(5) Empennage Ice Protection System
(a) Proportioning Unit
A proportioning unit is attached forward of the front spar of the vertical stabilizer.
The proportioning unit divides the fluid flow into three sub branches. For each sub-branch
there is a capillary which ensures that the correct amount of de-icing fluid flows to the related
horizontal or vertical tail porous panel.
(b) Horizontal Tail Ice Protection System
One porous panel is attached to the leading edge of the horizontal tail on the LH side.
Another panel is attached on the RH side. The panels discharge the fluid onto the horizontal
tail through many fine holes.
The panels are bonded to the horizontal tail leading edge. They cannot be removed without
damage.
(c) Vertical Tail Ice Protection System
One porous panel is attached to the leading edge of the vertical tail. The panel discharges
the fluid onto the vertical stabilizer through many fine holes.
The panel is bonded to the vertical tail leading edge. It cannot be removed without damage.
(d) Low Pressure Sensors
Three low pressure sensors are situated between the proportioning unit and the porous
panels on the empennage. If one of these panels is not supplied with sufficient pressure, then
the sensor activates a caution message on the G1000 PFD ("DEIC PRES LO").
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D. Windshield De-Icing System
(1) Windshield De-Icing Pumps
One outlet of the main pump assembly is connected to the inlets of the two windshield de-icing
pumps via an equal tee. The windshield de-icing pumps are connected in parallel. The pumps
are mounted to the bottom side of a lid in the floor of the nose baggage compartment on the LH
side. Only one pump is operative at a time, while the other pump is a backup. The active pump
is selected with a switch in the cockpit.
(2) Solenoid Valves
A solenoid valve is located in front of each windshield de-icing pump. When the pilot operates
the switch for the windshield de-icing system, then the valves allow the de-icing fluid to flow to
the spraybar for 5 seconds. The solenoid valves avoid that air is drawn into the system via the
spraybar.
(3) Spraybar
A spraybar is located in front of the canopy. It is aligned parallel with the center axis of the
airplane. When activated, it sprays de-icing fluid onto the canopy.
A deflector-wedge is mounted to the airplane in front of the spraybar for protection and airflow
guide purposes.
E. Ice Protection Control System
(1) De-Ice Control Box
The de-ice control box consists basically of relays and is connected to the de-ice control panel.
It is supplied with electrical power via the XFER PUMP / DE-ICE circuit breaker. It is installed to
control all 4 pumps of the ice protection system. The de-ice control box is mounted on the bottom
side of the LH baggage compartment floor.
(2) De-Ice Control Panel
The ice protection system (including ice-lights) installed in the DA 42 NG is operated via the de-
ice control panel. The de-ice control panel is connected to the de-ice control box and to the
instrument panel lighting bus. It is supplied with electrical power via the XFER PUMP / DE-ICE
circuit breaker.
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AIRCRAFT AMM
3. Operation
The system is operated through 4 toggle type switches and two push buttons located on the de-ice
control panel in the RH section of the instrument panel.
A. OFF/NORM/HIGH Switch
The left OFF/NORM/HIGH switch operates the main pumps and thus activates the system. It has
3 positions:
) Down position: OFF.
) Center position: NORM (normal). The main pumps produce a cycled fluid flow: for
30 seconds both main pumps provide fluid to the system, followed by a
90 seconds off. This mode is selected when icing conditions are
encountered and prior to ice formation. Maximum system operating time is
approximately 2.5 hours.
) Up position: HIGH. The active main pump produces a continuous fluid flow. This mode
is selected when icing conditions are more demanding or if ice has already
accumulated. Maximum system operating time is approximately 1.0 hour.
B. MAX Push Button
The upper push button activates the MAX mode of the ice protection system when the system is
presently in the HIGH mode. This mode is only active for 2 minutes. In this mode both pumps are
active simultaneously and provide fluid to the system. This mode is selected when icing conditions
are severe or if significant ice has accumulated on the airplane. Maximum system operating time
in the MAX mode is approximately 30 minutes.
C. PUMP1/PUMP2 Switch
The RH bottom switch selects one of the two main pumps and one of the two windshield pumps.
It has 2 positions.
Down position: PUMP 1. Main pump 1 is selected as the active pump in HIGH mode. Pump 2
is standby. Also windshield pump 1 is selected in case the windshield switch is
activated. Windshield pump 2 is inoperative.
Up position: PUMP 2. Main pump 2 is selected as the active pump in HIGH mode. Pump 1
is standby. Also windshield pump 2 is selected in case the windshield switch is
activated. Windshield pump 1 is inoperative.
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D. WINDSHIELD Push Button
The WINDSHIELD push button activates the selected windshield de-icing pump for a duration of 5
seconds. During this time it feeds de-icing fluid to the spraybar in front of the canopy.
The windshield de-icing works even when the OFF/NORM/HIGH switch of the ice protection system
is set to OFF. Air removal from the ice protection system is also provided by these pumps by
continuously pressing the WINDSHIELD push button.
E. ALTERNATE Switch
The ALTERNATE switch connects main pump 2 directly to the RH main bus. Thus, in case of a total
loss of the LH main bus in icing conditions, operation of the ice protection system similar to the
HIGH- mode is possible.
F. ICE LIGHT / ANNUN-TEST Switch
This switch activates either both ice lights or the annunciation test procedure.
(1) Ice Lights Operation
The ice lights are switched ON by setting the toggle switch to the upper position.
(2) Test of Annunciations
Proper function of the fluid level switch and the low pressure sensor can be tested with the
annunciation test mode.
(a) Test of the DEIC PRES LO Annunciation
After the switch is set to ANNUN-TEST, the DEIC PRES LO annunciation in the alert window
of the PFD appears with a delay of 2 minutes.
(b) Test of the DEICE LVL LO Annunciation
This test can only be carried out if the fluid level in the de-ice tank is less than 10 liter
(2.6 US gal). After the switch is set to ANNUN-TEST, the DEICE LVL LO annunciation in the
alert window of the PFD appears.
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DA 42 NG Series
AIRCRAFT AMM
4. Handling of Porous Panels
Only the following solvents are permitted for use on the porous panels:
) Water with soap or detergent.
) Approved de-icing fluids.
) Propylene glycol.
) Avgas.
) Jet fuel.
) Isopropylalcohol.
) Ethyl alcohol.
) Industrial methylated spirit.
CAUTION: DON’T USE OTHER MATERIALS AS THE ABOVE STATED ONES. THE
MICROSCOPIC LASER DRILLED HOLES MAY BE CLOGGED BY USE
OF ANY OTHER MATERIALS LIKE ADHESIVES, SEALANTS, PAINT, OR
ANY FINE PARTICLES. THIS MAY AFFECT PANEL PERFORMANCE
AND IS CAUSE FOR PANEL REJECTION.
Mask panel active area with low tack tape and plug inlet ports when working with adhesives near panels
or in a dusty environment.
The inlets should be protected with appropriate caps.
Note: The porous panels are not approved for temperatures above 82° C (180°F).
The following tapes are approved for use on the porous panels:
) Low tack masking tape: Scotch Flatback tape 2517, width 48 mm.
) Surface protection film: 3M Protective tape type 7007 AB, width 150 mm.
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Trouble-Shooting
1. General
The table below lists the defects you could have with the ice protection system.
If you have the trouble detailed in the Trouble column read across to the Possible Cause column. Then
Cycle time of the Internal failure of the de-ice Replace control box.
WINDSHIELD, NORM or/and control box.
MAX- mode is/are out of
tolerance.
No de-icing fluid comes out of De-icing fluid tank empty. Replenish.

the spraybar and porous De-icing fluid pump defective. Replace pump.
panels.
De-icing fluid filter(s) clogged. Replace filter(s).
De-icing fluid tubing leaky. Replace the affected part of

the tubing.
De-icing fluid tubing clogged. Replace the affected part of

the tubing.
No fluid dissipates from part of Trapped air in porous panel. Purge system.
the active area of a porous
panel.
% DEIC PRES HI De-icing fluid filter(s) clogged. Replace filter(s).
% caution altert active.
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1. General
These Maintenance Practices tell you how to perform an operational test of the ice protection system.
They also tell you how to remove and install the main components of the ice protection system.
WARNING: DO NOT GET DE-ICING FLUID ON YOUR SKIN OR ON YOUR

CLOTHES. DE-ICING FLUID IS HARMFUL AND CAN CAUSE INJURIES
TO PERSONS AND CAN DAMAGE YOUR CLOTHING.
CAUTION: HANDLE DE-ICING FLUID WITH CARE. DE-ICING FLUID IS

FLAMMABLE AND CAN CAUSE DAMAGE TO EQUIPMENT.
CAUTION: DO NOT APPLY POLISH OR WAX TO THE PANELS. CERTAIN

SOLVENTS, PARTICULARLY METHYL ETHYL KETONE (MEK),
ACETONE, LACQUER THINNER AND OTHER TYPES OF THINNERS
AND SOLVENTS DAMAGE THE INNER MEMBRANE OF THE PANELS.
MASK ACTIVE AREA OF PANELS WITH A LOW TACK TAPE WHEN
USING SOLVENTS OR PAINTING THE AIRPLANE IN THE PROXIMITY
OF THE PANELS OR WHEN THE AIRPLANE IS STORED IN A DUSTY
ENVIRONMENT. REFER TO PARAGRAPH 4 “HANDLING OF POROUS
PANELS” IN THE GENERAL SECTION OF THIS CHAPTER.
Note: It is of particular importance that components and tubes upstream of the

pumps and between the filters and the proportioning units are protected
from ingress of foreign matter, as particles in the orifices of the proportioning
units may cause a malfunction of the system. Cap ends of loose tubes
during maintenance with plastic caps. The use of self adhesive tape is not
recommended as protective material for nylon tubes.
2. Operational Test
A. Equipment

TKS set. 1 A00305.
TKS system test cart. 1 D60-3000-04-00-ST.
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AIRCRAFT AMM
B. Operational Test

(1) Drain the de-ice fluid tank and verify that it is Use the T-fitting of feed line installed in
empty. the front wheel well for drainage.
(2) Verify the following de-ice control panel settings:
S OFF/NORM/HIGH switch: OFF.
S ICE LIGHT / ANNUN-TEST switch: OFF.
S PUMP SELECTOR: PUMP 1.
(3) Set the ELECT MASTER switch to ON.
(4) Check the following indications: Press SYSTEM - ENGINE softkey to

indicate de-ice fluid level.
S MFD: De-ice fluid level indication must show
empty.
S PFD: No ice protection system related

message in the alert window is active.
% Annunciation Check
(5) Switch to ANNUN-TEST mode on the de-ice The DEICE LVL LO message appears
% control panel and check that the DEICE LVL LO only if less then approx. 6.0 liter
% message appears in the alert window of the (1.59 US gal) are in the de-icing fluid
PFD. tank.
(6) Wait 2 minutes and verify that the

DEIC PRES LO message appears in the alert
window of the PFD.
(7) Turn the ICE LIGHT / ANNUN-TEST switch

back into the OFF position and verify that both
messages disappear immediately.
Fluid Emission Test Preparation
(8) Verify that all gutters, catchment tanks and Recommended when system is turned
shieldings are fixed on the airplane and on inside of hangar. See also TKS
protection tapes on the porous panels are system test cart.
removed.
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(9) Sprinkle all 7 ice protection panels with
approved de-icing fluid by using a clean, lint free
cloth.
(10) Fill the de-icing fluid tank. Refer to Section 12-10.
(11) Verify that the de-ice level indication on the

MFD shows full.
(12) Switch to the ANNUN-TEST mode on the de-ice

control panel and verify that there is no
DEICE LVL LO message in the alert window of
the PFD.
(13) Set ICE LIGHT / ANNUN-TEST - switch to OFF.
Windshield Spraybar Check
(14) Verify that the canopy is closed.
(15) Check that each hole on the canopy spraybar

emits de-icing fluid with pump 1 and pump 2:
S Press the WINDSHIELD push-button on the Repeat procedure until de-icing fluid
de-ice control panel for 1 second. emits from all holes in the spraybar.
S Select PUMP2 on the de-ice control panel.
S Press the WINDSHIELD push-button on the Repeat procedure until de-icing fluid
de-ice control panel for 1 second. emits from all holes in the spraybar.
(16) If the check described in the previous step was

not successful, then shortly apply high air
pressure to blocked holes of the spray bar and
repeat the check procedure.
Main De-Ice Panel Test
(17) Verify that the Pump-Selector switch on the

de-ice control panel is in PUMP 1 position.
% (18) Open canopy and set the OFF/NORM/HIGH The DEIC PRES LO annunciation may
% switch to the HIGH position and check operation appear on the PDF in HIGH-mode. The
% of the annunciation light on the de-ice control ice protection system pressure depends
% panel. on the system temperature.
(19) Check all ice protection panels for evidence of

de-icing fluid.
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(20) After each part of the ice protection panels The DEIC PRES LO annunciation may
become wet select PUMP 2 on the de-ice appear on the PFD in HIGH-mode. The
control panel. ice protection system pressure depends
on the system temperature.
(21) Check that each panel emits de-icing fluid with

pump 1 or pump 2.
% (22) Turn the OFF/NORM/HIGH switch in NORM

% position and check the lower, white
% annunciation light is on.
(23) Verify that both main pumps are running.
% (24) Verify that no DEIC PRES LO warning is now Above 20°C (68°F) ambient
% indicated in the alert window on the PFD. temperature, warning cancellation may
% not be possible.
Cycle Time Test
(25) In the NORM - Mode the operation of both main

pumps is cycled. Therefore check runtime of the
cycles:
S Pumps ON: 30 s (Tolerance +1 s / -3 s).
S Pumps OFF: 90 s (Tolerance +9 s / -1 s).
(26) Turn the OFF/NORM/HIGH switch in the HIGH

position, press the MAX push-button and check
operation of both amber annunciation lights.
(27) Check the runtime of the MAX-mode.
Pumps ON: 120 s (± 10 s).
(28) Check the runtime of the WINDSHIELD-pumps. Verify that the canopy is closed.
Pump ON: 5 s (± 1s).
(29) Turn the OFF/NORM/HIGH switch in OFF

position.
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ICE LIGHT / ANNUN-TEST - Test
(30) Turn the ICE LIGHT / OFF/ ANNUN TEST

switch in ICE LIGHT position and check
operation of the LH and the RH Ice Light.
(31) Turn the ICE LIGHT / OFF/ ANNUN TEST back

in the OFF position.
(32) Set the ELECT MASTER switch to OFF.
3. Drain the Ice Protection System
(1) Open blanking plug on the T-fitting in the nose Refer to Figure 1.
wheel bay.
(2) Allow the de-icing fluid to flow into suitable

containers.
(3) Close blanking plug on the T-fitting in the nose

wheel bay.
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4. Remove/Install the De-Icing Fluid Tank
A. Remove the De-Icing Fluid Tank
(1) Drain the ice protection system. Refer to Paragraph 3.
(2) Open the RH door to the nose baggage

compartment.
(3) Disconnect all hose and electrical connections Use caps to protect the loose line
from the de-icing fluid tank. connections from contamination.
(4) Remove the 4 bolts and washers which attach

the tank to the nose baggage compartment.
(5) Remove the battery cover.
(6) Move the tank clear of the airplane. Twist the tank 90° clockwise inboard for
easier removal.
B. Remove the De-Icing Fluid Tank (if OÄM 42-203 is installed)
(2) Open the passenger door and remove short

baggage extension.
(3) Disconnect all hose and electrical connections

from the de-icing fluid tank.
(4) Remove the 2 bolts from the tank belts and

loosen both hose clamps from the TKS fluid
hose (diameter approx. 60 mm).
(5) Move the TKS fluid hose downwards and

parallel to the de-icing fluid tank neck.
(6) Move the tank clear of the airplane. Tilt the tank forward for easier removal.
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C. Install the De-Icing Fluid Tank
(1) Move the tank in position in the RH nose Twist the tank 90° counter-clockwise
baggage compartment. inboard for easier installation.
(2) Connect all hose and electrical connections to Remove caps.

the de-icing fluid tank. Use new O-rings. Keep the aluminum
olives free from dust.
(3) Install the 4 bolts and washers which attach the

tank to the nose baggage compartment.
(4) Install the battery cover.
(5) Close the RH door to the nose baggage

compartment.
(6) Replenish the ice protection system. Refer to Section 12-10.
(7) Carry out operational test. Refer to Paragraph 2.
D. Install the De-Icing Fluid Tank (if OÄM 42-203 is installed)
(1) Move the tank in position aft of the short

baggage extension.
(2) Install the TKS fluid hose and tighten 2 hose

clamps.
(3) Move the tank belts in position and install the

2 bolts on the belts.
(4) Connect the hoses and the electrical connectors

to the de-icing fluid tank.
(5) Install the short baggage extension.
(6) Replenish the ice protection system. Refer to Section 12-10.
(7) Carry out an operational test. Refer to Paragraph 2.
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5. Remove/Install the De-Icing Fluid Inlet Strainer
A. Equipment
Drive slot tool. 1 12160-01.
B. Remove the De-Icing Fluid Inlet Strainer
(1) Open the filler cap of the de-icing fluid tank.
(2) Removal of inlet strainer
S Put drive pins of tool into drive slots of lock Use drive slot tool.
ring.
S Unscrew the strainer lock ring

counter-clockwise.
S Remove strainer lock and O-ring.
S Take out inlet strainer of filler neck.
(3) Protect filler neck with glycol cap.
C. Remove the De-Icing Fluid Inlet Strainer (if OÄM 42-203 is installed)
(1) Remove the de-icing fluid tank. Refer to Paragraph 4.B.
(2) Unscrew the de-icing fluid strainer from the

de-icing tank filler neck.
(3) Protect the de-icing tank filler neck with a cap.
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D. Install the De-Icing Fluid Inlet Strainer
(1) Remove glycol cap from filler neck. Verify that interior of tank is clean before
installing the strainer
CAUTION: MAKE SURE THAT THE STRAINER DOESN’T TURN. A TURNING

STRAINER CAN DAMAGE THE TANK VENTILATION.
(2) Implementation of inlet strainer:
S Move strainer in place in the filler neck.
S Apply O-ring and strainer lock.
S Put drive pins of tool into drive slots of lock Use drive slot tool.
ring.
S Fix strainer lock ring by twisting clockwise.
(3) Close the filler cap of the de-icing fluid tank.
E. Install the De-Icing Fluid Inlet Strainer (if OÄM 42-203 is installed)
(1) Remove the cap from the de-icing fluid tank filler
neck.
(2) Mount the de-icing fluid strainer to the de-icing

tank filler neck.
(3) Install the de-icing tank. Refer to Paragraph 4.D.
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6. Remove/Install a De-Icing Metering Pump
A. Remove a De-Icing Metering Pump
(1) Remove the de-icing fluid tank. Only for removal of the main pumps
(RH side). Refer to Paragraph 4.
(2) Remove the bolts and washers which attach the

lid to the floor in the nose baggage
compartment.
(3) Lift the lid upward.
(4) Disconnect all electrical connectors from the

pumps.
(5) Remove the locking wire from all hose

connections.
(6) Disconnect all hose connections from the Use caps to protect the loose line
pumps. connections from contamination.
(7) Remove the bolts and washers which hold the

pump to the lid including the l-sections.
(8) Remove the pump from the lid.
B. Install a De-Icing Metering Pump
(1) Move the pump in place on the nose floor lid.
(2) Install the bolts and washers which hold the

pump to the lid including the l-sections.
(3) Move the lid in place in the nose baggage Leave a gap to connect the hoses and
compartment. electrical connectors.
(4) Connect all hose connections to the pumps. Remove caps. Use new seals.
(5) Secure all hose connections with locking wire
(6) Connect all electrical connectors to the pumps.
(7) Move the lid in place in the floor.
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(8) Attach the bolts and washers which attach the

lid to the floor in the nose baggage
compartment.
(9) Install the de-icing fluid tank. Only for installation of the main pumps
(RH side). Refer to Paragraph 4.
7. Replace the Filter Cartridge or Windshield Pump or Solenoid Valve
(1) Open front baggage door LH.

lid (small inspection hole) to the floor in the LH
nose baggage compartment.
(3) Remove locking wire of hose connections

downstream of the high pressure switch (½ in).
(4) Remove locking wire of both hose connections

downstream of equal tee (5/16 in).
(5) Disconnect hose line connections. Use caps to protect the loose line
connections from contamination.
(6) Lift up access lid in the nose baggage

compartment on the LH side.
(7) Disconnect all electrical connectors from the

windshield pump/solenoid valve.
(8) Remove locking wire of hose connection to

spray bar (3/16 in), filter bleeding hose (3/16 in)
and to the manifold block (½ in) downstream of
equal tee.
(9) Disconnect hose line connections. Use caps to protect the loose line
(10) Remove the access lid in the nose baggage Twist up outer edge of lid and push
compartment on the LH side. slightly rearward.
(11) Remove the locking wire from the hose

connections to the component(s) to be replaced.
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(12) Remove the bolts and washers which hold the

component(s) to the lid.
(13) Disconnect all hose line connections from the Use caps to protect the loose line
component(s). connections from contamination.
(14) Replace component(s).

new component(s) to the lid.
(16) Connect all hose connections to the new Remove caps.

component(s).
Use new seals.
(17) Secure all hose connections with locking wire.
(18) Move the lid in place in the floor.
(19) Connect all hose connections (spray bar, filter Remove caps.
bleeding hose and manifold block)
Use new seals.
(21) Connect all hose connections below small Remove caps.

inspection hole (High pressure switch and equal
Use new seals.
tee).
(22) Connect all electrical connectors of the

windshield pump/solenoid valve.

lids to the floor of the LH nose baggage
compartment.
(25) Close the door of the LH nose baggage

compartment.
(26) Bleed the de-icing system. Refer to Paragraph 8.
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8. Bleed the De-Icing System
(1) Bleed the metering pumps:
S Fill the de-icing fluid tank to at least one Refer to Section 12-10.
quarter of its capacity.
S Close canopy.
S Operate the windshield pumps of the ice To remove all air.

protection system several times.
S Operate the system on HIGH until evidence

of de-icing fluid on the porous panels is
noticed.
S If de-icing fluid tank is completely empty, Refer to Section 12-10.

re-fill the de-icing fluid tank with approx.
2 liter (0.5 US gal) of de-icing fluid.
(2) Bleed the filter elements.
S Move end of bleeding hose to the exterior of Accessible via the LH baggage
the airplane. compartment door behind carpet.
S Remove the blanking plug from the filter To prevent the baggage compartment
bleeding hose. floor from becoming contaminated.
S Set ELECT MASTER switch to ON.
S Set OFF/NORM/HIGH switch of the de-icing

control unit to HIGH.
S Operate system until air free fluid is

discharged from the bleeding hose of the
filter elements.
S Set OFF/NORM/HIGH switch of the de-icing

control unit to OFF.
S Set ELECT MASTER switch to OFF.
S Install the blanking plug to the filter bleeding Use new seal if necessary.
hose.
S Put bleeding hose back in place. Make sure that no leakage occurs.
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9. Purge the De-Icing System
Purging is required when part of the active area of one or more porous panels fails to dissipate fluid.

Open the small inspection panels on the To give access to the proportioning
outboard side of the proportioning unit. units.
(1) Open blanking plugs on the proportioning unit. LH and RH nacelles.
(2) Use external pump (max. 6 bar or 87 PSI) with LH and RH. Refer to the AFM for
filtration fitted (0.8 micrometers or 1/25,000 approved de-icing fluids.
inch) to force de-icing fluid through the porous
panels.
(3) Close blanking plugs on the proportioning unit. LH and RH nacelles.
(4) Close the small inspection panels on the

outboard side of the engine nacelles.
10. Remove/Install a Proportioning Unit
A. Remove a Proportioning Unit from the Nacelle
CAUTION: YOU MUST MARK THE HOSES AND PORTS SO THAT YOU CAN
RE-CONNECT THE HOSES TO THE CORRECT PORTS ON THE
PROPORTIONING UNIT. IF YOU DO NOT RE-CONNECT THE
HOSES CORRECTLY, THE SYSTEM WILL NOT WORK PROPERLY.
(2) Remove the bolts, washers and the spacer Hold the proportioning unit.
holding the proportioning unit.

connections to the filter element.
(4) Disconnect all hose connections from the Use caps to protect the loose line
proportioning unit. connections from contamination.
(5) Move the proportioning unit clear of the airplane.
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B. Install a Proportioning Unit to the Nacelle
(1) Move the proportioning unit in position in the

nacelle.
CAUTION: YOU MUST CONNECT THE HOSES TO THE CORRECT PORTS. IF

YOU DO NOT CONNECT THE HOSES CORRECTLY, THE SYSTEM
WILL NOT WORK PROPERLY.
(2) Connect all hose connections to the Remove caps.

proportioning unit.
(3) Secure all hose connections with wire lock.
(4) Install the bolts and washers which hold the

proportioning unit.
(5) Close the small inspection panels on the

outboard side of the engine nacelles.
11. Replace an Ice Protection Porous Panel
The porous panels for the ice protection system are bonded to the wing, vertical and horizontal
stabilizer leading edges. They cannot be removed without damage to the panels. Refer to the airplane
manufacturer when you must replace a porous panel.
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12. Replace De-Icing Fluid Nylon Tubing
Used diameters are: 3/16 in, 5/16 in and 1/2 in. Only replace tubes by tubes with the same diameter.
Refer to the CAV Aerospace Nylon Tubing and Coupling General Practices Manual for the replacement
procedure. For the feeder lines in the engine nacelle to the propeller only use PTFE tubing.
Minimum bending radius cold formed are:
Tool No. Tube outside Min. recommended bend radius inch

diameter (mm) measured to inside wall of tube,
cold formed
T300 - 112 A. 3/16 in 1 (25)
T300 - 120 A. 5/16 in 3 (75)
T300 - 144 A. 1/2 in 4 (100)
13. Replace Ice Protection Control Box
(1) Confirm that the XFER PUMP/ DE-ICE circuit

breaker is pulled.
(2) Open the access lid in the nose baggage To give access the ice protection control
compartment on the LH side. box.
(3) Unscrew the 2 mounting screws from the upper

side of the baggage compartment floor.
(4) Extract the de-ice control box via the access

hole.
(5) Disconnect plug no.: P3011 from control box.
(6) Connect plug no.: P3011 to new control box.
(7) Move the de-ice control box to the prior position

and fix it by using the 2 mounting screws and
the upper-floor reinforcement doubler.
(8) Close the access lid in the nose baggage

compartment on the LH side.
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14. Remove/Install the High Pressure Switch
A. Remove High Pressure Switch
(2) Open front baggage door LH.

small inspection lid to the floor of LH nose
(4) Lift the lid upward.
(5) Disconnect electrical connectors from high

pressure switch.
(6) Remove locking wire from all hose connections

on the high pressure switch.
(7) Disconnect all hose connections from the high Use caps to protect the loose line
pressure switch. connections from contamination.
(8) Remove cable ties which fix high pressure

switch to the nose cone.
(9) Remove high pressure switch from baggage

compartment.
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B. Install High Pressure Switch
(1) High Pressure Switch Values
HP Switch Value
Activate. 5.86 (± 0.35) bar / 85 (± 5) PSI
Reset. 4.83 (± 0.35) bar / 70 (± 5) PSI
(2) Install High Pressure Switch
(1) Move high pressure switch in place below the

small inspection lid on the LH side in the nose
(2) Connect hose line connection upstream of the Remove caps.

high pressure switch.
Use new seals.
(3) Fit tubing containing valve and dampened For appropriate range of manometer see
manometer downstream of the high pressure table above. Prepare collecting
switch. container for dissipating fluid.
(4) Operate ice protection system in HIGH mode.
(5) Adjust pressure in tubing with the vessel above See table above for limits.
the activation limit of the high pressure switch.
(6) Check high pressure caution on PFD of G1000

after 2 minutes (tolerance + 5 sec.) delay since
pressure adjusted above limit.
(7) Check low-pressure warning on PDF of G1000

after 2 minutes (tolerance + 5 sec.) delay since
pressure adjusted above limit.
(8) Check if high pressure indication extinguishes

after pressure in tubing has been adjusted
below reset value according the table above.
(9) Switch off ice protection system.
(10) Remove nylon tubing containing vessel and

manometer downstream of high pressure
switch.
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(11) Connect hose line connection downstream of Remove caps.

the high pressure switch.
Use new seals.
(12) Secure hose line connections of high pressure

switch with lock wire.
(13) Fix high pressure switch with cable ties to the Replace cable tie base if necessary.
nose cone.
(14) Move small inspection lid in place.
(15) Install bolts and washers which attach the lid to

the floor of the nose baggage compartment.
(16) Close LH door of nose baggage compartment.
(17) Do an operational test. Refer to Paragraph 2.
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15. Remove/Install the Low Pressure Switch Proportioning Unit
A. Remove the Low Pressure Switch Proportioning Unit
(1) Remove fairing cover from empennage.
(2) Remove cable ties.
(3) Disconnect VOR antenna (coaxial cable).
CAUTION: YOU MUST MARK THE HOSES AND PORTS SO THAT YOU CAN
RE-CONNECT THE HOSES TO THE CORRECT PORTS ON THE
PROPORTIONING UNIT. IF YOU DO NOT RE-CONNECT THE
HOSES CORRECTLY, THE SYSTEM WILL NOT WORK PROPERLY.
(4) Disconnect all electrical connectors from the low

pressure switches.
(5) Remove locking wire from the hose connections

pointing in flight direction.
(6) Disconnect the hose connections to the low Use caps to protect the loose line
pressure switches. connections from contamination.
(7) Remove bolts and washers, which hold the low

pressure switch proportioning unit to the vertical
stabilizer.
(8) Pull low pressure switch proportioning unit To give access to the feeder line of the
upward. fuselage section.
(9) Remove locking wire from the feeder line

connection.
(10) Disconnect feeder line to the low pressure Use caps to protect the loose line
switch proportioning unit. connections from contamination.
(11) Remove locking wire from the two hose

connections labeled as 2 and 3 on the
proportioning unit (LH & RH horizontal tail
panel).
(12) Disconnect the two hose connections labeled as Use caps to protect the loose line
2 and 3 on the proportioning unit (LH & RH connections from contamination.
panel).
(13) Remove low pressure switch proportioning unit.
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B. Install the Low Pressure Switch Proportioning Unit
(1) Connect feeder line to the low pressure switch

proportioning unit.
(2) Secure feeder line connection with locking wire.
(3) Move low pressure switch proportioning unit in To give access to the feeder line of the
position in the vertical stabilizer. fuselage section.
(4) Install bolts and washers which hold the low

pressure switch proportioning unit to the vertical
stabilizer.
(5) Connect the two hose connections to the

proportioning unit labeled as 2 and 3 on the
proportioning unit.
(6) Secure the two hose connections with locking

wire.
CAUTION: YOU MUST CONNECT THE HOSES TO THE CORRECT PORTS. IF

YOU DO NOT CONNECT THE HOSES CORRECTLY, THE SYSTEM
WILL NOT WORK PROPERLY.
(7) Connect the hose connections to the low Remove caps.

pressure switches. Use new seals.
(8) Secure the hose connections with locking wire.
(9) Connect all electrical connectors from the low

pressure switches.
(10) Connect VOR antenna (coaxial cable).
(11) Install cable ties.
(12) Install fairing cover to empennage.
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16. Remove/Install a Low Pressure Switch in the Horizontal Tail
A. Remove a Low Pressure Switch in the Horizontal Tail
(1) Remove the maintenance cap horizontal tail Cut sealant.

outboard.
(2) Disconnect the electrical connectors from the

low pressure switch.

connections and the screw connections.
(4) Disconnect the hose connections to the low

pressure switch
(5) Remove bolts and washers, which hold the

low pressure switch to the low pressure
switch bracket.
(6) Remove low pressure switch from bracket. Use caps to protect the loose line
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B. Install a Low Pressure Switch in the Horizontal Tail
(1) Connect the hose connection of the feeding

line (from the proportioning unit) to the low
pressure switch.
(2) Secure the hose connection with locking wire.
(3) Move the low pressure switch in position to In flight direction.

the low pressure switch bracket bonded to the
upper shell of the horizontal tail.
(4) Install bolts and washers which hold the low

pressure switch to the bracket.
(5) Secure the bolts with locking wire.
(6) Connect the hose connections of the feeding Max. length 200 mm.
line (to panel inlet) to the low pressure switch.
(7) Secure the hose connection with locking wire.
(8) Connect the electrical connector from the low

pressure switch.
(9) Carry out operational test.
(10) Install maintenance cap. Use sealant.
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DA 42 NG AMM Indicating Systems
AIRCRAFT
CHAPTER 31
INDICATING SYSTEMS
Doc # 7.02.15 Page 1

Indicating Systems DA 42 NG AMM
AIRCRAFT
Page 2
22 Dec 2021
31-TITLE Doc # 7.02.15
Rev. 5
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 31
INDICATING SYSTEMS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 31-10
Instrument and Control Panels
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Instrument Panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Center Console Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. De-Ice Control Panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Engine Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 31-20
Independent Instruments
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 31-40
Central Computers
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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AIRCRAFT
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a GDU 10XX Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3. Remove/Install a GIA 63 X Integrated Avionics Unit (IAU) . . . . . . . . . . . . . . . . . 208
4. Remove/Install the GTX33/335 R Transponder . . . . . . . . . . . . . . . . . . . . . . . . . 210
5. Remove/Install the GRS 7X Attitude, Heading and Reference Unit (AHRS) . . . 213
6. Remove/Install the GDC 7X Air Data Computer (ADC) . . . . . . . . . . . . . . . . . . . 216
7. Remove/Install the GEA 71/B Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
8. GMU 44 Magnetometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
9. G1000 Magnetometer Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
10. Remove/Install the De-Ice Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
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AIRCRAFT
CHAPTER 31
INDICATING SYSTEMS
1. General
This Chapter tells you about the indicating systems installed in the airplane. Refer to these Sections
for the related data:
) Section 31-10. The instrument and control panels installed in the DA 42 NG.
) Section 31-20. Independent instruments.
) Section 31-40. The integrated cockpit system.
The DA 42 NG has these indicating systems:
) An instrument panel. The instrument panel is made in several pieces with a shelf. The shelf
goes between the panel and the cockpit forward bulkhead.
) A control panel in the center console. This panel has the engine controls, fuel controls, cabin
heat control levers, parking brake and trim. It has a forward part and an aft part.
) Integrated cockpit system (ICS). The airplane has an integrated cockpit system with 2 displays
which give the airplane flight and navigation displays, engine instrument displays and airplane
systems indications. The ICS has “softkeys” on the display screens for the option of selecting
which indications will be displayed on the screen.
This Section does not tell you about the indicators that belong to systems. See the related system for
data. For example, see Section 27-31 for data about the trim indicator.
Service Bulletin.
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Section 31-10
Instrument and Control Panels
1. General
The DA 42 NG has these instrument and control panels:
) An instrument panel. The instrument panel is made in several pieces with a shelf. The shelf
goes between the panel and the instrument panel frame.
) A control panel in the center console. This panel has a forward cover and an aft cover. The
forward cover has the cabin heat control levers, parking brake lever and rudder trim control. The
aft cover has the engine controls and fuel transfer/shut-off valve.
See the related Chapter or Section for data about the controls. For example, see Section 76-00 for
data on the engine controls.
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Rev. 5 31-10-00 22 Dec 2021
AIRCRAFT
Emergency Switch
Artificial Horizon /
Compass ELT Control
Flood Light
Panel
ICS Light Airspeed Artificial ICS Oxygen
Display Unit Controls Indicator Horizon Altimeter Display Unit Pressure
Indicator
De Ice Panel
Fresh Air
Vent Fresh Air
Vent
Alternate Pitot Engine AV Audio Fuel Flap Circuit

Static Heat Starter Master Control Pumps Selector Breakers
Panel
Circuit Elect. Landing
Breakers Master Gear
ECU Test /
Alternator / ECU Voter
Figure 1: Instrument Panel
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AIRCRAFT
Optional, if OÄM 42-270 is installed
Figure 2: Instrument Panel (with OÄM 42-270)
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Rev. 5 31-10-00 22 Dec 2021
AIRCRAFT
2. Instrument Panel Description
Several pieces of aluminum alloy make the instrument panel. The panel has a vertical face with
instruments and a horizontal 'shelf' with electrical components. The shelf goes between the forward
bulkhead of the cockpit and the vertical face of the panel.
The DA 42 NG has an integrated cockpit system (ICS). The ICS has two large LCD display screens
which are located in the instrument panel. These two display screens can digitally display all of the
flight, navigation and airplane system data. An audio control panel is located between the display
screens. The audio control panel integrates with the ICS and is used to control all of the airplane radio
and navigation audio systems. Refer to Section 31-40 for more data about the ICS.
An airspeed indicator, artificial horizon, altimeter and magnetic compass are located along the top of
the instrument panel. Optional, if OÄM 42-270 is installed, the airspeed indicator, artifical horizon and
altimeter are combined in one unit named Standby Altitude Module. These instruments provides the
basic data required to fly the airplane in the event of a power failure and the loss of the ICS. The
artificial horizon or the standby attitude module can be powered from an emergency power pack. An
emergency switch is located near the artificial horizon or standby attitude module and has a guard
installed to prevent accidental selection.
Most circuit breakers for the electrical systems are located on the right side of the instrument panel.
The electrical system bus-bars are directly connected to the rear of the circuit-breakers.
Along the bottom of the instrument panel are the electrical, avionic and engine master switches. The
landing gear and flap control switches and fuel pump switches are also located along the bottom of
the instrument panel. The instrument panel and airplane light switches are located at the top-left of the
instrument panel.
The shelf part of the instrument panel holds relays, junction blocks, connectors and ground studs.
The instrument panel has a cover attached by screws.
Refer to Chapter 24 for more data about the electrical system and Chapter 22 for more data about the
autopilot system.
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Rudder Trim Wheel
R L
Forward Cover Plate rudder trim
P
R
A
E ON ON
R
L
K
E
I
A
N D
S
G E C
E
F A
Parking Brake R
O
B
I
B
R
A
S
T
N
Heater Controls
K L
E O OFF OFF
C
K
Engine Control 100% 100%
Cover Plate
R
L I
E G
F H
T T
E E
N N
G G
I I
N N
Left Engine Power Lever E E
Right Engine Power Lever
0% 0%
FUEL CONTROL
Left Engine ON
LEFT ENGINE RIGHT ENGINE
ON
Right Engine
Fuel Transfer/ Fuel Transfer/
Shut-Off Valve Shut-Off Valve
CROSS
FEED
CROSS
FEED Fuel Transfer/
OFF OFF Shut-Off Valve
Cover Plate
NOSE
DOWN
Elevator Trim Wheel
NOSE
UP
Figure 3: Center Console
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3. Center Console Description
Figure 3 shows the center console structure. Refer to the related chapters for the data on the controls.
The center console holds the engine control assembly. The engine control assembly holds the rudder
trim, parking brake, heating controls and engine power levers. Aft of the engine control assembly are
the controls for the fuel transfer/shut off valves and the elevator trim wheel.
The engine control assembly has two aluminum alloy side plates. Four brackets attach to the side
plates with rivets. The front bracket has holes to anchor the outer sheaths of the brake and heat control
cables. The top bracket has two anchor nuts. Bolts engage the anchor nuts to attach the engine control
assembly to the top of the floor panel.
The center bracket has two anchor nuts for the control cover plates. The rear bracket attaches to the
elevator trim control assembly.
There are no user maintainable parts in the engine control assembly structure or the center console
structure.
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4. De-Ice Control Panel Description
Figure 4 shows the de-ice control panel which is installed on the RH side of the instrument panel. All
functions of the de-ice system are operated by the de-ice control panel in conjunction with the de-ice
control box. Refer to Chapter 30 for a detailed description of the de-icing system.
DE ICE
MAX
A
L
T
E
R
HIGH N
A
NORM T
E
OFF
WIND
SHIELD ICE LIGHT PUMP 2
OFF
ANNUN- PUMP 1
TEST
Figure 4: DE-ICE Control Panel
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Trouble-Shooting
1. General
Parking brake or cabin heat Friction tension too low. Adjust the friction.
control levers do not stay in the
Too much wear in the friction Replace the friction washers.
set position.
washers.
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1. General
These Maintenance Practices tell you how to remove/install the engine control assembly.
2. Remove/Install the Engine Control Assembly
(1) Remove the knob from the rudder trim control:
S Remove the grub screw from the recess in

the knob.
S Pull the knob clear of the spindle.
(2) Remove the knob from the parking brake control

lever:
S Remove the screw that attaches the plain

knob to the threaded knob.
S Remove the knobs and spacer from the

lever.
(3) Remove the knobs from the heater control

levers. Do this procedure for each lever:


lever.
(4) Remove the forward cover plate:

plate to the engine control assembly.
S Lift the cover plate clear of the engine

control assembly.
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(5) Remove the engine control cover plate:

S Lift the cover plate clear of the engine

control assembly.
(6) Remove the knobs from the fuel transfer/shut off

control levers. Do this procedure for each lever:


lever.
(7) Remove the fuel transfer/shut off control

assembly cover plate:

plate to control assembly.
S Move the cover plate clear of the center

console.
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(8) Remove the engine control assembly:
S Remove the 2 bolts that attach the aft end of

the engine control assembly to the structure.
S Lift the engine control assembly up from the

center console and release these
components as they become accessible:
S The parking brake control cable. Refer to Section 32-40.
S The heater control cables. Refer to Sections 21-20 and 21-40.
S The electrical cables for the engine power Refer to Section 76-00.
levers.
S The rudder trim cable.

S The electrical cables for the engine control
At the in-line connectors.
assembly micro switches.
S When all the components are released lift

the engine control assembly clear of the
center console.
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A. Install the Engine Control Assembly
(1) Install the engine control assembly:
S Move the control into position in the cockpit

and hold above the center console and:
S Connect the rudder trim cable. Refer to Section 27-21.
S Connect the electrical cables for the micro At the in-line connectors.
switches in the engine control assembly.
S The electrical cables for the engine power Refer to Section 76-00.
levers.
S The heater control cables. Refer to Sections 21-20 and 21-40.
S The parking brake control cable. Refer to Section 32-40.
S When all the components are connected

lower the engine control assembly into
position in the center console.
S Install the 2 bolts at the rear of the engine

control assembly that attach the engine
control assembly to the center console.
(2) Install the fuel transfer/shut off control assembly

cover plate:
S Move the cover plate into position at the

center console.
S Install the 4 screws that attach the cover

plate to control assembly.
(3) Install the knobs onto the fuel transfer/shut off

control levers. Do this procedure for each lever:
S Install the plain knob, spacers and threaded

knob onto the lever.
S Install the screw that attaches the plain knob

to the threaded knob.
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(4) Install the engine control cover plate:
S Move the cover plate into position over the

power levers.

(5) Install the forward cover plate:
S Move the cover plate into position over the

engine control assembly.

(6) Install the knobs onto the heater control levers.

Do this procedure for each lever:
S Install the plain knob, spacer and threaded


(7) Install the knobs onto the parking brake lever:
S Install the plain knob, spacer and threaded


(8) Install the knob onto the rudder trim control:
S Move the knob into position over the

spindle.
S Install the grub-screw into the recess in the

knob.
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(9) Do a test for the correct operation of the rudder Refer to Section 27-21.
trim system. If necessary for your Airworthiness
Authority do a duplicate inspection of the rudder
trim system.
(10) Do a test for the correct operation of the parking Refer to Section 32-40.
brake system.
(11) Do a test for the correct operation of the Refer to Sections 21-20 and 21-40.
airplane heating and ventilation system.
(12) Do a test for the correct operation of the engine Refer to Section 76-00.
control system.
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Section 31-20
Independent Instruments
1. General
The DA 42 NG airplane has no independent instruments that are not part of the integrated cockpit
system (ICS). For more data about the ICS refer to Section 31-40.
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Section 31-40
Central Computers
1. General
The DA 42 NG has a Garmin G1000 integrated cockpit system (ICS). The ICS integrates all the usual
flight, avionic and airframe system indications into one system. The system displays the data on
two display screens located in the instrument panel. An audio control panel is located between the
two display screens. The audio control panel integrates and controls the airplane radio, navigation and
intercom systems.
Refer to Section 23-50 for more data about the audio control panel.
Electrical power is supplied to the ICS control and display screens when the ELECT. MASTER switch
is set to ON. Power is supplied to the audio control panel when the AV. MASTER switch is set to ON.
During normal operation the left display screen is referred to as the primary flight display (PFD) and
the right display screen as the multi function display (MFD). Either display can be used as PFD or
MFD. If one display fails the remaining screen can be toggled automatically to reversionary mode.
For more detailed data about the ICS refer to the G1000 Cockpit Reference Guide for the DA 42 NG
Airplane.
Figure 1 shows the ICS system schematic.
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AIRCRAFT
%
% Master
Configuration
%
Module
% GMA 1347/1360
% Audio Panel
Reversionary Reversionary
% Switch Switch
No. 1 No. 2
% GDU 10XX ARINC 429 GDU 10XX
% Primary Multi Function
Flight Display ARINC 429 Display
%
%
Ethernet
%
% Ethernet RS-232 Ethernet
% Digital COM Digital COM
% Audio Audio
No. 1 No. 2
% GIA 6X W
Digital NAV Digital NAV
GIA 6X W
Audio Audio
% Integrated Integrated
% Avionics RS-232 GPT 59 OAT Avionics
Unit Probe Unit
% RS-232 GDC 7X
Air Data ARINC 429
% ARINC 429
Computer
% Configuration
ARINC 429
% Module
RS-232
% GRS 7X RS-232
ARINC 429 AHRS
%
ARINC 429
% RS-485
Configuration
% Module GMU 44
% Magnetometer
%
% RS-232 GTX 3XX RS-232
% Transponder
% RS-485 RS-485
GEA 71/B
% Engine/Airframe
% Unit
% Engine/Airframe Configuration
% Sensors Module
%
Figure 1: Integrated Cockpit System Schematic Diagram
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2. Description
Figure 2 shows the schematic diagram for the ICS. The ICS has these main components:
A. Primary Flight Display (PFD)
The PFD is a 10.4 in liquid crystal display. Bezels on the left and right side of the PFD have the
controls for the ICS. The lower edge of the PFD has 'softkeys'. The function of the softkeys relates
to the on-screen display and the display will show the function of the key.
The PFD shows the basic primary flight display plus a number of additional options that can
selected manually. Some other indications will be generated automatically for example, alert
captions.
The left side bezel has these controls:
) NAV VOL/SQ knob. This controls the NAV audio level. Press the knob to toggle the ident filter
OFF/ON.
) NAV frequency transfer key. Press this key to make the standby NAV frequency the active
frequency.
) NAV knob. This control has a large outer knob and a smaller inner knob. Rotate these knobs
to select the NAV frequency. Rotate the large outer knob to select the MHz and the inner knob
to select the kHz. Pressing the smaller inner knob will toggle the tuning cursor between the
NAV1 and NAV2 frequency display.
) HDG knob. You can manually select the heading with this control. Pressing this knob will cause
a heading window to momentarily appear to the left of the heading indicator. This window will
show the airplane heading in a digital display and the heading bug will align with the compass
lubber line.
) ALT SEL knob. Sets the selected altitude in the window over the altimeter tape display. The
large outer knob sets the thousands indication and the inner knob sets the hundreds indication.
The right side bezel has these controls:
) COM VOL/SQ knob. Controls the COM audio level. Press the knob to toggle the COM automatic
squelch ON/OFF.
) COM frequency transfer key. Press this key momentarily to make the standby COM frequency
active. Press and hold this key to automatically make the emergency frequency (121.5 MHz)
the standby frequency.
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AIRCRAFT
Primary
Flight Multi Function
Display Display
NAV Vol/Sq
Garmin Display Unit
V OL PU SH
NAV Frequency VOL PUIDSH
NAV COM
SQ
Transfer
EMERG
NAV Frequency PUSH

1-2
PUSH
1-2
HDG CRS BARO
Selector SD Card Slots
Heading Selector PUSH
HDG SYNC
PUSH
CRS CTR
RANGE
PUSH
PAN
D MENU
FPL PR OC
CLR EN T
ALT DFLT MAP FMS
Altitude Selector
Left Side Bezel Soft Keys Right Side Bezel
Figure 2: Garmin G1000 Display Screens and Audio Integrating Unit
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AIRCRAFT
) COM knob. This control has a large outer knob and a smaller inner knob. Rotate these knobs
to select the COM frequency. Rotate the large outer knob to select the MHz and the inner knob
to select the kHz. Pressing the smaller inner knob will toggle the tuning cursor between the
COM1 and COM2 frequency display.
) CRS/BARO knob. This control has a large outer knob and a small inner knob. The outer knob
sets the barometric pressure. The inner knob sets the airplane course.
) RANGE/PAN JOYSTICK knob. Rotate the knob to increase/decrease the map scale. Use the
knob as a joystick to pan the map display.
) DIRECT TO key. Press this key to activate the direct-to function. This will give the direct course
to a waypoint selected from the active route or to a position indicated by the map cursor.
) MENU key. Press the key to display the menu. The menu displays the options associated with
the currently displayed page.
) FPL key. Press this key to display the active flight plan page. You can create or edit an existing
flight plan using the bezel controls and soft keys when this page is displayed.
) PROC key. Press this key to display the procedures page. If this page is used with a selected
flight plan then the procedures page will display the data associated with the flight plan. If the
page is not used with a flight plan then an airfield and its relate procedures can be selected from
a database.
) CLR key. Press this key to cancel an entry or delete information. Press and hold this key to
immediately display the 'Default Navigation Map Page'.
) ENT key. Press to accept a menu selection or data entry. Use this key to approve an operation
or to complete a data entry.
) FMS knobs. Use these concentric knobs select the page to be displayed. The outer large knob
selects a page group and the inner knob selects a specific page from within the selected page
group. Press the inner knob to activates an on-screen cursor. When the cursor is activated the
outer knob can be used to move the cursor on the page and the small inner knob can used to
scroll the cursor through an item or menu selected by the outer knob.
) Secure Digital (SD) cards. Secure Digital cards can be inserted into the slots in the right side
bezel. These cards can contain data such as updated GPS navigation charts or special-to-type
airplane checklists.
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Attitude Indicator
Nav Frequency Airspeed Waypoint Status Marker Beacon Com Frequency

Window Indicator Window Annunciation Window
NAV1 117.90 112.20 MPT KTYS DIS 140% DTK 291% TRX 291% 136.975 118.000 VOL PUSH
VOL PUSH SQ
ID
NAV2 108.00 117.95 136.975 118.000
COM
Vertical Speed
NAV
TRAFFIC
0
E MERG
Indicator
M
140 2
20 20
PUSH
6600
PUSH
Glideslope
1-2
1-2
HDG
130
10 10 6400
1
CRS BARO
Indicator
60
63 40 100
120 20
PUSH
110
10 10 6200 1 PUSH
Altitude
HDG SYNC
100 DOOR OPEN
ALTERNATOR
CRS CTR
RANGE
Indicator
291° 6000 2 PITOT OFF
80 R FUEL LOW
TAS 120%
w 30
33
29.68 L FUEL LOW
Warnings &
24
NORTH UP
GPS ENR
ALERTS PUSH
PAN
Cautions
21
DOOR OPEN - Canopy and/or rear

N
KCL
door isn't closed and locked.
ALTERNATOR - Alternator failed
D MENU Annunciation
S
Battery is only elec source.

6 PITOT OFF - Pitot heat is off. FPL PROC
15 E Turn switch on to avoid icing.
12
CLR ENT
OAT 08 XPDR 1200 STBY LD 12:03:25
ALT CDI OBS XPDR REFS NRST WARNING DFLT MAP FMS
INSET PFD
System Time
Outside Air Nav Map Horizontal Transponder Alerts

Temperature Situation Window Window
Window Indicator
Figure 3: Primary Flight Display
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The PFD window displays the usual primary flight instruments in a standard ‘T’ configuration. The
basic flight instruments are:
) Airspeed indicator (ASI). The airspeed indicator is on the left side of the display and indicates
the airspeed on a rolling number gauge using a moving tape. The airspeed indicator also
displays speed ranges for different airplane configurations, airspeed trends and ‘V’ speeds. If
the airspeed indicator fails the display marks the airspeed display area with a red ’X’ and yellow
text spelling out ‘AIRSPEED FAIL’ (if MÄM 42-978 is NOT installed).
) TAS. True airspeed is digitally displayed in a small window below the airspeed indicator.
) Attitude indicator (Artificial Horizon). The attitude indicator is located in the center of the PFD,
at the top. The attitude indicator shows the pitch, roll and yaw situation of the airplane. If the
attitude indicator fails the display marks the pitch attitude display area with a red ’X’ and yellow
text spelling out ‘ATTITUDE FAIL’ (if MÄM 42-978 is NOT installed).
) Altimeter. The altimeter is located at the top right of the PFD. The altimeter displays the airplane
altitude in feet on a rolling number gauge using a moving tape. The altimeter also shows a
altitude ‘bug’ at the selected altitude or the edge of the tape, whichever is closest to the current
altitude. If the altitude indicator fails the display marks the tape display area with a red ’X’ and
yellow text spelling out ‘ALTITUDE FAIL’ (if MÄM 42-978 is NOT installed).
) Barometric pressure indicator. The barometric pressure indicator is located immediately below
the altitude indicator. The indicator shows the barometric pressure that has been set in either
inches of mercury (Hg) or hectopascal number (hPa)
) Vertical speed indicator (VSI). The vertical speed indicator is located to the right of the altitude
indicator. The indicator displays the airplane vertical speed in feet/min. A numeric pointer moves
vertically up/down a fixed tape. The vertical speed indication is also shown digitally on the
pointer. A negative sign is shown on the pointer to indicate negative vertical speeds (airplane
descending). If the VSI fails the display marks the tape display area with a red or yellow ’X’ and
yellow text spelling out ‘VERT SPEED FAIL’ (if MÄM 42-978 is NOT installed).
) Horizontal situation indicator (HSI). The HSI s located in the center of the PFD at the bottom.
The HSI displays a rotating circular compass with heading markings. The HSI shows the
following information:
) Heading information. The heading is shown digitally in a window at the top of the rotating
compass.
) Turn rate indicator. A turn rate indicator is located between the digital heading window and the
rotating compass.
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) Course deviation indicator (CDI). The CDI is a line with an arrowhead that points to the airplane
heading on the rotating compass. The line can slide left or right of the center marking to show
the deviation of the actual course being flown to the required course. Course data can be
supplied from the airplane VOR, LOC or GPS system. If the heading data is invalid the digital
heading display window is marked with a red cross and yellow text spelling ‘HDG’.
) Vertical deviation (glidescope) indicator. The glidescope indicator is located to the left of the
altimeter.
) Alerts window. The alerts window is located on the lower right side of the PFD. This window
opens when an alert is activated or when the WARNINGS softkey is operated.
) Warnings and cautions window. The warnings and cautions window is located above the alerts
window. This window opens when a warning or caution is activated or if the WARNING softkey
is operated.
) NAV MAP. The NAV MAP window is located in the lower left of the PFD. The window is
activated by pressing the INSET softkey and when activated shows a pictorial view of the
airplane on a moving map.
Small windows in the top left corner of the PFD show active and standby NAV frequencies. Small
windows in the top right of the PFD show active and standby COM frequencies. A larger window
in the top of the PFD flight planning data when activated and autopilot mode annunciations.
A small window in the bottom left of the PFD shows the outside air temperature (OAT). A small
windows on the bottom right of the PFD shows the transponder settings and operational state.
Another small window in the right bottom corner of the PFD shows a digital clock.
A set of labels along the very bottom of the PFD identify the function of the softkeys for the current
page being displayed on the PFD.
The PFD has a self-monitoring system. If the PFD self-monitoring system detects a fault the PFD
enters reversionary mode. In the reversionary mode the PFD is configured to display the flight
instrument symbology and the basic engine parameter monitoring indications. The PFD
reversionary mode can also be entered by pressing the DISPLAY BACKUP selector. The DISPLAY
BACKUP selector is located on the bottom of the audio control panel.
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B. Multi-Function Display (MFD)
The MFD is a 10.4 in liquid crystal display. Bezels on the left and right side of the MFD have the
controls for the ICS. The lower edge of the MFD has ‘softkeys’. The function of the soft keys relates
to the on-screen display and if a key has a function related to the current display the display will
show the function of the key.
The MFD displays engine and airplane pages on the left slide of the screen. The remainder of the
screen is used to display navigational pages. The bezels on the left and right side of the MFD have
the same controls and function as the bezels on the PFD. The left side bezel on the MFD has also
the controls for the autopilot system. Refer to Chapter 22 for more information about the autopilot.
The Engine instrumentation system window (EIS) is on the left side of the MFD and displays a full-
time dedicated display of engine parameters. The information is presented in three displays:
) Engine Display. This is the default display and shows following critical engine and fuel
indicators:
) Engine load. The engine loads are displayed as a percentage. Pointers on each side of a
vertical scale move to show the engine load. If the system fails the display shows a red or
yellow cross to the left or right of the load indicator to show which engine system has failed.
) Engine RPM. Pointers on each side of a vertical scale move to show the engine rpm. If the
system fails the display shows a red or yellow cross to the left or right of the RPM indicator
to show which engine system has failed.
) Fuel flow. Small windows to the left and right of a GPH marking show the engine fuel flow
digitally. If the system fails a red or yellow cross is displayed in place of the digital indication
for the failed system(s).
) Oil temperature. Pointers above and below a range bar indicate the oil temperature. The
range bar is color coded, green to show the normal operating range, yellow in the cautionary
range and red in the warning range. The pointers move from left to right to indicate the oil
temperature. The pointer above the range bar indicates the oil temperature of the left engine
and the pointer below the range bar indicates the oil temperature of the right engine. If the
system fails a red or yellow cross is displayed above or below the range bar to show which
engine system has failed.
) Oil pressure. Pointers above and below a range bar indicate the oil pressure. The range bar
is color coded, green to show the normal operating range, yellow in the cautionary range and
red in the warning range. The pointers move from left to right to indicate the oil pressure. The
pointer above the range bar indicates the oil pressure of the left engine and the pointer below
the range bar indicates the oil pressure of the right engine. If the system fails a red or yellow
cross is displayed above or below the range bar to show which engine system has failed.
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) Coolant temperature. Pointers above and below a range bar indicate the coolant
temperature. The range bar is color coded, green to show the normal operating range, yellow
in the cautionary range and red in the warning range. The pointers move from left to right to
indicate the coolant temperature. The pointer above the range bar indicates the coolant
temperature of the left engine and the pointer below the range bar indicates the coolant
temperature of the right engine. If the system fails a red or yellow cross is displayed above
or below the range bar to show which engine system has failed.
) Fuel temperature. Pointers above and below a range bar indicate the fuel temperature. The
range bar is color coded, green to show the normal operating range, yellow in the cautionary
range and red in the high warning range. The pointers move from left to right to indicate the
fuel temperature. The pointer above the range bar indicates the temperature of the fuel in
the left fuel tank and the pointer below the range bar indicates the temperature of the fuel
in the right fuel tank. If the system fails a red or yellow cross is displayed in place of the
digital indication for the failed system(s).
) Fuel quantity. Pointers above and below a range bar indicate the fuel quantities. The pointers
move from left (low) to right (full) to indicate the fuel quantity. The pointer above the range
bar indicates the quantity of fuel in the left fuel tank and the pointer below the range bar
indicates the quantity of fuel in the right fuel tank. If the system fails a red or yellow cross is
displayed in place of the digital indication for the failed system(s).
) System Display (if MÄM 42-978 is NOT installed). This display shows graphic and numeric
readouts of following critical engine, electrical indicators and optional deice fluid quantity:
) Engine load. This indication is in the same format as in the ENGINE page.
) Engine RPM. This indication is in the same format as in the ENGINE page.
) Volts. The primary bus voltage is displayed. Pointers above and below a horizontal range
bar show the bus voltages. The top pointer indicates the left main bus voltage and the
bottom pointer indicated the right main bus voltage. The horizontal range bar is color coded.
The green central section of the bar indicates that the voltage is within limits. The red section
at the left end of the range bar indicates too low a voltage. The red section at the right end
of the range bar indicates too high a voltage. Above the range bar are left and right windows
displaying the main bus voltages digitally.
) Amps. The Generator load is displayed. Pointers above horizontal range bar show the
generator loads. The range bar is color coded, green in the normal load range and then red
at the high end of the range. The range bar is also marked numerically at the 0 and 80 Amp
indications. The pointers move from left to right to show the load on each generator. The top
pointer shows the left generator load. The bottom pointer shows the right generator load.
Small windows above the range bar show the related generator loads digitally.
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) Engine gearbox temperature. Pointers above and below a horizontal range bar show the
gearbox temperatures. The range bar is color coded, green in the normal temperature range,
yellow in the caution range and then red at the high end of the range. The pointers move
from left to right to show the temperature of each gear. The top pointer shows the left
gearbox temperature and the bottom pointer shows the right gearbox temperature. Small
windows above the range bar show the related gearbox temperatures digitally. If the system
fails the display shows red crosses in place of the indications for the failed system(s).
) Coolant temperature. Displays digital readouts of the coolant temperature.
) Oil temperature. Displays digital readouts of the oil temperature.
) Oil pressure. Displays digital readouts of the oil pressure.
) Deice fluid quantity (optional).
) Pressing the FUEL softkey at the bottom of the MFD will change the display to the FUEL page
in the EIS panel (if MÄM 42-978 is NOT installed). The display will now give the following
indications:
) Engine load and RPM. These indications are in the same format as in the ENGINE page.
) Fuel Quantity. Displays digital readouts of the fuel tank quantity.
) Fuel flow. Displays digital readouts of the fuel flow.
) Fuel temperature. Displays digital readouts of the fuel temperature.
From this page you can use softkeys to enter data for the fuel system. Refer to the Garmin
G1000 Cockpit Reference Guide for more data about entering data into the ICS.
) If MÄM 42-978 is installed, pressing the ENGINE softkey at the bottom of the MFD will change
the display of the MFD to a full engine indication system page, as shown in Figure 5.
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NAV1 110.20 117.80 ETE GS KT DIS NM TRK

122.650 118.525 COM1
VOL PUSH
VOL PUSH SQ
ID NAV2 COM2
MAP - NAVIGATION MAP
NAV 100 NORTH UP EMERG
COM
80
60
40
20
LOAD %
PUSH 3000 PUSH
2400 1-2
1-2 1800
HDG 1200 CRS BARO
600
RPM
FUEL FLOW
GPH
PUSH OIL TEMP PUSH

HDG SYNC CRS CTR
NO GPS POSITION RANGE
AP YD
OIL PRES
FD HDG
COOLANT TEMP
NAV AFR PUSH

FUEL TEMP
PAN
ALT D MENU
FUEL QTY GAL

NOSE FPL PROC
VS UP
0 5 10 15 20 25
NOSE 30NM CLR ENT
FLC DN
NO TRFC DATA MAP WPT AUX NRST
ALT ENGINE MAP DCLTR SHW CHRT CHKLIST DFLT MAP FMS
Figure 4: Multi Function Display
Figure 5: MFD Full EIS Page
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% C. GMA 1347/1360 Audio Control Panel
% The GMA 1347/1360 audio control panel is located in the airplane instrument panel between the
two display screens. The audio control panel integrates the NAV/COM digital audio, intercom
system and marker beacon controls. Manual display reversion is also controlled from the GMA
% 1347/1360. The GMA 1347/1360 communicates with both IAUs using RS-232 digital interface. For
more data about the audio control panel refer to Section 23-50.
% D. GIA 6X W Integrated Avionics Unit (IAU)
% The ICS has two GIA 6X W IAUs. The two IAUs are identical and independent. They are both
installed in the avionics rack in the rear fuselage, just aft of the rear baggage frame. The IAU
processes all the data that is displayed on the cockpit display. Either IAU can supply data to either
cockpit display. You cannot service the IAU.
E. GTX 33/335 R Transponder
The GTX 33/335 R transponder is a solid state Mode-S transponder. The transponder provides
modes A, C and S functions. The unit is operated directly through the PFD in the cockpit. The
transponder is linked to both IAUs via RS-232 digital interface. The transponder is installed in the
avionics rack in the rear fuselage, just aft of the rear baggage frame.
F. GRS 77/79 Attitude, Heading and Reference Unit (AHRS)
The GRS 77/79 provides airplane attitude and related flight data to the cockpit displays. The
GRS 77/79 receives data from the air data computer, the GMU 44 magnetometer and GPS signals
% from the GIA 6X W. The GRS communicates with both the GIA 6X Ws and the cockpit dispays via
ARINC 429 digital interface. The GRS 77/79 is located next to the avionics rack in the rear
fuselage, just aft of the rear baggage frame.
G. GDC 74A/72 Air Data Computer (ADC)
The ADC receives data from the pitot/static system, OAT sensor. The ADC uses this data to
provide pressure altitude, airspeed, vertical speed and outside air temperature data to the G1000
% system. The ADC communicates with the GIA 6X Ws, GDU 10XX display screens and the
GRS 77/79 using ARINC 429 digital interface. Software and configuration data is received through
% RS-232 digital interface with the GIA 6X Ws. The ADC is located on the instrument panel shelf.
% H. GEA 71/B
% The GEA 71/B is a microprocessor based unit that receives and processes signals from airframe
% and engine sensors. The GEA 71/B communicates directly with both IAUs using RS 485 digital
% interface. The GEA 71/B is located on the instrument panel shelf.
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I. GMU 44 Magnetometer
The magnetometer senses magnetic field information. Data is sent to the GRS 77/79 ARHS for
processing. The magnetometer receives power form the GRS 77/79 and communicates with the
GRS 77/79 using RS-485 digital interface. The magnetometer is located in the right outer wing and
can accessed through a panel in the lower surface of the wing.
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Trouble-Shooting
1. General
The Garmin ICS has a built-in test and trouble-shooting facility. For more data about troubleshooting
the ICS refer to the G1000 Cockpit Reference Guide for the DA 42 NG Airplane.
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1. General
These Maintenance Practices tell you how to replace the main components of the ICS. They do not
tell you how to maintain the components. For data about removing/installing the GMA 1347 audio
control unit refer to Section 23-50. For more data about maintaining the equipment refer to the G1000
Line Maintenance Manual. The G1000 Line Maintenance Manual gives you particular information on:
) Unit related alerts and problems.
) Equipment removal and installation.
) Uploading software, configuring and testing.
) Final system checkout.
) Periodic maintenance.
) G1000 system software and configuration.
) GDU lighting setup.
Refer to the DAI MSB 42NG-003 for data about the approved software configurations.
The specific DA 42 NG values as to the equipment basic setting are given in the table below:
Item Basic Setting
% Main Lighting S Display (PFD1, MFD1), if Source: 28 V

% MÄM 42-978 and/or MÄM 42-1072 are
Response Time: 3
% NOT installed
Minimum: 3.50
Edit Curve Vertex: none
Photo Transition: 20 %
Edit Photo Vertex: none
GMA Annunciator Gain: 1.00
GMA Annunciator Offset: 0
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Item Basic Setting
% Main Lighting S Key (PFD1, MFD1), if Source: 28 V

% MÄM 42-978 and/or MÄM 42-1072 are
Response Time: 1
% NOT installed
Minimum: 1.75
Edit Curve Vertex: none
GMA Key Gain: 2.00
GMA Key Offset: 2
Transponder Configuration VFR Code: specific to Country
(e.g. USA: 1200)
Aircraft Weight: < 15,500 lbs
Max Airspeed: <= 300 kts
Address Type - Europe: hex id
- USA: us tail
Flight ID Type - Europe: PFD Entry
- USA: same as tail
% GMA Configuration S Headset Volume, if Music #1: -20

% MÄM 42-1072 is NOT installed
Music #2 -20
Unswitched in #1: -20
Altitude Warning: -20
% GMA Configuration S Speaker Volume, if Crew Audio: 5

% GMA Configuration S Master Squelch, if Threshold Value: -16

GMA Configuration S Marker Beacon HI SENSE THRESHOLD: specific to airplane
LO SENSE THRESHOLD: specific to airplane
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Item Basic Setting
GMA Configuration S KEYPAD Disable COM3: set

% Annunciators, if MÄM 42-1072 is NOT
Disable TEL: set
% installed
Disable DME: specific to airplane
Disable ADF: specific to airplane
Disable AUX: set
Disable SPEAKER: blank
Disable PA: set
Disable PLAY: blank
Disable MUSIC: set
Disable REC: set
Disable CABIN: set
Note: Unlisted items are preset. You must not change their values.
Note: Some items are specific to the airplane. Note down the settings prior to performing
a software upload.
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2. Remove/Install a GDU 10XX Display
A. Remove a GDU 10XX Display
(1) Make sure that the ELECT. MASTER switch is

set to OFF.
(2) Set the PFD and MFD circuit breakers open. Right side of instrument panel.
(3) Remove the display unit: Refer to Figure 6.
S Rotate the 4 locking studs that attach the

display to the instrument panel 90° counter-
clockwise.
S Move the display aft and disconnect the At the in-line connector.
electrical cables.
S Move the display unit clear of the instrument

panel.
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Locking Socket
Rivet
In-Line Connector
GDU 10XX Display Unit

Locking Studs
Figure 6: GDU 10XX Display Unit Installation
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B. Install a GDU 10XX Display
(1) If necessary, set the PFD and MFD circuit Right side of instrument panel.
breakers open.
(2) Install the display unit:
S Move the display unit into position at the

instrument panel.
S Connect the electrical cables to the display At the in-line connector.

unit.
S Move the display unit fully forward into Make sure that you do not trap the
position on the instrument panel. electrical cables.
S Rotate the 4 locking studs that attach the The locking studs should be oriented
display unit to the instrument panel 90° with the alignment marks in the vertical
clockwise. position for installation. When locked,
the alignment marks are in the
horizontal position.
(3) Reset the PFD and MFD circuit breakers. Right side of instrument panel.

integrated cockpit system (ICS):
S Set the ELECT. MASTER switch to ON. The ICS must power-up and
successfully complete its self-test
procedure.
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%
%
% Garmin GIA 6X W Units
% Retainer
%
%
%
%
%
%
% Locking Screws
%
%
%
%
%
%
GIA 6XW Mounting Racks
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
% Avionics Enclosure
%
%
Figure 7: GIA 6X W Integrated Avionics Unit
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% 3. Remove/Install a GIA 6X W Integrated Avionics Unit (IAU)
% A. Remove a GIA 6X W Integrated Avionics Unit (IAU)

set to OFF.
(2) Remove the lower access panel from the rear Refer to Section 25-50.
% (3) Remove the GIA IAU: Refer to Figure 7.
S Identify the unit that you will remove.
S Release the locking screw from the retainer.
S Lift the retainer clear of the unit.
S Lift the IAU clear of the mounting rack and

the airplane.
% B. Install a GIA 6X W Integrated Avionics Unit (IAU)
(1) Install the IAU:
S Move the GIA IAU into position at the Make sure that the unit is seated
mounting and lower the unit into position in correctly. Do not force the unit into
the rack. position!
S Move the retainer into position and secure

with the locking screw.
(2) Install the lower access panel in the rear Refer to Section 25-50.

S Set the ELECT. MASTER switch to ON. The ICS must power up and
successfully complete its selftest
procedure.
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AIRCRAFT
Locking Screw
Retainer
GTX33 / 335 R
Transponder
GTX33 / 335 R
Mounting Rack
Avionics Enclosure
Figure 8: GTX33/335 R Transponder Installation
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AIRCRAFT
4. Remove/Install the GTX33/335 R Transponder
A. Remove the GTX33/335 R Transponder

set to OFF.
(3) Remove the GTX33/335 R: Refer to Figure 8.
S Identify the unit that you will remove.
S Release the locking screw from the retainer.
S Lift the retainer clear of the unit.
S Lift the GTX33/335 R clear of the mounting

rack and the airplane.
B. Install the GTX33/335 R Transponder
(1) Install the GTX33/335 R:
S Move the GTX33/335 R into position at the Make sure that the unit is seated
mounting and lower the unit into position in correctly. Do not force the unit into
the rack. position!
S Move the retainer into position and secure

with the locking screw.

procedure.
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AIRCRAFT
GRS77 AHRS Unit
Connector
Figure 9: GRS 77 Attitude, Heading and Reference Unit (AHRS) Installation
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GRS 79 AHRS Unit
Connector
Mounting Rack
Figure 10: GRS 79 Attitude, Heading and Reference Unit (AHRS)
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5. Remove/Install the GRS 7X Attitude, Heading and Reference Unit (AHRS)
A. Remove the GRS 7X Attitude, Heading and Reference Unit (AHRS)

set to OFF.
(3) Remove the GRS 7X: Refer to Figure 9 or 10.
S Disconnect the electrical cables.
S Loosen the 4 or 2 (if MÄM 42-978 is

installed) screws that attach the GRS 7X to
the mounting.
S Move the GRS 7X clear of the airplane.
B. Install the GRS 7X Attitude, Heading and Reference Unit (AHRS)
(1) Install the GRS 7X unit:
S Move the unit into position next to the

avionics rack.
S Tighten the 4 or 2 (if MÄM 42-978 is

installed) screws that attach the unit to the
mount. At the in-line connector.
S Connect the electrical cables.
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S Set the ELECT. MASTER switch to ON. The ICS must power up and
procedure.
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Garmin GDC 74 Unit
Pitot Air Port
Static Air Port

Garmin GDC 72 Unit
Pitot Port
In-Line Electrical
Connector Mounting
Static Port Rack
Mounting Rack
Figure 11: GDC 7X Air Data Computer (ADC) Installation
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6. Remove/Install the GDC 7X Air Data Computer (ADC)
A. Remove the GDC 7X Air Data Computer (ADC)
(3) Remove the GDC 7X: Refer to Figure 11.
S Locate the GDC 7X on the instrument panel

shelf.
S Disconnect the electrical cables.
S Disconnect the Pitot/static tubes from the Note the connections!

unit.
S Remove the 2 screws of the adapter plate

that attaches the GDC 7X to its mounting
rack.
S Move the GDC 7X clear of the airplane.
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B. Install the GDC 7X Air Data Computer (ADC)
(1) Install the GDC 7X:
S Move the GDC 7X assembly into position on

the mounting rack.
S Install the adapter plate and tighten the

2 screws that attach the GDC 7X to the
mounting rack.
S Install the Pitot/Static tubes to the unit. As noted in 6A.

S Connect the electrical cables. At the in-line connector.

procedure.
(5) Do a Pitot/static leak test. Refer to Section 34-10.
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% 7. Remove/Install the GEA 71/B Processor
% A. Remove the GEA 71/B Processor
% (3) Remove the GEA 71/B: Refer to Figure 12.
% S Locate the GEA 71/B instrument panel shelf.
S Release the screw that secures the retainer.
S Move the retainer clear and lift the GEA

% 71/B clear of the mounting.
% B. Install the GEA 71/B Processor
% (1) Install the GEA 71/B:
% S Move the GEA 71/B into position at its

mounting.
% S Lower the GEA 71/B into its mounting.
S Install the retainer and secure the retainer

with the retaining screw.

procedure.
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AIRCRAFT
Garmin GEA 71/B Unit
Retainer
Screw
Retainer
Mounting Rack
% Figure 12: GEA 71/B Processor Installation
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8. GMU 44 Magnetometer
A. Remove the GMU 44 Magnetometer

set to OFF.
(2) Remove the magnetometer assembly:
S Remove the 3 screws that attach the Support the assembly.

magnetometer assembly to the lower
surface of the right wing.
S Lower the magnetometer assembly clear of

the structure and disconnect the electrical
cables.
S Move the magnetometer assembly clear of

the airplane.
(3) If necessary, remove the magnetometer from

the panel.
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AIRCRAFT
Electrical
Screw Connector
Magnetometer, GMU 44
Screw Mounting Ring
Spacer
Inspection Panel
Panel Screw
Figure 13: Magnetometer Assembly Installation
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AIRCRAFT
B. Install the GMU 44 Magnetometer
(1) Install the magnetometer assembly:
S Move the magnetometer assembly into Pay attention on the dedicated mounting
position at the right wing. direction marked by an arrow!
S Connect the electrical cables to the At the in-line connector.

magnetometer assembly.
S Move the magnetometer assembly fully into

position in the lower surface of the right
wing.
S Install the 3 screws that attach the

magnetometer assembly to the wing.

The ICS must power up and
procedure.
(3) Do a magnetometer calibration. Refer to Paragraph 9.
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9. G1000 Magnetometer Calibration
Note: This calibration procedure must be carried out on a compass rose in order to
guarantee measurements free of environmental magnetic disturbances. Attempting
to carry out this maneuver on a typical ramp area will not yield a successful
calibration. The accuracy of the AHRS cannot be guaranteed if this calibration is
not performed on a magnetically clean compass rose.
(1) Taxi the airplane to a compass rose. Ensure

that there are no nearby magnetic materials. If
unavoidable, maneuver the airplane to keep the
magnetometer from passing within 6 meter
(19.7 feet) of such objects. At the compass
rose, align the airplane to a heading of magnetic
north (± 5°).
(2) With the airplane stationary, initiate the

GRS 7X AHRS magnetometer calibration
procedure as follows:
S Enter the GDU configuration mode by

holding the ENTER button while applying
power. Release the ENTER button when the
words INITIALIZING SYSTEM are displayed
on the GDU.
S Press the FMS inner knob to select which

calibration procedure to run. Select
MAGNETOMETER and press the ENTER
button.
S Follow the checklist items displayed on the

GDU and press the ENTER button as each
one is completed or confirmed. When the
CALIBRATE field is blinking, press the
ENTER button to begin the procedure.
S The GDU display advises the operator when

to turn the airplane, when to stop, and when
to turn again.
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(3) Upon advice to turn, taxi the airplane in a right

turn. After approximately 25° to 30° of turn from
the last heading the GDU display advises the
operator to stop the airplane.
(4) The GDU display guides the operator to dwell at

multiple headings around a complete circle.
Note: The operator may use outside references to turn the airplane by about 30° each
time the GDU displays that it is time to turn, rather than attempting to use the
GDUs real-time indication of how much additional turn is needed. Simply turning
the airplane by roughly 30° (± 5°) increments and dwelling for the time
recommended by the GDU is all that is needed for successful calibration.
(5) Repeat the turn-and stop process until the GDU

display advises that a successful calibration is
complete. The GRS 7X AHRS then enters its
normal operational mode. Press the ENTER
button on the GDU to conclude this procedure.
Refer to the GRS 7X/GMU 44 Installation Manual for more information on the post installation
configuration and checkout procedure.
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10. Remove/Install the De-Ice Control Panel
A. Remove De-Ice Control Panel from Instrument Panel
(1) Set the DE-ICE/XFER circuit breaker open. Right side of instrument panel.
(2) Remove instrument panel cover.
(3) Disconnect plug No. P3015 from socket J3015.
(4) Remove all cable ties which used for the de-ice
panel installation.
(5) Remove the 4 bolts, washers and locknuts Take care that no washer or nut falls
which attach the de-ice control panel to the into the instrument panel.
instrument panel.
(6) Move the control panel clear from instrument

panel.
B. Install the De-Ice Control Panel in the Instrument Panel
(1) Set the DE-ICE/XFER circuit breaker open. Right side of instrument panel.
(2) Attach the de-ice control panel in the designated Right side of instrument panel.
cutout on the RH side of the instrument panel.
(3) Screw in all 4 bolts, washers and locknuts in the Take care that no washer or nut falls
designated holes around the control panel. into the instrument panel.
(4) Connect plug No. P3015 to socket J3015.
(5) Use cable ties to fix loose cables of the de-ice

control panel.
(6) Install instrument panel cover.
(7) Set the DE-ICE/XFER circuit breaker closed.
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DA 42 NG AMM Landing Gear
AIRCRAFT
CHAPTER 32
LANDING GEAR
Doc # 7.02.15 Page 1

Landing Gear DA 42 NG AMM
AIRCRAFT
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TABLE OF CONTENTS
CHAPTER 32
LANDING GEAR
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation on the Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Operation in the Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section 32-10
Main Landing Gear
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Main Gear Leg (Completely with Axle and Brake Unit) . . . . 203
3. Disassemble/Assemble a Main Landing Gear Leg . . . . . . . . . . . . . . . . . . . . . . . 212
4. Fill/Charge the Damper Assemblies on the Main Gear Legs . . . . . . . . . . . . . . . 217
5. Required Strut Extension of the Main Gear Damper Assemblies . . . . . . . . . . . . 224
6. Remove/Install a Main Landing Gear Damper . . . . . . . . . . . . . . . . . . . . . . . . . . 225
7. Disassemble/Assemble Main Landing Gear Damper . . . . . . . . . . . . . . . . . . . . . 227
8. Remove/Install a Main Landing Gear Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
9. Remove/Install the MLG Folding Stay / Hydraulic Actuator . . . . . . . . . . . . . . . . 234
10. Remove/Install a Folding Stay Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
11. Disconnect/Connect the MLG Folding Stay Assembly . . . . . . . . . . . . . . . . . . . 240
12. Test Main Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
13. Adjustment of the MLG Wheel in Retracted Position and Check of MLG Door Pre-
Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
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Section 32-20
Nose Landing Gear
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Nose Landing Gear Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3. Remove/Install a Nose Gear Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4. Remove/Inspect/Install Nose Landing Gear Damper Assembly . . . . . . . . . . . . . 209
5. Required Strut Extension of the Nose Landing Gear Damper Assembly . . . . . . 213
6. Fill/Charge the Damper Assembly on the Nose Gear Leg . . . . . . . . . . . . . . . . . 214
7. Disconnect/Connect the NLG Folding Stay Assembly . . . . . . . . . . . . . . . . . . . . 220
8. Remove/Install the NLG Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
9. Remove/Install the Nose Landing Gear Mounting Bracket (if MÄM 42-659 is
installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Section 32-30
Extension and Retraction
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Disassemble/Assemble the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3. Landing Gear Extension and Retraction Test (Normal Extension) . . . . . . . . . . . 209
4. Landing Gear Emergency Extension System Test . . . . . . . . . . . . . . . . . . . . . . . 212
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Section 32-40
Wheels and Brakes
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description - Main Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Description - Nose Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Description - Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Operation - Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Main Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Nose Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4. Disassemble/Assemble Main/Nose Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
5. Remove/Install Brake System Components - General . . . . . . . . . . . . . . . . . . . . 211
6. Remove/Install a Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
7. Remove/Install the Parking Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
8. Remove/Install a Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
9. Bleed the Wheel Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
10. Replace the Brake Friction Linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Section 32-50
Steering
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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Maintenance Procedures
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Steering Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Centering Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Nose Wheel Steering Friction Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Section 32-60
Position and Warning
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install an Engine Power Lever Switch . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Replace a Landing Gear Switch (Excluding the Nose Gear Folding Stay Switch)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4. Replace a Nose Gear Folding Stay Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
5. Adjust Landing Gear Indication Micro Switches (Excluding Nose Gear Folding Stay
Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
6. Test the Landing Gear Position and Warning System . . . . . . . . . . . . . . . . . . . . 212
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CHAPTER 32
LANDING GEAR
1. General
This Chapter tells you about the landing gear for the DA 42 NG airplane. Refer to Chapter 57-00 for
data about the wing structure where the main landing gear attaches. Refer to Chapter 53-00 for data
about the fuselage structure where the nose landing gear attaches.
Refer to Chapter 92-00 for the wiring diagrams for the position control and position indicating systems
of the landing gear.
2. Description
Figure 1 shows the main components of the landing gear. The landing gear absorbs landing loads and
let you move the airplane on the ground. The landing gear also provides steering control and braking
when the airplane is on the ground.
The DA 42 NG has a tricycle landing gear. The landing gear can retract. The left main gear leg
attaches to the wing center section on the left side of the fuselage. The right main landing gear
attaches the wing center section on the right side of the fuselage. The nose gear leg attaches to the
fuselage front bulkhead. All three legs have CFRP doors that seal the landing gear bays when the
landing gear is retracted in flight.
Each main leg is a tubular steel strut. A trailing arm attaches to the bottom of the strut and an axle for
the wheel assembly attaches to the trailing arm. A damper behind the tubular strut also attaches to the
trailing arm and absorbs the landing loads. The landing gear hydraulic system holds the main gear legs
in the retracted position. When the main gear legs are extended the legs geometrically lock and a latch
holds the legs in the locked position during rebound loads.
Each main gear leg has a single main-wheel and a hydraulic disk-brake. Toe pedals on the rudder
pedals operate the disk-brakes.
The nose gear leg attaches to the fuselage front bulkhead. A steel strut with an integral telescopic
damper absorbs the landing loads. The nose gear leg carries a single nose-wheel. The pilot uses the
rudder control pedals to steer the nose-wheel. Two steering stops attached to the gear leg limit the
rotary motion of the nose landing gear.
The landing gear hydraulic system holds the nose leg in the retracted position. When the nose leg is
extended the leg geometrically locks and a latch holds the leg in the locked position during rebound
loads.
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The landing gear has a electrically powered hydraulic supply and control system. The hydraulic supply
and control system is mounted on a bracket located in the rear fuselage, near the rear baggage
compartment. Refer to Chapter 29 and Section 32-30 for more data about the hydraulic system.
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Hydraulic Supply and

Control System
(Refer to Chpater 29)
Hydraulic Actuator
Hydraulic Actuator
Folding Stay
Folding Stay Tubular Steel Strut
Damper
Damper
Tubular Steel Strut

Nose Wheel
Main Wheel
NOSE LANDING GEAR ASSEMBLY MAIN LANDING GEAR ASSEMBLY
Figure 1: Landing Gear - Main Components
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3. Operation on the Ground
The pilot can steer the airplane with the rudder pedals. When he pushes the left rudder pedal forward
the nose gear leg turns to the left and the airplane turns to the left. When he pushes the right rudder
pedal forward the nose gear turns to the right and the airplane turns to the right.
Refer to Section 32-50 for more data about the nose-wheel steering.
If the pilot pushes the toe brake pedals, hydraulic fluid from the brake master cylinders flows to the disk
brake cylinders and applies the brakes. If the pilot sets the parking brake lever while he pushes the
toe brake pedals, the parking brake valve keeps the brakes in the ON position.
Refer to Section 32-40 for more data about the wheels and brakes.
Each landing leg has an oil/gas damper. When the airplane is moving on the wheels over uneven
ground the dampers can compress and absorb the loads. The dampers can absorb loads that are
greater than the normal landing loads.
Refer to Section 32-10 for more data about the main landing gear components and refer to Section
32-20 for more data about the nose landing gear components.
4. Operation in the Air
When the airplane is airborne, the pilot can retract the landing gear into the landing gear bays. The
landing gear bays have doors which close when the landing gear is retracted. Refer to Section 32-30
for more data about the extension and retraction system for the landing gear.
5. Emergency Operation
If the hydraulic system fails the pilot can extend the landing gear by setting the landing gear lever to
the DOWN position. The weight of the landing gear assisted by a spring, will cause the gear to extend.
When the gear is fully extended spring loaded latches operate and hold the landing gear legs
geometrically locked in the down position. The pilot can make a normal landing. The pilot can NOT
retract the landing gear if the hydraulic system has failed.
Note: A failure of the on-board electrical system causes the landing gear automatically
to extend. The hydraulic pump is not driven anymore and both solenoid valves
open. The hydraulic locking mechanism of the landing gear system is inoperable.
When the gear is fully extended it will geometrically lock in the down position.
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Section 32-10
Main Landing Gear
1. General
This Section tells you about the main landing gear. See the related Sections for data about these
systems that connect to the main gear:
) Section 32-30. Extension and retraction.
) Section 32-40. Wheels and brakes.
) Section 32-60. Position and warning.
) Section 57-00. Wing structure.
Refer to Chapter 92 for data about the electrical wiring of the landing gear systems.
2. Description
Figure 1 shows the main landing gear.
Each main landing gear is a tubular steel strut. The strut has a longitudinal pivot at the top. Large
bearings at each end of the longitudinal pivot hold the leg to the wing structure. A trailing arm attaches
to the bottom of the tubular steel strut. A gas/oil filled damper attaches to the rear of the tubular steel
strut and it attaches to the trailing arm.
The trailing arm carries an axle for the main-wheel assembly. Four bolts attach the axle to the trailing
arm. The axle has a steel plate that holds the brake unit. Clips and cable binders hold the hydraulic
hose for the brake unit and the electrical cables for the micro-switches to the leg.
Each main gear leg has a large hydraulic actuator to retract and extend the leg. One end of the
hydraulic actuator connects to the top of the tubular steel strut, near the longitudinal pivot. The other
end of the actuator connects to the wing structure via a folding stay.
3. Operation
Each main leg transmits vertical loads (for example, landing loads) to the airplane structure. When the
leg has a vertical load, the wheel pushes up the trailing arm. The trailing arm moves and compresses
the damper. The damper pushes up on the top of the tubular strut.
The damper can compress quickly but can only extend slowly. This prevents the leg from pushing the
airplane up after the landing and it also prevents vibration.
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Hydraulic Actuator
Tension Spring
Folding Stay
Aft Pivot Bearing
Longitudinal Pivot
Forward Pivot Bearing
Damper
Tubular Steel Strut

CFRP Door
Trailing Arm
Axle
Figure 1: Main Landing Gear
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Trouble-Shooting
1. General
This table gives you the trouble-shooting procedures for the main landing gear. Refer to Section 32-30
for trouble-shooting the main gear extension/retraction system. Refer to Section 32-40 for trouble-
shooting the main gear wheels and brakes. Refer to Section 32-60 for trouble-shooting the main
landing gear position and warning system. Refer to Chapter 29 for trouble-shooting on the hydraulic
power generation.
If you find the trouble given in Trouble column read across to the possible cause column. Then do the
Airplane stands on ground with Uneven ground. Move airplane to level ground.
one wing low.
Heavy landing. Do a test for heavy landing.

Replace damaged parts.
Damper pressure low. Inflate the damper to the

correct pressure. Refer to
MAINTENANCE PRACTICES,
Paragraphs 3 & 4 of this
Section.
Damper defective. Replace damper.
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1. General
These Maintenance Practices tell you how to remove/install the main gear leg components. The
Maintenance Practices are applicable to both the left and right main gear legs. You can remove the
main gear leg with the wheel or you can remove the wheel first.
Refer to Section 32-30 for data on the main gear retraction system. Refer to Section 32-40 for data on
the main gear wheels/brakes. Refer to Section 32-60 for data about the landing gear position and
warning system.
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Castle Nut
Bearing Housing, Rear Washer
Splint
Bearing Housing, Front
Main Landing Gear Damper Unit

Leg Assy, LH
Spacer
Bolt
Joint
Bolt
Spacer Washer
Self Locking Nut Self Locking Nut
Washer Washer Spacer
Bushing
Washer
Self Locking Nut Nut

Washer Washer
Bolt
Trailing Arm, LH
Torque Plate
Washer
Bolt Axle
Figure 2: Main Landing Gear Leg Assy
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2. Remove/Install the Main Gear Leg (Completely with Axle and Brake Unit)


A. Equipment
Aft bearing centering tool. 1 VR-D60-3217-12-31.
Front bearing centering tool. 1 VR-D60-3217-12-30.
Bearing housing puller. 1 VR-D60-3217-11-00.
B. Remove the Main Landing Gear Leg

ACCIDENTALLY.
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(2) Bleed the system: Refer to Section 32-30.
S Retract the landing gear to bleed the

system.
S Operate the emergency extension of the

landing gear (repeat this step one or two
times).
(4) Disconnect the main gear door from the main Refer to Figure 2.
gear leg:
S Remove the nut, washer and spacer that

attach the door connecting arm to the main
gear leg.
S Pull the connecting arm clear of the main

gear leg attachment and secure to the door.
S Move and hold the main gear door clear of

the main gear leg.
(5) Remove the brake calliper. Refer to Section 32-40.
(6) Remove the main-wheel. Refer to Section 32-40.
(7) Remove all cable binders which secure the

flexible brake hose and the electric cables to the
micro switch.
(8) Remove the weight-on-wheels switch. Refer to Section 32-60.
(9) Remove the MLG folding stay switch. Refer to Section 32-60.
(10) Disconnect the folding stay assembly of the Refer to Paragraph 10.
MLG.
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(11) Remove the rear bearing housing:
S Remove the cotter-pin from the castle nut. Refer to Figures 2 and 3.
S Remove the castle nut.
S Remove the 7 bolts, nuts and washers and Support the main gear leg and make
washer sheet(s), which hold the bearing sure not to scratch the surface.
housing onto the fuselage.
S Remove the bolt, 3 washers, 2 spacers, the

spacer sleeve and the nut from the bearing
housing.
S Use the bearing housing puller to get the

bearing housing off the longitudinal pivot.
(12) Remove the fuel filter element. Refer to Section 28-20.
(13) Optional:
Remove the flexible heat pipe from the clamp to

gain more space to reach the front bearing
housing.
(14) Optional:
Remove the front bearing housing: Refer to Figures 2 and 3.
S Remove the 8 bolts, nuts, washers and

washer sheet(s) which hold the bearing
S Use the bearing housing puller to get the

bearing housing off the longitudinal pivot.
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(15) Remove the main gear leg:
S Move the leg aft to slide the forward

longitudinal pivot clear of its bearing
housing.
S Lower the forward longitudinal pivot clear of

the landing gear bay.
S Move the leg forward until aft longitudinal

pivot is clear of the main gear web.
S Move the leg clear of the airplane.
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Hydraulic
Actuator
Folding Stay
Washer Sheets Aft Pivot Bearing
8 Washers
8 Bolts Longitudinal Pivot

8 Nuts
Forward Pivot Bearing
Bolt
Spring Lever
Tension Spring Washer

Spacer
Spacer
Washer Bolt Castle Nut
Washer Cotter Pin
Nut Spacer
Sleeve
Washer
Lightning Protection
Bolt x6
Washer x6
Bonding Wire Aft Pivot Bearing
Washer Sheets GFRP Spacer

OR Washer Sheets
Nut x6 OR
Figure 3: Main Landing Gear Installation
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Puller
Spacer
Washer
Bolt
AFT Bolt with Offset
FRONT
Puller
Washer
Bolt
Bolt with Offset
Figure 4: Removal of the Main Landing Gear Leg
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C. Install the Main Landing Gear Leg
(1) Install the main gear leg: Support the main gear leg and make
sure not to scratch the surface.
S If the single washer sheet is used:

Position the washer sheet on the MLG pivot.
S Slide the main gear leg into the aft main

gear web.
S Move the forward longitudinal pivot up and

engage it with the front bearing.
S Move the leg forward until the forward

longitudinal pivot is fully engaged in the front
main gear bearing.
(2) Install the front bearing housing: Refer to Figure 3.
S Use the front bearing centering tool to pull

the longitudinal pivot into the bearing
housing.
If removed previously:
S Install the 8 bolts, nuts and washers / Use new self-locking nuts.
washer sheet(s) which secure the bearing
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(3) Install the rear bearing housing: Refer to Figure 3.
S Use the aft bearing centering tool to push

the bearing housing onto the longitudinal
pivot.
S Install the 7 bolts, nuts, washers and washer Use new self-locking nuts.
sheet(s) which secure the bearing housing
onto the fuselage.
S Install the bolt, 4 washers, 2 spacers, the Use new self-locking nuts.
spacer sleeve and the nut onto the bearing
housing.
S Check the axial clearance of the gear leg. Required axial clearance: max. 0.2 mm.
S Install the castle nut and adjust axial Tighten by hand.

clearance by tightening the castle nut.
S Check the axial clearance again.
S Install the cotter-pin onto the castle nut.
(4) Optional:
Install the flexible heat pipe back onto the worm-

drive clamp if it was removed.
(5) Install the fuel filter element. Refer to Section 28-20.
(6) Connect the folding stay assembly of the MLG. Refer to Paragraph 10.
(7) Install the main gear wheel. Refer to Section 32-40.
(8) Install the brake calliper. Refer to Section 32-40.
(9) Bleed the brake system. Refer to Section 32-40.
(10) Install the weight on wheels switch. Refer to Section 32-60.
(11) Install the MLG folding stay switch. Refer to Section 32-60.
(12) Adjust the weight on wheels switch and the Refer to Section 32-60.
MLG folding stay switch.
(13) Install all cable binders to secure the electrical

cables and the flexible brake hose.
(15) Adjust the wheel in retracted position and check Refer to Paragraph 12.
MLG door pre-load.
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of the airplane.
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3. Disassemble/Assemble a Main Landing Gear Leg
A. Equipment
B. Disassemble Main Landing Gear Leg

ACCIDENTALLY.
(1) Remove main landing gear leg. Refer to Section 32-10.
(2) Optional: Refer to Section 32-40.
If not removed before, remove the main gear

wheel.
(3) Remove the main gear damper. Refer to Section 32-10.
(4) Remove the trailing arm from the main gear leg:
S Remove the bolt, self locking nut, washers,

bushing and the spacer.
(5) Remove the joint from the trailing arm. Refer to Paragraph 3.D.
(6) Remove the axle installation from the trailing

arm:
S Remove the four bolts, washers and self

locking nuts which hold the axle.
S Remove the torque plate.
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C. Assemble Main Landing Gear Leg

ACCIDENTALLY.
(1) Install the axle installation onto the trailing arm:
S Move the torque plate and the axle in

position.
S Install the four bolts, washers and self Use a new self locking nut.
locking nuts which secure the axle and the
torque plate.
(2) Install the top of the damper to the main landing Refer to Paragraph 6.B.
gear leg.
(3) Install the trailing arm onto the main gear leg:
S Slide the outer spacer into the trailing arm.
S Move the trailing arm into position.
S Slide the inner spacer through the main

landing gear leg and trailing arm.
S Install the trailing arm onto the main gear leg Use a new self locking nut.
by installing the bolt, washers and self
locking nut.
(4) Install the joint on main landing gear leg. Refer to Paragraph 3.D.
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D. Remove/Install a Joint on Main Landing Gear Leg
(1) Equipment
(2) Remove a Joint on Main Landing Gear Leg

ACCIDENTALLY.
(3) Support the tire and remove the nut, washer, Refer to Figure 2.
lower bolt and bushing from the joint.
(4) Move the damper and the joint clear of the

trailing arm.
(5) Remove the nut, washer, spacer and the upper Refer to Figure 2.
bolt from the joint.
(6) Move the joint clear of the MLG damper.
(7) Measure the joint. Refer to Figure 5.
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(8) Make a note of ordering numbers of the LH and RH joint sizes:
S D64-3217-23-00 Joint: x = 62 mm, z = 32 mm
S D64-3217-23-01 Joint oversize 1: x = 64 mm, z = 34 mm
Note: Different part numbers may be used on LH and RH MLG of the airplane.
Figure 5: Main Landing Gear Joint Measurement
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(3) Install a Joint on Main Landing Gear Leg
(1) Use a joint according to your measurement. As noted in Subparagraph (2).
Note: You must use the correct joint / joint oversize.
(2) Install joint on damper:
S Move joint on damper
S Verify smooth and easy movement
S Install the bolt, washer, spacer and self Use new self-locking nut.
locking nut.
(3) Connect joint to main landing gear trailing arm:
S Move trailing arm into position
S Install bushing, bolt, washer and self locking Use new self locking nut.
nut.
(4) Adjust the wheel in retracted position and check Refer to Paragraph 12.
MLG door pre-load.
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4. Fill/Charge the Damper Assemblies on the Main Gear Legs
The following procedure tells you how to fill the main gear damper assemblies with hydraulic fluid and
then charge with nitrogen.
A. Equipment
Bottle. 1 Commercial.
Bleed tube. 1 Commercial.
Valve core removal tool. 1 Commercial.
Nitrogen charging equipment. 1 Commercial.
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B. Material



(MIL-PRF-5606 H) or
AMG-10 (GOST 6794-75
Amdt 1-5), see CAUTION
above.
Grease for sliding interfaces. As required. DOD-L-25681 or

NATO S-1735
(for example,
Mocil 50/50).
Gaseous nitrogen. As required. Commercial.
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C. Procedure

WARNING: DO NOT LET NITROGEN AT HIGH PRESSURE BLOW ONTO YOUR

SKIN. NITROGEN AT HIGH PRESSURE CAN PENETRATE THE SKIN
AND CAUSE SERIOUS INJURY.

CAUTION: YOU MUST FILL/CHARGE THE MAIN-WHEEL DAMPER ASSEMBLIES

CORRECTLY. IF YOU DO NOT FILL/CHARGE THE MAIN-WHEEL
DAMPER CORRECTLY THE MAIN LANDING GEAR WILL NOT
OPERATE CORRECTLY. THIS CAN CAUSE DAMAGE TO THE MAIN
LANDING GEAR AND THE AIRPLANE STRUCTURE.

ACCIDENTALLY.
WARNING: THE TRAILING ARM AND THE WHEEL ARE CONNECTED TO THE
GAS LOADED DAMPER. DUE TO THE HIGH FORCES INVOLVED THE
ELEMENTS OF THE DAMPING SYSTEM CAN CAUSE SERIOUS
INJURY TO PERSONS.
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(3) Release the nitrogen pressure from the damper:
S Remove the dust cap from the charging

valve.
S Press and hold down the pin inside the

valve until all the pressure is released.
WARNING: YOU MUST RELEASE ALL THE NITROGEN PRESSURE FROM THE
DAMPER BEFORE YOU REMOVE THE CHARGING VALVE.
NITROGEN AT HIGH PRESSURE CAN PENETRATE YOUR SKIN.
THIS CAN CAUSE INJURY.
(4) Remove the core of the charging valve from the

damper assembly.
(5) Compress the damper assembly.
WARNING: DO NOT GET HYDRAULIC FLUID ON YOUR SKIN. HYDRAULIC

FLUID CAN CAUSE SKIN DISEASE.
(6) Connect the tube of the hydraulic fluid filler

bottle to the charging valve.


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(7) Turn the bottle to the open position and allow Use Aeroshell Fluid 41
the hydraulic fluid to flow from the bottle into the (MIL-PRF-5606 H) or
damper. AMG-10 (GOST 6794-75 Amdt 1-5)
hydraulic fluid (see CAUTION above)
with 0.3 % grease compliant with
DOD-L-25681 or NATO S-1735
(for example, Mocil 50/50) added.
(8) Extend the damper assembly by hand to allow

the hydraulic fluid to fill the damper assembly.
(9) Compress and extend the damper not less than

6 times to release the air from the damper and
allow the hydraulic fluid to flow into the damper.
(10) Compress the damper and hold the damper Keep the damper compressed.
compressed while you close the bottle and
remove the tube from the charging valve.
(11) Install the core of the charging valve.
(12) Connect the gaseous nitrogen charging Allow the damper to extend as it is
equipment to the damper charging valve. charged.
(13) Charge the damper with nitrogen to the correct Refer to Paragraph 4. The damper must
pressure. be fully extended.
(14) Disconnect and remove the gaseous nitrogen

charging equipment from the damper charging
valve.
(15) Install the dust cap onto the charging valve.
(17) Remove the rear fuselage and wing trestles

clear of the airplane.
(18) Lower the airplane with the jacks. Refer to Section 07-10. Make sure that
the area around the airplane is clear of
equipment.
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D. Fluid Change from Aero Shell Fluid 41 to AMG-10
Note: If the damper is disassembled, clean the inner surface of the damper and fill
with AMG-10. Refer to Paragraph C of this Chapter and to item (2) of this
table.
(1) Repeat the Fill/Charge the Damper Assemblies Refer to Paragraph C.

on the Main Gear Legs procedure 3 times.
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AIRCRAFT
Hydraulic Fluid
AeroShell Fluid 41
AMG-10
Placard MLG
(LH shown, RH similar)
Figure 6: Position of the Hydraulic Fluid Placard - Main Landing Gear Dampers
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5. Required Strut Extension of the Main Gear Damper Assemblies
The subsequent table tells you about the correct strut extension and pressure of the unloaded, fully
extended main landing gear dampers.
MLG Damper Strut Extension (unloaded) Gas Pressure

(visible length of bare piston)
LH 15 cm (6 inches) 19 bar (276 PSI).
RH 15 cm (6 inches) 19 bar (276 PSI).
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6. Remove/Install a Main Landing Gear Damper
A. Remove a Main Landing Gear Damper
It is possible but not necessary to remove the main landing gear from the airplane.

ACCIDENTALLY.
INJURY TO PERSONS.

valve.

(4) Remove the nut, washer and bolt that attach the
top of the damper to the main gear leg.
(5) Remove the spacer, nut, washer and bolt that

attach the bottom of the damper to the trailing
arm.
(6) Move the damper clear of the main gear leg.
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B. Install a Main Landing Gear Damper

ACCIDENTALLY.
INJURY TO PERSONS.
(1) Move the damper in position at the main gear

leg.
(2) Install the spacer, nut, washer and bolt that Use a new lock nut.
attach the bottom of the damper to the trailing
arm.
(3) Install the nut, washer and bolt that attach the Use a new lock nut.
top of the damper to the main gear leg.
(4) Fill the damper if necessary. Refer to Paragraph 4.
(5) Charge the damper. Refer to Paragraph 4.
(6) Remove the trestles and lower the airplane with Refer to Section 07-10.
the jacks.
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7. Disassemble/Assemble Main Landing Gear Damper
A. Disassemble Main Landing Gear Damper
Note: If the damper unit D60-3277-10-00_1 is installed, refer to RSB 42NG-017.
If RSB 42NG-017 is carried out, refer to RSB 42NG-017.
If the damper unit D60-3277-10-00_1 is not installed and RSB 42NG-017 is not
carried out it is recommended to carry out RSB 42NG-017.
(1) Remove the MLG damper. Refer to Section 32-10.
(2) Release nitrogen and oil from the damper:
S Install a drain hose onto the charging valve Use a suitable container to catch the
of the damper. damper oil (approx. 0.5 l [0.13 US gal]).
S Wait until the nitrogen is fully released.
S Compress the damper to drain the oil.
(3) Remove the charging valve from the damper. Refer to Figure 7.
(4) Remove the bottom cap: Refer to Figure 7.
S Remove M6 lower cross bolt, washer and

lock nut.
S Pull the bottom cap from the damper

assembly.
S Remove the O-ring from the cap.
(5) Disassemble damper tube: Refer to Figure 7.
S Slide the inner cylinder out of the damper Use a screwdriver or a thin metal plate.
tube. Make sure not to damage the parts.
S Remove the quad ring and the two backup

rings from the tube.
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(6) Disassemble the inner cylinder: Refer to Figure 7.
S Remove the M8 nut and pull the orifice plate Make sure not to damage the orifice
from the damper pipe. plate.
S Pull the upper cap together with the center

bolt from the damper pipe.
S Remove the O-ring from the lid.
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B. Assemble Main Landing Gear Damper
(1) Assemble the inner cylinder: Refer to Figure 7.
S Install the O-ring onto the upper cap. Use a new O-ring. Apply Teflon oil S408
onto the O-ring.
S Install the upper cap together with the center If MÄM 42-659 is NOT installed: Make
bolt onto the damper pipe. sure to install the cap onto the correct
side (grooves are different on cod side).
S Install the orifice plate onto the damper pipe. Make sure not to damage the orifice
plate.
S Install the lock nut.
Use new self-locking nut.
Apply Loctite 262 on thread and tighten

with 15 Nm (11.1 lbf.ft.).
(2) Assemble damper tube: Refer to Figure 7.
S Install the quad ring and the two backup Use new O-rings.
rings onto the tube.
S Put inner cylinder onto a tube (special tool)

to raise it.
S Slide the damper tube onto the inner

cylinder.
(3) Install the bottom cap: Refer to Figure 7.
S Install the O-ring onto the cap. Use a new O-ring.
Apply Teflon oil S408 onto the O-ring.
S Push the bottom cap onto the damper tube.
S Install the M6 lower cross bolt, washer and Use new self-locking nut.
lock nut to secure the cap.
Apply Loctite 262 onto the thread.
(4) Install the charging valve onto the damper. Apply Teflon oil S408 onto the O-ring.
(5) Charge the damper with nitrogen and oil. Refer to Section 32-10.
(6) Install the MLG damper. Refer to Section 32-10.
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Bushings
Charging Valve Backup Ring

O-Ring
Quad Ring
Upper Cap Backup Ring
O-Ring
Damper Tube
Centre Bolt
Lower Cross Bolt
Inner Cylinder Washer

Lock Nut
O-Ring
Bottom Cap
Different Orifice Plate
Bushings
Lock Nut Orifice Plate
Figure 7: Main Landing Gear Damper Assembly
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8. Remove/Install a Main Landing Gear Door
A. Remove a Main Gear Door

ACCIDENTALLY.
(1) Pull the GEAR circuit breaker. On the right side of instrument panel.
(2) Disconnect the door operating rod from the door Refer to Figure 8.
that will be removed:
S Remove the nut, washers, spacers and the At the door end of the rod.
bolt from the rod end.
S Pull the operating rod clear of the angle

bracket.
(3) Remove the door:
S Remove the two bolts, washers and self At the hinge mounted on the door.
locking nuts from one of the hinges.
S Remove the hinge.
S Unhinge and move the door clear of the Support the door.
main gear bay.
S Mount the hinge back on the door with the For not loosing the hinge and hardware.
two bolts and washers.
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Hinge, Rear
Self Locking Nut

Washer
Washer
Hinge, Front Bushing
Door Operating
Rod
Bolt Screw
Washer
Nut
Spacer
Washer
Angle Bracket
LH Shown, RH similar
Main Landing Gear Door
Figure 8: Main Landing Gear Door
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B. Install a Main Gear Door
(1) Install the main gear door:
S Remove the two bolts, washers and self

locking nuts from one of the hinges on the
main gear door.
S Move the main gear into position at the main

gear bay.
S Push the removed hinge onto the hinge in Refer to Figure 8.

the main gear bay and align the gear door
with the hinge.
S Install the two bolts, washers and self Use new self locking nuts.
locking nuts.
(2) Connect the door operating rod to the door that

you installed:
S Push the door operating rod onto the angle Refer to Figure 8.
bracket.
S Install the nut, washers, spacers and the Use a new self locking nut.
bolt onto the rod end on the door side.
(3) Reset the GEAR circuit breaker. On the right side of the instrument panel.
(4) Carry out a test of the MLG door preload. Refer to Paragraph 12.
(5) Do a test of the extension/retraction system. Refer to Section 32-30.
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9. Remove/Install the MLG Folding Stay / Hydraulic Actuator


A. Equipment
B. Remove the Folding Stay / Hydraulic Actuator

ACCIDENTALLY.
(2) Retract the landing gear. Use the landing gear switch.
(5) Depressurize the hydraulic system: Refer to Section 29-10.
S Operate the emergency extension lever of

the landing gear.
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(6) Disconnect the main landing gear door from the Refer to Figure 8.
main landing gear leg.
(7) Remove the folding stay switch. Refer to Section 32-60.
(8) Disconnect the MLG folding stay assembly. Refer to Section 32-10.
(9) Disconnect the hydraulic lines from the actuator. Use a suitable container to catch spilt
(Only if removing the actuator). hydraulic fluid. Fit caps on all open
connections.
(10) Measure and record the distance from the Refer to Figure 9.
actuator safety lock washer to the center of Note the distance marked ‘x’.
spherical rod-end bearing.
(11) Disassemble the folding stay/actuator: Refer to Figure 10.
S Remove the nut, 4 spacers, washer and bolt

from the driver plate.
S Move the spring lever with spring, the latch

operating arm, the drag lever assembly and
the actuator clear from the airplane.
Figure 9: MLG Actuator Measurement
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AIRCRAFT
Washer
Spacer
Bolt
Driver Plate
Spring Lever
Spacer
Spacer
Driver Plate Folding Stay Bracket
Self Locking Nut
Self Locking Nut
Tension Spring
Spacer Washer
Bolt
Self Locking Nut
Washer Washer
Nut Snap Ring Actuator

Bolt
Washer Drag Lever
Hydraulic Lines Bolt
Spacer
Lock Hook
Latch Operating
Arm
Snap Ring Snap Ring
Self Locking Nut Bearing Shaft Bolt

Drag Strut
Washer
Figure 10: Main Landing Gear Folding Stay
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C. Install the Folding Stay / Hydraulic Actuator
(1) Verify the distance from the actuator safety lock Refer to Figure 9.
washer to the center of the spherical rod-end
bearing with your record or adjust base setting Base setting equals min. screw-in depth.
of 34 mm (1.34 in). Maximum distance x (min. screw-in
depth): 34 mm (1.34 in).
(2) Connect actuator with folding stay: Refer to Figure 10.
S Following parts will be connected in the next

step: Spring lever, latch operating arm, the
drag lever assembly and the actuator.
S Install the nut, 4 spacers, washer and bolt

onto the driver plate.
(3) Connect the hydraulic lines with the actuator. Remove caps from all open connections.
(4) Replenish the hydraulic reservoir if necessary. Refer to Section 29-10.
(5) Connect the folding stay assembly of the MLG. Refer to Section 32-10.
(6) Install and adjust the folding stay assembly of Refer to Section 32-60.
the MLG.
(9) Carry out a test for the correct operation of the Refer to Section 32-30.
landing gear retraction and extension system.
(10) Carry out a test for the correct pre-load of the Refer to Paragraph 12.
main landing gear door.

of the airplane.
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% 10. Remove/Install a Folding Stay Bracket
% A. Remove a Folding Stay Bracket
% Detail Steps/Work Items Key Items/References
% WARNING: TAKE PRECAUTIONS BY SECURING THE AREA AROUND THE

% AIRPLANE BEFORE YOU PERFORM MAINTENANCE ON THE
% LANDING GEAR. THE LANDING GEAR RETRACTION SYSTEM CAN
% CAUSE SERIOUS INJURY TO PERSONS IF OPERATED
% ACCIDENTALLY.
% (1) Remove the Folding Stay/ Hydraulic Actuator. Refer to Paragraph 9, Section B.
% (2) Remove the folding stay bracket:

% S Mark or record the orientation of the folding
% stay bracket flange (if OÄM 42-356 is carried
% out).
% S Remove 8 bolts and 8 washers.
% S Move the folding stay bracket clear from the

% airplane.
%
% B. Install a Folding Stay Bracket
% (1) Move the folding stay bracket in place. Refer to Figure 11.
% If OÄM 42-356 is carried out:
% Make sure that the flange is orientated like your

% record or marking.
% (2) Install the folding stay bracket: Use the three longer bolts at thicker
% flange section of the folding stay
% S Install 8 bolts and 8 washers.
% bracket.
%
% For wet installation of components use
% CA 1000.
% (3) Install the MLG folding stay. Refer to Paragraph 9, Section C.
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AIRCRAFT
%
%
%
%
%
%
% Washer
Spacer
% Bolt
Driver Plate
% Spring Lever
% Spacer
Spacer
%
Folding Stay Bracket Driver Plate
%
Self Locking Nut
% Self Locking Nut
Self
% Locking Washer Spacer
Nut Bolt
% Washer
Tension Spring
% Washer
% Actuator Snap Ring Nut
Bolt
%
Drag Lever Washer
%
Bolt Hydraulic Lines
%
% Spacer
Lock Hook
%
% Latch Operating
% Arm
Snap Ring Snap Ring
%
Bolt Bearing Shaft Self Locking Nut
%
Di
% Main Landing Gear Leg of recti
Drag Strut Fli on
% gh
t
% Washer
% Figure 11: Main Landing Gear Folding Stay (RH side, if OÄM 42-356 is installed)
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% 11. Disconnect/Connect the MLG Folding Stay Assembly
A. Equipment
B. Disconnect the Folding Stay Assembly of the MLG

ACCIDENTALLY.
(5) Bleed the system: Refer to Section 32-30.
S Retract the landing gear to bleed the

system.

landing gear (repeat this step one or two
times).
CAUTION: THE MAIN LANDING GEAR LEG MAY GET DAMAGED IF THE
FUSELAGE SKIN IS NOT PROTECTED WHEN DISCONNECTING
THE FOLDING STAY.
(7) Put foam plastic between MLG leg and the

airplane fuselage to protect it.
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(8) Remove the nut, spacer and bolt which connect Disconnect at the lock hook.
the latch operating arm with the folding stay and Refer to Figure 10.
disconnect the arm.
WARNING: THE FOLDING STAY AND THE ACTUATOR ARE TENSED BY THE
SPRING. IT CAN CAUSE SERIOUS DAMAGE IF HANDLED
IMPROPERLY. MAKE SURE TO SUPPORT THESE PARTS WHEN
REMOVING THEM.
(9) Disconnect the drag strut: Refer to Figure 10.
S Remove the DIN 471-20 snap ring between

the drag strut and the drag lever from the
folding stay.
S Push the drag lever outward to release the

stress from the folding stay and slowly
remove the bearing shaft from the folding
stay.
S Open the lock hook and slowly release the

drag lever.
S Move the drag strut free from the drag lever.
S Remove the bolt and the washer which

connects the drag strut with the MLG leg.
S Remove the drag strut.
CAUTION: WHEN DISCONNECTING THE ACTUATOR THE MAIN LANDING

GEAR LEG WILL MOVE OUTWARDS. DON’T FORGET THE FOAM
PLASTIC TO PROTECT THE FUSELAGE SKIN.
(10) Disconnect the actuator:
S Remove the nut and washer which connects Make sure to support the actuator after
the actuator with the MLG leg. removing the bolt.
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(11) Disconnect the tension spring: Refer to Figure 10.
S Pull the tension spring out of its mounting

where it is connected to the MLG leg.
S Move the tension spring clear of the MLG

leg.
(12) Disconnect the folding stay assembly:
S Remove the snap ring and the washer from

the drag lever were it connects to the folding
stay bracket.
S Pull the drag lever and the actuator off the

folding stay bracket.
S The whole assembly will come off but is still

connected to the fuselage through the
actuator hydraulic lines and the MLG folding
stay switch.
S Make sure to affix the whole assembly so

that the hydraulic lines and the electrical
connections are not stressed.
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C. Connect the Folding Stay Assembly to the MLG
(1) Connect folding stay assembly: Refer to Figure 10.
S Install the drag lever and the actuator

together with the whole assembly onto the
folding stay bracket.
S Move the actuator to the main gear leg until

it is on top of it.
S Bring the main gear leg and the actuator into

position.
S Install the bolt, washer and nut to secure the Use new self locking nuts.
actuator.
S Install the washer and the snap ring onto the Use a new snap ring.
drag lever to secure the whole folding stay /
actuator assembly onto the folding stay
bracket.
(2) Make sure the lock wire for the hydraulic

actuator is installed.
(3) Connect the tension spring: Refer to Figure 10.
S Move the tension spring into position. The openings of the tension spring
bearings must face towards the spring.
S Push the tension spring into its mounting
where it is connected to the MLG leg.
S Make sure the spring fits solidly to the

spacer.
CAUTION: MAKE SURE TO SUPPORT THE DRAG LEVER UNTIL THE BEARING
SHAFT IS INSTALLED. OTHERWISE THE FOLDING STAY SWINGS
BACK AND CAN CAUSE SERIOUS DAMAGE AND INJURIES.
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(4) Connect the drag strut: Refer to Figure 10.
S Move the drag strut into position.
S Install the bolt and the washer which

connects the drag strut with the MLG leg.
S Push the drag lever outward to align the

drag lever with the drag strut.
S Close the lock hook.
S Install the bearing shaft.
S Install the DIN471-20 snap ring which Use a new snap ring.
connects the drag strut and the drag lever.
(5) Install the nut, spacer and bolt which connect Refer to Figure 10.
the latch operating arm with the folding stay.
(6) Remove the foam plastic between MLG leg and

the GFRP of the airplane fuselage.
(9) Do a test for the correct operation of the landing Refer to Section 32-30.
gear retraction and extension system.
(10) Do a test for the correct pre-load of the main Refer to Paragraph 12B.
landing gear door.

of the airplane.
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% 12. Test Main Landing Gear
A. Equipment
Slide sheets - 2 per side. 4 Commercial.
E-protractor. 1 Commercial.
B. Test Main Landing Gear (Wheel Track and Camber)
% (1) Make sure that the airplane is at the empty weight. Refer to Wheel Track and Camber
% Report. Section 06-00.
% (2) Remove the main landing gear doors. Refer to Paragraph 8.
% (3) Move the airplane to put the main wheels on the Make sure the floor is level in the
% slide sheets. Make sure there is no horizontal work area. Refer to Figure 13.
% friction load on the landing gear.
% (4) Measure the wheel track: Refer to Figures 12 and 13.
% S Measure from the front wing root edge LH and

% RH (between wing and fuselage) perpendicular
% to the ground.
% S Mark these points on the ground and draw a

% line or use a straight beam which aligns with
% both points.
% S Use a metal angle or similar and hold it onto the

% measured line from the previous step to the rim
% of the main gear wheel.
% S Measure the wheel track in the front and the

% rear.
% S Substract the two measurements and write this

% wheel track measurement down.
% S Use the wheel track table to convert your

% measurement into degrees.
%
% (5) Measure the camber using an e-protractor.
% (6) Measure overall track with. Refer to Section 06-00.
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% (7) Fill out the Wheel Track and Camber Report. Refer to Section 06-00, Figure 10.
% (8) If the Wheel Track and Camber Report does not

% meet the requirement: contact DAI.
% (9) Move the airplane off the slide sheets.
% (10) Install the main gear door. Refer to Paragraph 8.
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DA 42 NG Wheel Track Table

(valid for DA 42 NG with 6" - Parker rim P/N: 40-75Z)
mm ° mm ° mm °
0,1 0,03 3,4 1,04 6,7 2,05
0,2 0,06 3,5 1,07 6,8 2,08
0,3 0,09 3,6 1,10 6,9 2,11
0,4 0,12 3,7 1,13 7 2,15
0,5 0,15 3,8 1,16 7,1 2,18
0,6 0,18 3,9 1,20 7,2 2,21
0,7 0,21 4 1,23 7,3 2,24
0,8 0,25 4,1 1,26 7,4 2,27
0,9 0,28 4,2 1,29 7,5 2,30
1 0,31 4,3 1,32 7,6 2,33
1,1 0,34 4,4 1,35 7,7 2,36
1,2 0,37 4,5 1,38 7,8 2,39
1,3 0,40 4,6 1,41 7,9 2,42
1,4 0,43 4,7 1,44 8 2,45
1,5 0,46 4,8 1,47 8,1 2,48
1,6 0,49 4,9 1,50 8,2 2,51
1,7 0,52 5 1,53 8,3 2,54
1,8 0,55 5,1 1,56 8,4 2,57
1,9 0,58 5,2 1,59 8,5 2,61
2 0,61 5,3 1,62 8,6 2,64
2,1 0,64 5,4 1,65 8,7 2,67
2,2 0,67 5,5 1,69 8,8 2,70
2,3 0,70 5,6 1,72 8,9 2,73
2,4 0,74 5,7 1,75 9 2,76
2,5 0,77 5,8 1,78 9,1 2,79
2,6 0,80 5,9 1,81 9,2 2,82
2,7 0,83 6 1,84 9,3 2,85
2,8 0,86 6,1 1,87 9,4 2,88
2,9 0,89 6,2 1,90 9,5 2,91
3 0,92 6,3 1,93 9,6 2,94
3,1 0,95 6,4 1,96 9,7 2,97
3,2 0,98 6,5 1,99 9,8 3,00
3,3 1,01 6,6 2,02 9,9 3,03
% Figure 12: DA 42 NG Wheel Track Table
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Note: Ensure that the floor is

levelled in the work area
Wing Root Edge
LH shown
RH similar
Straight Edge
Angle Bracket
Top View Rear Wheel Track

Measurement
Wheel Track
Measurements Front Wheel Track
Measurement
185
Greased Plates
Angle
Bracket
Higher Wheel Track Value
-
Lower Wheel Track Value
=
Straight Edge Final Wheel Track Value > Look up in table to convert to degrees
% Figure 13: Main Gear Wheel Track
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% 13. Adjustment of the MLG Wheel in Retracted Position and Check of MLG Door Pre-Load
A. Adjustment of the Main Landing Gear Wheel in Retracted Position

ACCIDENTALLY.
(2) Remove the dust cup from the wheel.
(3) Verify the tire pressure. Refer to the AFM for correct pressure.
(4) Disconnect the MLG door from the MLG leg. Refer to Paragraph 8.
(6) Retract the landing gear.
(7) Check the clearance between the MLG tire and

the lower wing-shell, wheel bay cutout:
S Put a trestle under the MLG wheel.
S Set the emergency gear lever to the

EXTEND position.
% S Support the MLG wheel in the position Refer to Figure 14.

% shown in Figure 14.
S Measure the clearance between the MLG Minimum clearance: 4 mm (0.16 in)
% tire and the wheel bay cutout. circumferential and along full depth of the
% wheel bay cutout.
S Remove the trestle and extend landing
gear.
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(8) If the clearance is asymmetric between front

and rear side:
S Adjust the clearance by use of an oversize For replacement refer to Paragraph 3.D.
joint and replace joint.
S Too small gap on front side: use a shorter

joint.
S Too big gap on front side: use a longer joint.
B. Check of Main Landing Gear Door Pre-Load
(1) Connect the MLG door. Refer to Paragraph 8.
(2) Push the emergency landing gear extension

lever.
(4) Retract the landing gear.
% (5) Measure the distance between the end plane of Refer to Figure 15.
the wheel axle and the lower wing shell.
(6) If the measurement does not meet the

requirements:
S Adjust the rod end bearing of the MLG Refer to Section 32-30 for disassembly
actuator until obtaining the above and assembly of the MLG actuator.
mentioned value. Therefore change screw-
in depth of rod and bearing.
Note: Check assembly for min. screw-in depth.
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% (7) Measure the MLG door pre-load: Refer to Figure 16.
S Attach the spring-scale / load cell to the

MLG door.
S Calibrate the spring scale / load cell to

display zero.
S Read the force value, when the MLG door

starts to lift off from the lower wing shell.
The correct pre-load is 5 to 10 kg (11 to 22 lbf).
(8) If the measurement does not meet the

requirements:
S Adjust the MLG door pre-load with the MLG

door operating rod.
(9) Carry out a test of the correct operation of the Refer to Section 32-30.
(10) Extend the landing gear.
(12) Install the dust cap on the wheel.

of the airplane.
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% Figure 14: Main Landing Gear Tire Clearance Measurement
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% Figure 15: Main Landing Gear Door Measurement
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% Figure 16: Main Landing Gear Door Pre-Load Measurement
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Section 32-20
Nose Landing Gear
1. General
The nose landing gear is housed in the nose gear bay and is attached to the surrounding structure by
the nose landing gear mounting-bracket. The nose gear leg has an oleo-pneumatic strut and a single
wheel. The nose gear bay has two composite doors and the rudder control system operates the nose
wheel steering.
2. Description
Figures 1 and 2 show the nose landing gear. The nose gear bay is located in the nose of the airplane
and is an integral part of the nose structure. The nose landing gear attaches to a mounting bracket.
Bolts attach the mounting bracket to the cockpit front frame and the nose gear bay.
The nose gear leg has a tubular steel housing. The tubular steel housing makes the top of the leg and
has the leg swivel mountings. Bronze bushes in the tubular steel housing hold a tubular strut. The strut
can turn in the housing. Stops on the tubular steel housing and the tubular steel strut limit the amount
that the tubular steel strut can turn.
The tubular strut carries a universal joint coupling at the top. The coupling has three parts. A top pivot
gimbal, a bottom pivot gimbal and a central pivot block. The top pivot gimbal has a steering actuator
lever. Refer to Section 32-50 for more data about the nose wheel steering.
A sliding tube is located in the bottom of the tubular steel strut. A seal holds the sliding tube in the
tubular steel strut. The bottom part of the sliding tube contains hydraulic fluid. The top part of the
tubular steel strut contains nitrogen at high pressure. These components make the nose gear leg
damper. Two torque-links hold the sliding tube aligned with the tubular steel strut.
Four bolts attach the nose wheel fork to the bottom of the sliding tube. The fork holds the nose wheel.
Refer to Section 32-40 for more data about the nose wheel.
The nose gear bay is sealed by two doors when the landing gear is retracted. Each nose gear door
has four hinges. Two short operating rods connect the nose gear bay doors to the nose gear leg
operating mechanism.
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Connecting Rod
Hinge
Hinge
Right Door
Hinge Steering Arm Bracket
Hinge
Connecting Rod
Hinge
Left Door
Hinge
Steering Linkage
Linkage Buffer
Tension Spring
Nose Landing Gear

Mounting Bracket
Hydraulic Actuator
Folding Stay
Centering Unit
Nose Gear Leg Assembly
Nose Wheel Assembly
Figure 1: Nose Gear Assembly
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3. Operation
The nose gear leg has two functions. It absorbs vertical loads and it provides steering on the ground.
If the nose gear has vertical load (for example during landing), the sliding tube moves up into the
tubular strut. This movement compresses the nitrogen in the damper. When the load decreases the
sliding tube moves out of the tubular strut. The sliding tube can move quickly into the tubular strut. In
the reverse direction the speed of the sliding tube is limited by a damper. This prevents the airplane
from being pushed up after the landing and it also prevents vibration.
Refer to Section 32-50 for data about the nose wheel steering. Refer to Section 32-30 for data about
the extension and retraction system.
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Steering Actuator Lever
Swivel Mount
Cardan Joint Bracket
Cardan Joint Swivel Mount
Tubular Steel Housing
Centering Unit
Steering Stops
Steering Brace
Upper
Tubular Steel Strut
Steering Brace
Lower
Sliding Tube
Nose Wheel Fork
Figure 2: Nose Gear Leg Assembly
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Trouble-Shooting
1. General
This table gives you the trouble-shooting procedures for the nose landing gear. Refer to Section 32-30
for trouble-shooting the nose gear extension/retraction system. Refer to Section 32-40 for trouble-
shooting the nose wheel assembly. Refer to Section 32-50 for trouble-shooting the nose wheel
steering. Refer to Section 32-60 for trouble-shooting the nose landing gear position and warning
system.
If you find the trouble given in Trouble column read across to the Possible Cause column. Then do the
Nose gear leg cracked or bent. Hard landing. Do the hard landing inspection
given in Section 05-50.
WARNING: THE FOLDING STAY AND THE DAMPER ARE SPRING LOADED.
DUE TO THE HIGH FORCES INVOLVED THE ELEMENTS OF THE
DAMPING SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS.
Nose gear leg extension too Nitrogen pressure in the Charge the leg with nitrogen to
small. Airplane sits nose-down damper to low. the correct pressure. Refer to
when parked on level ground. MAINTENANCE PRACTICES,
Paragraphs 5 and 6.
Damper leaking. Remove the nose gear leg.

Disassemble the nose gear leg
in a workshop and
repair/replace the damper
seals. Assemble and install the
nose gear leg.
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1. General
The Maintenance Practices in this Section tell you how to remove/install the nose gear leg and other
main nose landing gear components. They also tell you how to charge the damper with hydraulic
fluid/nitrogen. You can remove the nose gear leg complete with the nose wheel or you can remove the
wheel first
Refer to Section 32-30 for data about the nose gear retraction/extension system. Refer to Section
32-40 for data about the nose-wheel. Refer to Section 32-60 for data about the landing gear position
and warning system.
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Bolt
Bushing
Nose Landing Gear

Mounting Bracket
Nut
Washer
Cardan Joint Cardan Joint Bracket
4 Bolts
Centering Guidance Plate
Bolt Washer
Bolt
Steering Brace, Upper
Washer
Spacer
Spacer
Washer
Bolt
Cotter Pin
Washer Castle Nut, Thin
Nut Spacer
Cotter Pin
Washer Castle Nut, Thin
Washer Bolt
Washer
Steering Brace,
Washer Lower
(If MÄM 42-659
is installed) Cotter Pin
Spacer
Plate
(If MÄM 42-659 Washer
Castle Nut, Thin
is NOT installed)
Nose Wheel Fork
Bolt
Figure 3: Nose Landing Gear Leg
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2. Remove/Install the Nose Landing Gear Leg
A. Equipment
B. Remove the Nose Landing Gear Leg

ACCIDENTALLY.
WARNING: THE FOLDING STAY AND THE DAMPER ARE SPRING LOADED. DUE
TO THE HIGH FORCES INVOLVED THE ELEMENTS OF THE
(4) Remove the two nose gear folding stay switches Refer to Section 32-60.
and move them together with the electrical
connections clear of the landing gear.
(5) Disconnect the NLG folding stay assembly. Refer to Section 32-20.
(6) Disconnect the NLG actuator from the NLG leg.
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(7) Disconnect the nose-wheel steering rod from

the steering lever at the top of the nose gear
leg:
S Remove the bolt, nut and washer.
S Move the nose-wheel steering rod clear of

the nose gear leg.
(8) Remove the cardan joint assy: Refer to Figure 3.
S Remove the bolt, washer and nut from the

front cardan joint mount.
S Remove the bolt, washer and nut from the Steer the nose gear by hand so you get
rear cardan joint mount. better access to the rear joint mount.
S Remove the cardan joint bracket from the

pin and the cardan joint.
(9) Remove the carpet in the front baggage

compartment.
(10) Airplanes with de-icing system: Refer to Section 30-00.
S Remove the de-icing fluid tank.
S Remove the de-icing metering pump. This step is necessary to get access to
the nose gear leg mount.
S Remove the filter cartridge.
(11) Airplanes without de-icing system:
S Remove the LH and RH aft access panels in

the baggage compartment.
(12) Remove the nose landing gear leg: Refer to Figure 3.
S Remove the bolt, bushing, washer and nut

on the LH and RH side of the nose gear.
S Move the nose gear leg clear of the Support the nose gear.
airplane.
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C. Install Nose Landing Gear Leg
(1) Install the nose gear leg: Refer to Figure 3.
S Move the nose gear leg into position. Support the nose gear.
S Install the bolt, bushing, washer and nut on Use new self-locking nut.
the LH and RH side of the nose gear.
(2) Airplanes with de-icing system: Refer to Section 30-00.
S Install the filter cartridge. This step is necessary to get access to

the nose gear leg mount.
S Install the de-icing metering pump.
S Install the de-icing fluid tank.
(3) Airplanes without de-icing system:
S Install the LH and RH aft access panels in

the front baggage compartment.
(4) Install the carpet in the front baggage

compartment.
(5) Install the cardan joint assy: Refer to Figure 3.
S Install the cardan joint bracket onto the pin

and move the cardan joint into position.
S Install the bolt, washer and nut onto the rear Use new self locking nuts.
cardan joint mount.
S Install the bolt, washer and nut onto the front

cardan joint mount.
(6) Connect the nose-wheel steering rod onto the

steering lever at the top of the nose gear leg:
S Install the bolt, nut and washer. Use new self locking nut.
(7) Connect the NLG folding stay assembly. Refer to Section 32-20.
(8) Connect the NLG actuator to the NLG leg. Make sure the lock wire for the hydraulic
actuator is installed correctly.
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(9) Install the two nose gear folding stay switches Refer to Section 32-60.
and secure the electrical connections with cable
binder.
(11) Do a test for the correct operation of the landing

gear retraction and extension system.

of the airplane.
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3. Remove/Install a Nose Gear Door
A. Equipment
B. Remove a Nose Gear Door

ACCIDENTALLY.
WARNING: THE FOLDING STAY AND THE DAMPER ARE SPRING LOADED. DUE
TO THE HIGH FORCES INVOLVED THE ELEMENTS OF THE
(3) Disconnect the door operating rod from the door

that you will remove:
S Remove the safety clip from the end of the At the door-end of the rod.
operating rod.
S Pull the operating rod clear of the ball-fitting.
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(4) Remove the door:
S Remove the roll-pins from the door hinges. All 4 hinges.
S Remove the 4 hinge pins from the door. Support the door.
S Move the door clear of the nose gear bay.
C. Install a Nose Gear Door
(1) Install the nose gear door:
S Move the nose gear door into position at the

nose gear bay.
S Align the hinges of the door with the hinges

at the nose gear bay and install the 4 hinge
pins.
S Install the roll-pins into the door hinges. Use new roll-pins.
(2) Connect the door operating rod to the door that

you installed:
S Push the rod onto the ball-end fitting.
S Install the safety clip onto the end of the

operating rod.
(4) Do a test of the retraction/extension system. Refer to Section 32-30.
(5) Remove the rear fuselage and wing trestles

equipment.
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4. Remove/Inspect/Install Nose Landing Gear Damper Assembly
A. Equipment
Narrow wrench. 1 Commercial.
B. Remove the Nose Landing Gear Damper Assembly

ACCIDENTALLY.
(1) Pull the GEAR circuit breaker. On the right side of instrument panel.
(3) Remove the nose gear wheel. Refer to Section 32-40.
(4) Remove the nose wheel fork: Refer to Figure 3.
S Remove the four bolts, washers, nuts and

the plate from the nose wheel fork.
S Move the fork clear from the nose gear.
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(5) Remove the damper assembly: Support the nose gear. Refer to Figure 2.
S Remove the four bolts which hold the whole Use the special tool (narrow wrench).
damper assembly.
S Remove the shim and slide plate. The

cardan joint assembly stays mounted.
S Slide the damper assembly out of the nose

gear.
(6) Remove the torque links: Refer to Figure 3.
S Remove the bolts, washers, spacers and

lock nuts from the nose gear.
S Move the torque links clear from the nose

gear.
(7) Remove the centering guidance plate: Refer to Figure 3.
S Remove the locking wire. Alternatively the bolts may be secured

with Loctite.
S Remove the spacers, washers and bolts.
S Move the centering unit clear from the

damper assembly.
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C. Inspect the Nose Landing Gear Damper Assembly
(1) Inspect the nose wheel:
S Examine the wheel bearings. Refer to Section 32-40.
S Check the wheel rim. Look specially for scratches and

deformation.
S Examine the tire and check the pressure. Refer to Section 12-10.
(2) Inspect the nose wheel fork:
S Examine the structure. Look for cracks.
(3) Inspect the torque links. Look for cracks, deformation, and play.
(4) Inspect the nose gear damper:
S Examine the sliding tube. Look specially for surface damages and
deformation.
S Check the strut extension. Refer to Paragraph 6.
S Check for oil leakage. In case of oil leakage:

Contact DAI.
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D. Install the Nose Landing Gear Damper Assembly

ACCIDENTALLY.
(1) Install the centering guidance plate: Refer to Figure 3.
S Move the centering guidance plate into Use a new self locking nut.
position.
S Install the spacers, washers and bolts. Apply Loctite 262 on the thread.
Alternatively secure the bolts with locking
S Secure the bolts with locking wire.
wire if bolts with drilled heads are used.
(2) Install the torque links: Refer to Figure 3.
S Move the torque links into position. Use a new self locking nut.
S Install the four bolts, washers and lock nuts Apply Loctite onto the thread. There
onto the nose gear. must be a play sideways of 0.1 - 0.3 mm
(0.004 - 0.012 in).
(3) Install the nose gear damper assembly: Refer to Figure 3.
S Slide the damper assembly into the nose Use a new self locking nut.
gear.
S Move the shim, slide plate and the cardan

joint assembly into position.
S Install the four bolts which hold the whole Apply Loctite onto the thread.
damper assembly.
(4) Install the nose gear fork: Refer to Figure 3.
S Move the fork into position.
S Install the four bolts, washers, plate (if it was Use new self locking nuts.
installed) and nuts into the nose wheel fork.
(5) Install the nose gear wheel. Refer to Section 32-40.
(6) Reset the GEAR circuit breaker. On the right side of instrument panel.
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5. Required Strut Extension of the Nose Landing Gear Damper Assembly
The subsequent table tells you about the correct strut extension and pressure of the unloaded, fully
extended nose landing gear damper.
Strut Extension (unloaded) Gas Pressure

(visible length of bare piston)
20 cm (8 inches) 16 bar (232 PSI)

at 20°C (68°F)
10 bar (145 PSI)
at 20°C (68°F)
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6. Fill/Charge the Damper Assembly on the Nose Gear Leg
The following procedure tells you how to fill the nose gear damper assembly with hydraulic fluid and
then charge with nitrogen.
A. Equipment
Bottle. 1 Commercial.
Bleed tube. 1 Commercial.
Valve core removal tool. 1 Commercial.
Nitrogen charging equipment. 1 Commercial.
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B. Material



(MIL-PRF-5606 H) or
AMG-10 (GOST 6794-75
Amdt 1-5), see CAUTION
above.
Grease for sliding interfaces. As required. DOD-L-25681 or

NATO S-1735
(for example,
Mocil 50/50).
Gaseous nitrogen. As required. Commercial.
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C. Procedure

WARNING: DO NOT LET NITROGEN AT HIGH PRESSURE BLOW ONTO YOUR

SKIN. NITROGEN AT HIGH PRESSURE CAN PENETRATE THE SKIN
AND CAUSE SERIOUS INJURY.

CAUTION: YOU MUST FILL/CHARGE THE NOSE-WHEEL DAMPER ASSEMBLY

CORRECTLY. IF YOU DO NOT FILL/CHARGE THE NOSE-WHEEL
DAMPER CORRECTLY THE NOSE LANDING GEAR WILL NOT
OPERATE CORRECTLY. THIS CAN CAUSE DAMAGE TO THE NOSE
LANDING GEAR AND THE AIRPLANE STRUCTURE.

ACCIDENTALLY.

valve.

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DAMPER BEFORE YOU REMOVE THE CHARGING VALVE.
NITROGEN AT HIGH PRESSURE CAN PENETRATE YOUR SKIN.
THIS CAN CAUSE INJURY.
(4) Remove the core of the charging valve from the

damper assembly.
(5) Compress the damper assembly.
WARNING: DO NOT GET HYDRAULIC FLUID ON YOUR SKIN. HYDRAULIC

FLUID CAN CAUSE SKIN DISEASE.
(6) Connect the tube of the hydraulic fluid filler

bottle to the charging valve.


(7) Turn the bottle to the open position and allow Use Aeroshell Fluid 41
the hydraulic fluid to flow from the bottle into the (MIL-PRF-5606 H) or
damper. AMG-10 (GOST 6794-75 Amdt 1-5)
hydraulic fluid (see CAUTION above)
with 0.3 % grease compliant with
DOD-L-25681 or NATO S-1735
(for example, Mocil 50/50) added.
(8) Extend the damper assembly by hand to allow

the hydraulic fluid to fill the damper assembly.
(9) Compress and extend the damper not less than

6 times to release the air from the damper and
allow the hydraulic fluid to flow into the damper.
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(10) Compress the damper and hold the damper Keep the damper compressed.
compressed while you close the bottle and
remove the tube from the charging valve.
(11) Install the core of the charging valve.
(12) Connect the gaseous nitrogen charging Allow the damper to extend as it is
equipment to the damper charging valve. charged.
(13) Charge the damper with nitrogen to the correct Refer to Paragraph 5. The damper must
pressure. be fully extended.
(14) Disconnect and remove the gaseous nitrogen

charging equipment from the damper charging
valve.
(15) Install the dust cap onto the charging valve.
(17) Remove the rear fuselage and wing trestles.

equipment.
D. Fluid Change from Aero Shell Fluid 41 to AMG-10
Note: If the damper is disassembled, clean the inner surface of the damper and fill
with AMG-10. Refer to Paragraph C of this Chapter and to item (2) of this
table.
(1) Repeat the Fill/ Charge the Damper Assembly Refer to Paragraph C.
on the Nose Gear Leg procedure 3 times.
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Hydraulic Fluid
AeroShell Fluid 41
AMG-10
Placard NLG
Figure 4: Position of the Hydraulic Fluid Placard - Nose Landing Gear Damper
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7. Disconnect/Connect the NLG Folding Stay Assembly
The NLG folding stay assembly consists of the following main parts:
) Folding stay.
) Curve part.
) Nose landing gear brace assembly.
) Tension spring.


A. Equipment
B. Disconnect the Nose Landing Gear Folding Stay Assembly

ACCIDENTALLY.
(2) Disconnect the main battery. Refer to Section 24-31.
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(3) Pull the GEAR circuit breaker and secure Right hand side of instrument panel.
against inadvertent operation.

landing gear.
(6) Disconnect the nose landing gear doors:
S Remove the pins attaching the door Make sure to collect all pins.
connecting arms to the nose landing gear
door.
S Move the connecting arms clear of the nose

landing gear door.
CAUTION: WHEN DISCONNECTING THE FOLDING STAY THE NOSE LANDING

GEAR LEG SWINGS BACK AND CAN DAMAGE THE DIFFERENTIAL
SWITCH. HOLD THE NOSE LANDING GEAR LEG FIRMLY.
(7) Put foam plastic in between the nose landing

gear leg and the airplane fuselage for damage
protection.
(8) Disconnect the differential switch located in the Refer to Section 32-60.
nose gear bay:
S Remove the two bolts, four washers and two

nuts which mount the switch assembly to
the nose landing gear mounting bracket.
S Remove the cable ties which hold the

electrical cables of the switch.
S Move the differential switch clear of the

airplane.
(9) Remove the two nose landing gear extension Refer to Section 32-60.
switches.
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CAUTION: THE NOSE LANDING GEAR FOLDING STAY IS SPRING LOADED.

DUE TO THE HIGH FORCES INVOLVED THE ELEMENT OF THE
FOLDING STAY CAN CAUSE SERIOUS INJURY TO PERSONS.
WARNING: FOR THE FOLLOWING STEP SIT IN FRONT OF THE NOSE LANDING
GEAR LEG FACING THE AFT. MAKE SURE TO POSITION YOURSELF
SO THAT THE NOSE LANDING GEAR FOLDING STAY CANNOT HIT
YOU WHEN IT IS RELEASED.
WARNING: DO NOT REMOVE THE PIN WHICH CONNECTS THE NOSE LANDING
GEAR FOLDING STAY DRAG LEVER AND THE DRAG STRUT WHEN
STILL MOUNTED IN THE AIRPLANE. THE FOLDING STAY SWINGS
BACK AND CAN CAUSE SERIOUS INJURY TO PERSONS.
(10) Release the nose landing gear folding stay Refer to Figure 5.
tension:
S Remove the nut and washer from the nose Support the folding stay with your hands
landing gear leg which holds the folding and at the same time hold the nose
stay. landing gear leg with your feet.
S Carefully remove the bolt with spacer while The nose landing gear leg falls
securing the folding stay firmly. backwards, when the bolt is removed.
S Release the nose landing gear folding stay

slowly until the tension is fully released.
(11) Remove the tension spring: Refer to Figure 5.
S Remove the bolt, nut, washer, spacer and Note the directions of the bushing and
bushing which connects the tension spring the spring. The slot of the bushing must
to the nose landing gear leg. point to the direction of the spring. The
spring hook tip must be on top.
S Move the tension spring clear of the nose
landing gear leg.
(12) Remove the carpets from the front baggage

compartment.
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(13) If a de-icing system is installed: Refer to Section 30-00.

In some cases the de-icing fluid tank can
S Remove the de-icing fluid tank.
be moved sideways by loosening the
mounting belt and thus access to the
nose landing gear brace mounting bolt
heads is gained.
(14) Disconnect the nose landing gear actuator from Refer to Figure 5.
the nose landing gear brace:
S Remove the bolt which connects the nose

landing gear actuator to the nose landing
gear brace.
S Move the nose landing gear actuator clear

of the nose gear brace assembly.
(15) Disconnect the curve part from the fuselage: Refer to Figure 5.
S Remove the bolt, bushing, washer and nut

from both sides of the curve part.
(16) If MÄM 42-659 is NOT installed: Refer to Paragraph 2.B.
Remove the nose landing gear leg.
Disconnect the nose landing gear brace Refer to Figure 5.

assembly.
S Remove the 6 mounting bolts, washers and

nuts from both sides of the brace.
Disconnect the nose landing gear mounting

bracket:
S Remove the 22 bolts, washers and nuts

which hold the mounting bracket on the
nose landing gear frame.
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(19) If MÄM 42-659 is installed:
Remove the nose landing gear brace axle: Refer to Figure 6.
S Remove the nut and the special washer on

RH side.
S Pull axle from LH side. Hold the folding stay assembly in place
when pulling the axle.
(20) Move the nose landing gear folding stay

assembly, if MÄM 42-659 is NOT installed with
the nose landing gear mounting bracket, clear of
the nose gear bay:
S The nose landing gear actuator is still

connected via the hydraulic lines.
S Secure all parts so that the hydraulic lines

are not stressed.
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View A
Bolt Tension Spring
6 Nuts Bolt
Latch
6 Washers Operating
Arm
Washer
Bushing Spacer
Bolt Sleeve
6 Nuts
Bushing Drag Lever
6 Washers
Hook Tip
Slot
Bolt Tension Spring
Curve Part A Washer Actuator

Bushing Bushing Nut
Nose Gear Bracket Assy
6 Bolts Hook Tip
Washer
Nose Gear Brace Assy Nut Slot Spacer
Circlip
Nose Gear Actuator
Nose Gear Brace Axle Assy Bracket Assy
Pin
Latch Operating Arm
Circlip
6 Bolts
Drag Lever
Bolt
Spacer Sleeve
Washer
Nut
Nut
Washer Washer
Bolt
Drag Strut
Spacer
Nose Gear Leg
Figure 5: Nose Landing Gear Extension and Retraction
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AIRCRAFT
View A
Special Washer
Bolt
6 Nuts Tension Spring
Bolt
6 Washers Nut Latch
Operating Arm
Washer
Bushing
Spacer
Bolt
Sleeve
6 Nuts
Bushing Drag Lever
6 Washers
Hook Tip
Nut Slot
Washer Tension Actuator
Curve Part Spring Nut
Nut A Washer
Special Washer Bushing
Bushing
Nose Gear Bracket Assy Hook Tip
6 Bolts
Nose Gear Brace Assy Slot Spacer
Circlip
Nose Gear Actuator
Nose Gear Brace Axle Bracket Assy
Pin
Latch Operating Arm
Circlip
6 Bolts
Drag Lever
Spacer Sleeve Bolt

Washer
Nut
Nut
Washer
Bolt
Drag Strut
Spacer
Nose Gear Leg
Figure 6: Nose Landing Gear Extension and Retraction (if MÄM 42-659 is installed)
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C. Connect the Nose Landing Gear Folding Stay Assembly

ACCIDENTALLY.
(1) Move the nose landing gear folding stay

assembly into position on the mounting bracket.
Move the nose landing gear mounting bracket

with the folding stay assembly in position on the
nose landing gear frame:
S Connect the mounting bracket with the Seal the bonding connections.
22 bolts, washers and nuts to the nose
landing gear frame.
Connect the nose landing gear brace assembly Refer to Figure 5.

to the nose landing gear bay:
S Install the 6 bolts, washers and nuts on both Use new self locking nuts.
sides of the nose landing gear brace.
Install the nose landing gear brace axle: Refer to Figure 6.
S Shift in axle axle from LH side.
S Install special washer and nut on RH side. Use new self locking nut.
(5) Connect the curve part in the nose landing gear Refer to Figure 5.
bay:
S Install the bolt, bushing, washer and nut on Use new self locking nuts.
both sides of the curve part.
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AIRCRAFT

Refer to Paragraph 2B.
Install the nose landing gear leg.
(7) Connect the nose landing gear actuator to the Refer to Figure 5.
nose landing gear brace assembly:
S Move the nose landing gear actuator into

position in the nose landing gear brace
assembly.
S Install the bolt, washer and nut connecting Use new self locking nut.
the actuator to the nose landing gear brace
assembly.
(8) If a de-icing system is installed: Refer to Section 30-00.
S Install the de-icing fluid tank.
(9) Install the carpets in the front baggage

compartment.
(10) Install the tension spring: Refer to Figure 5.
S Move the tension spring into position. Make sure to mount the tension spring
and the bushing as noted during
S Install the bolt, nut, washer, spacer and
disassembling.
bushing which connects the tension spring
to the nose landing gear leg.
(11) Connect the nose landing gear folding stay to

the nose landing gear leg:
S Push the folding stay towards the nose Hold the nose landing gear leg with your
landing gear leg slowly. feet and move it close to the folding stay.
S Install the bolt and the spacer while

supporting the folding stay.
S Install the nut and washer onto the folding

stay bolt.
(12) Remove the protective foam plastic.
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AIRCRAFT
(13) Install the nose landing gear differential switch: Refer to Section 32-60.
S Install the two bolts, four washers and two

nuts which mount the nose landing gear
differential switch to the nose landing gear
bay.
S Install the cable ties which hold the electrical

cables of the differential switch.
(14) Adjust the differential switch. Refer to Section 32-60.
(15) Install the two nose landing gear extension Refer to Section 32-60.
switches.
(16) Adjust the nose landing gear extension Refer to Section 32-60.
switches.
(17) Connect the nose landing gear door arms to the

nose landing gear doors.
(19) Set the GEAR circuit breaker.
(21) Perform a test of the correct operation of the Refer to Section 32-30.

of the airplane.
(23) Lower the airplane to the ground. Refer to Section 07-10.
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AIRCRAFT
Nose Gear Leg Tube
Nose Gear Brace
Nose Gear Wheel

Landing Gear Door
20mm
Min 5 mm (0.8 inch)
(0.2 inch)
Figure 7: Nose Landing Gear Actuator
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8. Remove/Install the NLG Actuator


A. Equipment
B. Remove the Nose Landing Gear Actuator

ACCIDENTALLY.
(2) Retract the landing gear. Use the landing gear switch.
(4) Pull the GEAR circuit breaker and secure Right hand side of instrument panel.

landing gear.
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(7) Disconnect the nose landing gear doors:
S Remove the pins attaching the door Make sure to collect all pins.
connecting arms to the nose landing gear
door.
S Move the connecting arms clear of the nose

landing gear door.
CAUTION: WHEN DISCONNECTING THE FOLDING STAY THE NOSE LANDING

GEAR LEG SWINGS BACK AND CAN DAMAGE THE DIFFERENTIAL
SWITCH. HOLD THE NOSE LANDING GEAR LEG FIRMLY.
(8) Put foam plastic in between the nose landing

gear leg and the airplane fuselage for damage
protection.
CAUTION: THE NOSE LANDING GEAR FOLDING STAY IS SPRING LOADED.

DUE TO THE HIGH FORCES INVOLVED THE ELEMENT OF THE
FOLDING STAY CAN CAUSE SERIOUS INJURY TO PERSONS.
WARNING: FOR THE FOLLOWING STEP SIT IN FRONT OF THE NOSE LANDING
GEAR LEG FACING THE AFT. MAKE SURE TO POSITION YOURSELF
SO THAT THE NOSE LANDING GEAR FOLDING STAY CANNOT HIT
YOU WHEN IT IS RELEASED.
WARNING: DO NOT REMOVE THE PIN WHICH CONNECTS THE NOSE LANDING
GEAR FOLDING STAY DRAG LEVER AND THE DRAG STRUT WHEN
STILL MOUNTED IN THE AIRPLANE. THE FOLDING STAY SWINGS
BACK AND CAN CAUSE SERIOUS INJURY TO PERSONS.
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(9) Release the nose landing gear folding stay Refer to Figure 5.
tension:
S Remove the nut and washer from the nose Support the folding stay with your hands
landing gear leg which holds the folding and at the same time hold the nose
stay. landing gear leg with your feet.
S Carefully remove the bolt with spacer while The nose landing gear leg falls
securing the folding stay firmly. backwards, when the bolt is removed.
S Release the nose landing gear folding stay

slowly until the spring tension is fully
released.
(10) Disconnect the hydraulic lines from the actuator. Use a suitable container to catch spilt
hydraulic fluid. Fit caps on all open
connections.
(11) Disconnect the actuator from the nose landing

gear:
S Remove the circlip which secures the ball

joint of the actuator.
S Remove the pin with the second circlip.
S Remove the bolt from the nose landing gear

brace assembly.
S Move the actuator clear of the airplane.
(12) Measure and record the distance from the Refer to Figure 8. Note the distance
actuator safety lock washer to the center of the marked ‘Y’.
ball joint.
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AIRCRAFT
Figure 8: Nose Landing Gear Actuator Measurements
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22 Dec 2021 32-20-00 Rev. 5
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C. Install the Nose Landing Gear Actuator

ACCIDENTALLY.
(1) Install the hydraulic fittings to the actuator. Make sure to achieve appropriate
orientation.
Remove all caps.
(2) Install the ball joint rod to the piston rod of the Refer to Figure 8.
actuator. Adjust the ball joint center according to
the measurement ‘Y’.
(3) Connect the hydraulic lines to the actuator. Remove all caps.
(4) Connect the nose landing gear actuator to the

nose landing gear:
S Move the nose landing gear actuator into

position in the nose landing gear brace
assembly.
S Install the bolt, washer and nut connecting Use new self locking nuts.
the actuator to the nose landing gear brace
assembly.
S Install the pin with the two circlips to connect Use new circlips.
the actuator to the nose landing gear leg.
(5) Connect the nose landing gear folding stay to

the nose landing gear leg:
S Push the folding stay towards the nose Hold the nose landing gear leg with your
landing gear leg slowly. feet and move it close to the folding stay.
S Install the bolt and the spacer while

supporting the folding stay.
S Install the nut and washer onto the folding

stay bolt.
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(6) Remove the protective foam plastic.
(8) Replenish the hydraulic reservoir as necessary. Refer to Section 29-10.
WARNING: DUE TO THE HIGH FORCES INVOLVED, THE LANDING GEAR

RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO
PERSONS. MAKE SURE THAT NO PERSON CAN BE HIT OR
CRUSHED WHEN OPERATING THE LANDING GEAR RETRACTION
SYSTEM.
(12) Retract the landing gear:
S Set the Landing Gear switch to the UP

position and secure against inadvertent
operation.
(13) Pull the emergency landing gear lever to the

emergency extension position.
(14) Measure and record the distance in between the Refer to Figure 8. Note the distance ‘X’.
nose landing gear actuator safety lock washer
to the cylinder head.
(15) Extend the landing gear:
S Set the gear selector to DOWN.
S Push the landing gear emergency lever to

the normal position.
(16) Pull the GEAR circuit breaker and secure

(18) Measure the distance in between the nose Refer to Figure 8. Note the distance ‘X’.
landing gear actuator safety lock washer to the
cylinder head.
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22 Dec 2021 32-20-00 Rev. 5
AIRCRAFT
(17) The difference of the measurements in step 12 Refer to Figure 8.

and step 16 must lie in between
0.1 mm (0.004 inch) and 0.9 mm (0.035 inch).
If the measurements do not meet the

requirement:
S Adjust the pushrod of the nose landing gear Maximum distance ‘Y’ (Min. screw-in
actuator. depth of rod end bearing): 34 mm
(1.34 in).
S Repeat steps 8 to 17.
(19) Tighten the nose landing gear actuator counter

nut and install the safety lock wire.
WARNING: DUE TO THE HIGH FORCES INVOLVED, THE LANDING GEAR

RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO
PERSONS. MAKE SURE THAT NO PERSON CAN BE HIT OR
CRUSHED WHEN OPERATING THE LANDING GEAR RETRACTION
SYSTEM.
S Set the Landing Gear Switch to the UP

position and secure against inadvertent
operation.
(23) Check the clearance between the nose landing Refer to Figure 7.
gear tire and the nose landing gear doors:
S Close one NLG door by hand.
S The clearance must be at least 20 mm

(0.8 in).
If the clearance does not meet the requirement:

Contact DAI.
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AIRCRAFT
(24) Check the clearance between the nose landing Refer to Figure 7.
gear leg strut and the nose landing gear brace.
The clearance must be at least 5 mm (0.2 in).
If the clearance does not meet the requirement:

Contact DAI.
(25) Set the Landing Gear switch to DOWN.
(26) Connect the nose landing gear door arms to the

nose landing gear doors.
(27) Perform a test of the correct operation of the Refer to Section 32-30.
landing gear extension and retraction system.

of the airplane.
(29) Lower the airplane to the ground. Refer to Section 07-10.
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22 Dec 2021 32-20-00 Rev. 5
AIRCRAFT
9. Remove/Install the Nose Landing Gear Mounting Bracket (if MÄM 42-659 is installed)
A. Equipment
B. Remove the Nose Landing Gear Mounting Bracket
(1) Remove the nose landing gear leg. Refer to Paragraph 2.
(2) Remove the LH and the RH nose gear bracket

assy:
S Remove the 6 mounting bolts, washers and Refer to Figures 5, 6.

nuts from both sides of the baggage
compartments and nose gear bay.
(3) Disconnect the nose landing gear mounting

bracket:
S Remove the 22 bolts, washers and nuts

which hold the bracket in the nose landing
gear bay.
(4) Move the nose landing gear mounting bracket

clear of the nose gear bay.
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Rev. 5 32-20-00 22 Dec 2021
AIRCRAFT
C. Install the Nose Landing Gear Mounting Bracket
(1) Install the nose landing gear mounting bracket:
S Install the 22 bolts, washers and nuts which Use new self-locking nuts.
hold the bracket in the nose landing gear
bay.
(2) Install the LH and RH nose gear bracket assy:
S Install the 6 mounting bolts, washers and Use new self-locking nuts.
nuts on both sides of the baggage
compartment and nose gear bay.
Install bracket assy with plain bearing on
the LH side.
Orientation of LH side bracket according

to Figure 9.
Position Identification Hole

must be up and forward
when looking outboard
LH Nose Gear Bracket Assy
Bolts
Washers
Figure 9: LH Nose Gear Mounting Bracket Position (if MÄM 42-659 is installed)
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AIRCRAFT
Section 32-30
Extension and Retraction
1. General
This Section tells you about the components that extend and retract the landing gear. It tells you how
the system operates in normal operation and it tells you how the systems operates in an emergency.
Refer to Section 32-10 for data about the main gear legs. Refer to Section 32-20 for data about the
nose gear leg. Refer to Section 32-60 for data about the landing gear position and warning system.
Refer to the wiring manual for data about the related electrical systems.
2. Description
Figure 1 shows the main components of the of the extension and retraction system. Figure 2 shows
the main landing gear extension and retraction system and Figure 3 shows the nose landing gear
extension and retraction system. The landing gear has a dedicated hydraulic system to extend and
retract the legs. Folding stays that attach to the legs and the surrounding structure unfold to lock the
legs in the extended position. A spring operated latching mechanism holds the folding stays in a
geometrically locked position. The initial movement of the gear actuator when moving to retract the
landing gear operates the mechanism to unlock the folding stay. As the gear retracts, the folding stay
folds and retracts into the landing gear bay with its related leg. The landing gear extension and
retraction system has these main components:
A. Hydraulic Actuators
The hydraulic actuators are located in the related main gear bay. The actuators use hydraulic fluid
pressure to extend and retract the airplane landing gear during normal operation of the system.
B. Folding Stays
Each landing gear leg has a folding stay. The folding stay holds the extended leg locked in the
down position. When the leg extends to the fully down position the folding stay unfolds and a
latching mechanism locks the stay in the unfolded position. When the pilot retracts the landing gear
the hydraulic actuator operates a mechanism to unlatch the folding stay. The folding stay then folds
into the landing gear bay with the landing gear.
Doc # 7.02.15 Page 1

Rev. 5 32-30-00 22 Dec 2021
AIRCRAFT
Gear Extension
Max 160 KIAS
EMERGENCY
Selector Handle
ALTERNATE AIR
ALTERNATE AIR
ALTERNATE AIR
ON
Emergency Extension Lever
Hydraulic Supply and

Control System
Extension/Retraction Actuator
Extension / Retraction
Actuator
Nose Gear
Folding Stay Main Gear
Folding Stay
Figure 1: Extension and Retraction System Main Components
Page 2 Doc # 7.02.15

22 Dec 2021 32-30-00 Rev. 5
AIRCRAFT
Hydraulic Actuator
Tension Spring
Longitudinal
Pivot
Folding Stay
Latching Hydraulic Actuator

Mechanism Tension Spring
Folding Stay
Tubular Steel
Strut
Damper Longitudinal Pivot
Tubular Steel Strut

Trailing Arm
Left gear leg shown, right similar
EXTENDED
(VIEW FROM AFT)
RETRACTED
(VIEW FROM AFT)
Figure 2: Main Landing Gear - Extension and Retraction
Doc # 7.02.15 Page 3

Rev. 5 32-30-00 22 Dec 2021
AIRCRAFT
C. Selector Handle
The selector handle is located in the cockpit, in the instrument panel. The selector lever is used for
normal extension and retraction of the landing gear. Three LEDs located on the instrument panel
next to the selector handle show the status of the main landing gear.
D. Emergency Extension System
The emergency extension system allows the pilot to extend the landing gear in the event of a
system failure. The forces of gravity are used to extend the legs and a spring-loaded mechanism
on each leg folding-stay locks the leg in the extended position. The main component of the
emergency extension system is the:
) Emergency extension valve. The emergency extension valve is located on the hydraulic control
and is operated by the emergency extension lever. When the emergency extension valve is
operated (emergency extension position) the return flow from the actuators by-passes the
actuator regulating valves. The emergency extension lever is located on the left side of the
cockpit, below the instrument panel. A micro switch located at the emergency extension valve
isolates the hydraulic pump when the valve has been set to the EMERGENCY position.
Page 4 Doc # 7.02.15

22 Dec 2021 32-30-00 Rev. 5
AIRCRAFT
Tension Spring
Nose Landing Gear

Mounting Bracket
Hydraulic Actuator
Nose Landing Gear
Mounting Bracket
Nose Landing Gear Hydraulic Actuator
Folding Stay
Latching
Mechanism
Tubular Steel Strut EXTENDED

(VIEW FROM LEFT)
RETRACTED
(VIEW FROM LEFT)
Figure 3: Nose Landing Gear - Extension and Retraction
Doc # 7.02.15 Page 5

Rev. 5 32-30-00 22 Dec 2021
AIRCRAFT
3. Operation
Figures 4 thru 7 show the hydraulic schematic diagrams for the operation of the landing gear.
A. Retraction
When the pilot sets the landing gear selector handle to UP during flight the following occurs:
) The electrical circuit to the hydraulic pump is made and the pump will operate if the system
pressure is less than 96.5 bar (1400 PSI). The retract solenoid valve is energized through the
LH main gear ‘weight-on-wheels’ micro switch and allows fluid to flow from the pump to the
retract side of the actuator. The extend solenoid valve is de-energized and allows fluid to flow
from the pump to the extend side of the actuator (Figure 4).
) The pump pressure switch operates the pump as necessary to maintain the system pressure
at 96.5 - 113.8 bar (1400 - 1650 PSI). Fluid at pump pressure acts on both sides of the actuator
piston. The effective surface area of the retract side of the piston is larger than the effective
surface area on the extend side of the actuator piston. Because the same fluid pressure is
acting on different effective areas of the actuator pistons the resulting ‘differential pressure’
acting on the piston causes the actuator to move the landing gear leg towards the retract
position.
) The initial movement of the hydraulic actuators towards the retract position releases the folding
stay latching mechanism. The folding stay can then fold into the landing gear bay with the
landing gear.
) When the landing gear is fully retracted the nose landing gear UP micro switch operates and
the extend solenoid valve is energized and moves to the ‘full pressure’ position (Figure 5). Fluid
returning from the extend side of the actuators flows through the extend solenoid valve and back
into the reservoir. The full pump pressure acting on the retract side of the actuator pistons holds
the landing gear in the fully retracted position.
) The pump pressure switch operates the pump as necessary, to maintain the system pressure
at 96.5 - 113.8 bar (1400 - 1650 PSI). If there are no internal leaks in the system the hydraulic
accumulator will maintain the pressure in the system without the hydraulic pump operating.
Page 6 Doc # 7.02.15

22 Dec 2021 32-30-00 Rev. 5
AIRCRAFT
Nose Gear Actuator

Retract LG
Extend LG
Main Gear Actuator LH Main Gear Actuator RH

Retract LG Retract LG
Extend LG Extend LG
R E
R E R E
Emergency Schrader
Extension Gas Valve
Valve Accumulator
Pump Pressure Switch

2-Way <1400 psi ON
Flow Control >1650 psi OFF
Valve
NRV Accumulator
Dump Valve
Flow
1.5
Retract
Solenoid Regulating Valve
Regulating Valve NRV 1750-1850 psi
Valve (Main RH)
Flow
1.7
Regulating NRV
Flow Valve (Nose)
1.5 Relief Valve
Regulating 2600 psi
Valve (Main LH)
Bypass Valve
(Emergency NRV
NRV
Extension)
Extend Solenoid Valve
HP Filter
Breather Filter Pump
Filler
Closing Valve Motor, Cap
Safety Valve 24V
(14 psi)
Tank Level Indicator
Drain Fitting
Figure 4: Hydraulic Schematic Diagram - ‘Differential Pressure’ Retraction Operation
Doc # 7.02.15 Page 7

Rev. 5 32-30-00 22 Dec 2021
AIRCRAFT
Nose Gear Actuator

Retract LG
Extend LG

Extend LG Extend LG
R E
R E R E
Emergency Schrader
Extension Gas Valve
Valve Accumulator

2-Way <1400 psi ON
Valve
NRV Accumulator
Dump Valve
Flow Retract
1.5
Solenoid
Valve Regulating Valve
Regulating NRV 1750-1850 psi
Valve (Main RH)
Flow
1.7
Regulating NRV
Flow Valve (Nose)
1.5 Relief Valve
Regulating 2600 psi
Valve (Main LH)
Bypass Valve
(Emergency NRV
NRV
Extension)
HP Filter
Filler
Safety Valve 24V
(14 psi)
Drain Fitting
Figure 5: Hydraulic Schematic Diagram - ‘Full Pressure’ Retraction Operation
Page 8 Doc # 7.02.15

22 Dec 2021 32-30-00 Rev. 5
AIRCRAFT
Nose Gear Actuator

Retract LG
Extend LG

Extend LG Extend LG
R E
R E R E
Emergency Schrader
Extension Gas Valve
Valve Accumulator

2-Way <1400 psi ON
Valve
NRV Accumulator
Return Dump Valve
Solenoid
Flow Valve
1.5
Regulating Valve
Valve (Main RH)
Flow
1.7
Regulating NRV
Flow Valve (Nose)
1.5 Relief Valve
Regulating 2600 psi
Valve (Main LH)
Bypass Valve
(Emergency NRV
NRV
Extension)
Supply Solenoid Valve
HP Filter
Filler
Safety Valve 24V
(14 psi)
Drain Fitting
Figure 6: Hydraulic Schematic Diagram - Normal Extension Operation
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Rev. 5 32-30-00 22 Dec 2021
AIRCRAFT
B. Extension
When the pilot sets the landing gear selector handle to DOWN during normal operation the
following occurs:
) The electrical circuit to the hydraulic pump is closed and the pump will operate if the system
pressure is less than 96.5 bar (1400 PSI). The extend solenoid valve de-energizes (Figure 6)
and fluid from the hydraulic pump flows through the extend solenoid valve into the extend side
of the actuator. The retract solenoid valve de-energizes and allows the hydraulic fluid to flow
from the retract side of the actuators, through the regulating valves and back into the reservoir.
) The pump pressure switch operates the pump as necessary to maintain the system pressure
at 96.5 -113.8 bar (1400 - 1650 PSI). The pressure acting on the extend side of the actuator
piston moves the piston to extend the landing gear legs.
) As the legs reach the fully extended position the latches on the folding stays operate against
spring pressure to lock the stay in the unfolded position.
) When all the hydraulic actuators are fully retracted (legs fully extended) the pressure in the
system increases until the system pressure reaches 113.8 bar (1650 PSI). The pump pressure
switch opens at 113.8 bar (1650 PSI) and isolates the hydraulic pump. If there are no internal
leaks in the system the hydraulic accumulator will maintain the pressure in the system without
the hydraulic pump operating.
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AIRCRAFT
Nose Gear Actuator

Retract
Extend

Retract Retract
Extend Extend
R E
R E R E
Emergency Schrader
Extension Gas Valve
Valve Accumulator

2-Way <1400 psi ON
Valve
NRV Accumulator
Retract Dump Valve
Solenoid
Flow Valve
1.5
Regulating Valve
Valve (Main RH)
Flow
1.7
Regulating NRV
Flow Valve (Nose)
1.5 Relief Valve
Regulating 2600 psi
Valve (Main LH)
Bypass Valve
(Emergency NRV
NRV
Extension)
HP Filter
Filler
Safety Valve 24V
(14 psi)
Drain Fitting
Figure 7: Hydraulic Schematic Diagram - Emergency Extension Operation
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Rev. 5 32-30-00 22 Dec 2021
AIRCRAFT
C. Emergency Extension
Figure 7 shows the schematic diagram for the main landing gear emergency hydraulic extension
system. The pilot can use this system to extend the landing gear when there is a problem with the
normal extension system. You cannot retract the landing gear with the emergency system. The
emergency extension lever is located on the left side of the cockpit, below the instrument panel.
A flexible cable connects the emergency extension lever to the emergency extension valve. When
the pilot operates the emergency extension lever these events occur:
) The emergency control lever opens the emergency extension valve. The actuating lever for the
emergency extension valve also operates a micro switch which isolates the electrical power
from the hydraulic pump. The pump cannot run.
) Gravity causes the weight of each landing gear leg to move the piston in each actuator inwards.
The open emergency extension valve allows the fluid on the retract side of the piston in each
actuator to flow through the by-pass valves. The by-pass valves allow the hydraulic fluid flowing
from the actuators to by-pass the regulating valves and return to the reservoir. The position of
the solenoid valves does not affect the operation of the emergency extension system.
) As each landing gear leg extends the related folding stay unfolds. Tension springs located in
each landing gear bay ensure that each folding stay fully unfolds. When the stay fully unfolds
the spring operated latching mechanism positively locks the folding stay open. The locked stay
holds the related landing gear leg fully extended.
) When the folding-stays are locked, the related folding-stay switches (LDG GEAR DOWN) are
closed and electrical ground is supplied to the related green indicator lights. The electrical circuit
for the selected indicator light is closed and the green light illuminates.
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Trouble-Shooting
1. General
This table gives you the trouble-shooting procedures for the landing gear extension and retraction
system. Refer to Section 32-10 for trouble-shooting the main landing gear assembly. Refer to Section
32-20 for trouble-shooting the nose landing gear assembly. Refer to Section 32-40 for trouble-shooting
the nose wheel assembly. Refer to Section 32-50 for trouble-shooting the nose wheel steering. Refer
to Section 32-60 for trouble-shooting the nose landing gear position and warning system.
Landing gear does not retract Hydraulic pump (GEAR) circuit Reset GEAR circuit breaker.
when the selector lever is set to breaker pulled.
UP.
Emergency extension lever Reset emergency extension

operated. lever.
Hydraulic pump defective. Replace hydraulic pump.
Hydraulic supply and control Replace hydraulic supply and

assembly defective. control assembly.
Wiring from landing gear Do a test for continuity of the

selector to hydraulic supply related wiring. Replace or
and control panel defective. repair defective wiring as
necessary. Refer to Chapter 92
for the Wiring Diagrams.
Landing gear does not extend Hydraulic supply and control Replace hydraulic supply and
when the selector lever is set to assembly defective. control assembly.
DOWN.
Wiring from landing gear Do a test for continuity of the

selector to hydraulic supply related wiring. Replace or
and control panel defective. repair defective wiring as
necessary. Refer to Chapter 92
for the Wiring Diagrams.
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One landing gear leg does not Defective hydraulic actuator. Replace defective hydraulic
retract correctly. actuator.
Hydraulic pump runs Accumulator pressure Recharge/replace accumulator.

continuously / keeps cycling. low/defective.
Pump pressure switch Replace pump pressure

defective. switch. Refer to
MAINTENANCE PRACTICES,
Paragraph 5.
Internal leak in the hydraulic Replace hydraulic supply and

supply and control assembly. control assembly.
Hydraulic system fluid level Hydraulic fluid leak. Do a test for leaks in the
low. hydraulic system. Tighten
leaking connections.
Repair/replace leaking
components.
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1. General
The Maintenance Practices in this Section tell you how to remove/install the main components of the
landing gear extension and retraction system. They also tell you how to do a test for the correct
operation of the landing gear extension and retraction system.
Refer to Section 32-10 for data about the main landing gear. Refer to Section 32-20 for data about the
nose landing gear. Refer to Section 32-40 for data about the wheels and brakes. Refer to Section
32-50 for data about the nose wheel steering system. Refer to Section 32-60 for data abut the landing
gear position and warning system.
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Figure 8: Main Landing Gear Hydraulic Actuator Installation
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Threaded Ring
Hydraulic Fitting
Outer Cylinder
Spherical Bearing
Hydraulic Fitting
Piston Rod Assy
Washer
Counter Nut
Cylinder Head
Spherical Rod End Bearing
Figure 9: Landing Gear Hydraulic Actuator Assembly

(for Correct Alignment of Hydraulic Fittings Refer to Figure 10)
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Main Landing Gear Actuator
Nose Landing Gear Actuator
Figure 10: Hydraulic Actuator Alignments
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2. Disassemble/Assemble the Actuator
A. Equipment
Spanner wrench. 1 Commercial.
Seal ring protection. 1 Commercial.


B. Disassemble the Actuator
(1) Measure and make a note of the distance from Refer to Figure 11.
the actuator safety lock washer to the center of
the rod-end bearing.
(2) Remove spherical rod end bearing: Refer to Figure 9.
S Remove the lock wire from the counter nut.
S Remove the spherical rod end bearing,

counter nut and the washer from the actuator.
(3) Clamp the actuator:
S Put two washers onto the spherical bearing This helps protecting the spherical
on the actuator assembly. bearing.
S Use a vice to clamp the actuator assembly at Make sure not to damage or scratch the
the spherical bearings side. This helps when actuator.
disassembling the actuator.
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(4) Remove the cylinder head: Refer to Figure 9.
S Remove the lock wire from the cylinder head.
S Place the spanner wrench (special tool) onto

the cylinder head.
S Place the hook wrench onto the threaded

ring.
S Loosen the cylinder head by turning the hook

wrench and holding the spanner wrench
(special tool) against it.
S Remove the cylinder head.
(5) Remove the hydraulic fitting, the threaded ring Refer to Figure 9.
and the piston rod from the actuator.
Figure 11: MLG Actuator Measurement
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C. Assemble the Actuator
(1) Install the piston rod. Slide into the outer cylinder.
(2) Slide the threaded ring from the backside onto Refer to Figure 9.
the actuator assembly which has an already
installed “snap ring”.
CAUTION: THERE IS A DIFFERENT ALIGNMENT FOR THE MAIN GEAR

ACTUATOR THAN FOR THE NOSE GEAR ACTUATOR. REFER TO
FIGURE 10 TO SEE THE DIFFERENCE.
(3) Install the hydraulic fitting onto the actuator. Refer to Figure 9.
(4) Install the cylinder head: Make sure the alignment of the cylinder
head is correct. Refer to Figure 10.
S Install the seal ring protection (special tool)
onto the piston rod.
S Slide the cylinder head onto the piston rod.
S Remove the seal ring protection (special tool)

from the piston rod.
S Apply Rivolta F.L.A on the cylinder head

thread, the O-ring and the snap ring.
S Install the spanner wrench (special tool) onto

the cylinder head.
S Place the hook wrench onto the threaded

ring.
S Tighten the cylinder head by turning the hook

wrench and hold the spanner wrench (special
tool) against it.
S Secure the cylinder head with 120 Nm

(88.5 lbf.ft.) by using a torque hook wrench.
S Install the lock wire onto the cylinder head.
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(5) Install spherical rod end bearing: Install the lock wire not until installing
the actuator into the airplane because
of correct alignment.
S Apply Rivolta F.L.A on the spherical rod end
bearing thread.
S Install the rod end together with the counter Refer to Figure 9.
nut and washer.
S Adjust the main landing gear rod-end bearing Refer to Figure 11.
according to the measurement or the base
Base settings equals min. screw-in
setting of 34 mm (1.34 in) from the safety lock
depth.
washer to the center of the rod-end bearing.
Maximum distance x (min. screw-in
depth): 34 mm (1.34 in).
(6) Remove the actuator from the vice and remove

the protection washers.
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3. Landing Gear Extension and Retraction Test (Normal Extension)
A. Equipment
B. Landing Gear Extension and Retraction Test
WARNING: DO NOT LET PERSONS NEAR THE LANDING GEAR WHEN YOU DO
THE EXTENSION AND RETRACTION TEST. THE LANDING GEAR
CAN CAUSE INJURY TO PERSONS.
BE DAMAGED.

airplane.
(4) Set both engine power levers to 100%. Fully forward.
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S Set the landing gear selector lever to UP

and these events must occur:
S The hydraulic pump operates.

Refer to Section 32-60 for more data
S The green (SAFE) leds switch off.
about the landing gear indicating system.
S The red led (UNSAFE) illuminates.
S The landing gear retracts.
S When the gear is fully retracted:
S The red led (UNSAFE) switches off.
S The hydraulic pump stops operating

(allow 15 sec. after gear is fully retracted).

gear warning horn:
S Move the left engine power lever to IDLE. The landing gear warning horn must
operate.
S Move the right engine power lever to IDLE. The landing gear warning horn must
operate.
S Move the left engine power lever to 100%. The landing gear warning horn must
operate.
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gear extension system:
S Set the landing gear selector lever to

DOWN and these events must occur:
S The landing gear extends.
S When all the landing gear legs are fully

extended and locked:
S The green (SAFE) leds illuminate.

(allow 15 sec. after gear is fully extended).
S Set both engine power levers to IDLE.
(9) Disconnect the external power supply from the Refer to Section 24-40.
airplane.

airplane.
airplane is clear.
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4. Landing Gear Emergency Extension System Test
A. Equipment
Airplane jacks. 3 Commercial
B. Landing Gear Emergency Extension Test
THE EMERGENCY EXTENSION TEST. THE LANDING GEAR CAN
CAUSE INJURY TO PERSONS.
BE DAMAGED.

airplane.
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S Set the landing gear selector lever to UP


Refer to Section 32-60 for more data
S The green (SAFE) leds switch off.
about the landing gear indicating system.

(allow 15 sec. after gear is fully retracted).
(5) Set the EMERGENCY EXTENSION lever to the Pull fully aft.
EXTEND position, these events must occur:
S The hydraulic pump must not operate.
S The red (UNSAFE) led illuminates.
S The landing gear extends. When the landing

gear is fully extended and locked:
S The red (UNSAFE) led remains on.
S The 3 green (SAFE) leds illuminate.
(6) Reset the landing gear emergency extension

lever:
S Set the normal landing gear selector to

DOWN.
S Set the emergency extension lever to close Fully forward.

S The hydraulic pump operates until the

system pressure stabilizes at
96.5 - 113.5 bar (1400 - 1650 PSI).
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(7) Do a test of the correct operation of the landing Refer to Paragraph 3.

gear normal retraction and extension system.

airplane.
airplane is clear.
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Section 32-40
Wheels and Brakes
1. General
The DA 42 NG has two main wheels and a nose wheel. All wheels have split hubs and tires with inner
tubes. The main wheels are standard Cleveland components.
The main wheels have brake disks and a Cleveland brake caliper. Toe-brake pedals operate hydraulic
cylinders. Hydraulic pipes and hoses connect the cylinders to the brake calipers. A parking valve locks
the brakes ON.
Each main wheel has an independent brake system. The left pedal of each rudder pedal assembly
operates the left wheel brake and the right rudder pedal operates the right wheel brake.
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Bolt Brake Disc

Snap Ring
Ring-Grease Seal
Felt-Grease Seal
Ring-Grease Seal
Hub
Tire B A
Bearing
Hub
Ring-Grease Seal
Felt-Grease Seal
Inner Tube Bearing

A
Ring-Grease Seal
Snap Ring
Ring-Grease Seal Dust Shield

Felt-Grease Seal Screw
Hub B
Snap
Ring
Bearing Hub
Ring-Grease Seal
Felt-Grease Seal
Tire Snap Ring

Inner Tube Bearing
Figure 1: Main and Nose Wheel Assemblies
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2. Description - Main Wheels
Figure 1 shows the main and nose wheel assemblies. The main wheel hub has two halves. Each half
of the hub is made from light alloy. Three bolts with nuts and washers hold the two halves of the hub
together. The bolts also hold a brake disk to the wheel.
Each half of the hub has a roller bearing assembly. Each bearing has two grease seals and a felt seal.
Snap rings hold each bearing assembly in position.
Each main wheel has a Goodyear 15x6.00-6, 6 PR, TT, 160 mph, FS II tire with a Goodyear 6.00-6 /
15x6.00-6 (G15/6.00-6) inner tube, valve type TR 20. If MÄM 42-659 is installed, each main wheel may
have a Goodyear 15x6.00-6, 6 PR, TT, 160 mph, FC III or FS II tire with a Goodyear 6.00-6 /
15x6.00-6 (G15/6.00-6) inner tube, valve type TR 20.
Two red slip marks - one on the tire and the other on the wheel - are aligned.
3. Description - Nose Wheel
Figure 1 shows the main and nose wheel assemblies. The nose wheel has a split hub. Each half of
the hub is made from light alloy. Three AN-bolts hold the two halves of the hub together. Each hub half
has a sealed bearing.
The nose wheel has a Goodyear 5.00-5, 10 PR, TT, 120 mph, FS II tire with a Goodyear
5.00-5 / 15x6.00-5 / 380x150-5 inner tube, valve type TR 67.
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Max Level 12 mm (0.5 in.)

Min Level 25 mm (1 in.)
Vented Plug
Master Master Fluid Level

Cylinders Cylinders
Brake Fluid
Reservoir
Pilot's Pedals Co-Pilot's Pedals
RELEASE
PARKING BRAKE
Flexible Hose LOCK
Parking Brake Valve
Brake Disk
Pressure
Flexible Hose Plate
Back-
Brake Caliper Plate
Figure 2: Wheel Brake System Schematic Diagram
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4. Description - Brake System
Figure 2 shows the brake system schematic diagram.
The left and right wheel brakes are independent systems. Each system has a reservoir on the
co-pilot’s brake pedals. The reservoirs are directly connected to the brake master cylinders. Two
flexible hoses connect the master cylinders on the co-pilot’s brake pedals to the master cylinders on
the pilot’s brake pedals.
Two more flexible hoses connect the pilot’s left and right master cylinders to the parking brake valve.
Flexible hoses connect the parking brake valve to each main-wheel brake caliper. The parking brake
valve is mounted on the floor of the fuselage, below the seats. A flexible cable connects the parking
brake valve to an operating lever mounted in the cockpit center console.
The brake calipers are standard Cleveland components. Two pistons in each caliper push a friction
lining against the brake disk and a back-plate attached to the caliper pulls the other friction lining
against the outer face of the brake disk. The caliper can move laterally on two anchor pins.
Each main wheel has a brake disc. Bolts attach the brake disk to the wheel. The brake disk turns
between the friction linings in the brake caliper. The caliper is located on an torque plate which is
attached to the landing gear axle.
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Back Plate
Attaching Bolt
Washer
Caliper
Pressure Plate
Anchor
Pins
Back Plates
Bleed Nipple
Brake Torque Plate

Friction Lining
LH installation shown,
RH installation similar
Figure 3: Main Wheel Brake Assembly
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5. Operation - Brake System
If you press on the toe brake of a rudder pedal the fluid in the master cylinder is pushed along the
outlet hose. The fluid at the brake caliper pushes the two pistons. The pistons push the pressure plate
onto the wheel brake disk. The reaction of the pressure plate pushing on the wheel brake disk forces
the brake caliper away from the wheel disk. The caliper moving away from the brake disk pulls the
friction lining of the caliper back-plate against the other side of the disk. The wheel brake disk is held
between the friction linings.
If you release the pressure on the brake pedal the fluid can go back into the master cylinder and the
brake caliper releases the brake disk. The wheel is free to turn.
The right brake pedal of each set of rudder pedals operates the right wheel brake. The left brake pedal
of each set of rudder pedals operate the left wheel brake.
If you push on the left brake pedal and the right brake pedal together, then both wheel brakes operate.
If you set the parking brake to LOCK while you push on both brake pedals the parking brake valve
traps the fluid in the brake units and the wheel brakes stay on. Move the parking brake lever to
RELEASE to release the brakes.
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Trouble-Shooting
1. General
This table gives you the trouble-shooting data for the wheels and brakes.
Too much wheel run-out. Wheel bearing(s) defective. Replace the defective wheel
bearing(s).
Brake disk damaged. Hard landing. Replace damaged brake disk.

Do a hard landing inspection.
Excessive braking. Replace brake disk(s).
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Brake(s) do not operate. No brake fluid. Examine the brake system.

Look specially for leaks.
Repair/replace defective
components. Fill the brake
reservoir(s) with brake fluid.
Air trapped in brake system. Bleed the brake system.
Master cylinder defective. Examine the brake system.

Look specially for leaks. Do a
test for the correct operation of
each master cylinder. Replace
defective master cylinder(s).
Brake caliper defective. Examine the brake caliper.

Look specially for leaks and for
a piston that is seized.
Repair/replace the caliper.
Brake friction linings worn Replace the brake friction

excessively. linings.
Brake hose connector leaking. Tighten/replace leaking

connectors.
Parking brake does not Parking brake valve operating Adjust the parking brake valve
operate correctly. cable out of adjustment. operating cable.
Parking brake valve defective. Replace parking brake valve.
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1. General
This Section tells you how to remove/install the wheels and the main brake system components. It also
tells you how to disassemble/assemble the wheels.
Refer to the component manufacturers manuals for repair of all other components in the workshop.
2. Remove/Install a Main Wheel
A. Equipment
B. Remove a Main Wheel
WARNING: DO NOT LIFT THE AIRPLANE ON JACKS IN THE OPEN IF THE WIND
SPEED IS MORE THAN 10 KM/H (6 KNOTS).

ACCIDENTALLY.
CAUTION: MAKE SURE THAT THE PARKING BRAKE IS SET TO RELEASE

BEFORE YOU RELEASE THE BRAKE CALIPER.
CAUTION: DO NOT STRAIN THE BRAKE HOSE. YOU CAN CAUSE DAMAGE TO
THE BRAKE HOSE AND CAUSE BRAKE FAILURE.
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Back Plate
Attaching Bolt
Washer
Caliper
Pressure Plate
Back Plates
Wheel
Brake Torque Plate
Axle
Castellated Nut
Washer
LH Wheel shown,
RH Wheel similar
Cotter Pin
Screw
Dust Shield
Figure 4: Remove/Install a Main Wheel
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(3) Release the brake caliper: Refer to Figure 4.
S Remove the 4 bolts that attach the back-

plates to the caliper.
Do NOT remove the brake caliper from
S Move the back-plates clear of the wheel
the torque plate.
disk.
(4) Examine the wheel. Make sure that the wheel

turns smoothly.
(5) Remove the wheel from the axle:
S Remove the dust shield.
S Remove the cotter pin from the castle nut.
S Remove the castle nut that holds the wheel

to the axle.
S Pull the wheel off the axle and clear of the

airplane.
(6) Examine the wheel bearings:
S Examine the wheel bearings for Look specially for sand, dust or similar
contamination. contaminants.
S Look for damage to the bearings. Signs of overheating or scoring. Replace

damaged bearings.
S Turn the bearing slowly and listen for noise

that may indicate wear to the bearings.
Make sure that the bearing turns freely and
quietly.
Replace damaged bearings.
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C. Install a Main Wheel
(1) Install the wheel:
S Make sure that the axle is clean.
S Move the wheel into position on the axle.
S Install the castle nut. Tighten the castle nut

with 17 - 23 Nm (12 - 17 lbf.ft.) during
turning the wheel. Thereafter untighten it
completely. Repeat fastening with 5 Nm
(3.7 lbf.ft.). Then tighten the wheel nut until
split pin fits into next drillhole.
S Install the cotter pin.
(2) Make sure that the wheel turns freely and with No perceptible play in the bearings
no noise. allowed.
(3) Move the caliper into position at the wheel. Make sure that the pressure plate is
Make sure that the mounting spigots engage correctly located within the caliper.
with the locating bushes of the torque plate.
(4) Install the back-plates:
S Move the back-plates into position at the

caliper.
S Install the 4 bolts and Washers that attach

the back-plates to the caliper, finger tight.
S Make sure that the wheel brake disk can

rotate freely between the caliper pressure
plate and the back-plates.
S Tighten the bolts that attach the back-plates Torque according to Cleveland/Parker
to the caliper. Maintenance Manual, latest revision or
placard on caliper.
(4) Install dust shield.
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BE DAMAGED.
CAUTION: MAKE SURE THAT THE LANDING GEAR IS LOCKED DOWN

BEFORE YOU LOWER THE AIRPLANE WITH THE JACKS.
(5) Reset the GEAR circuit breaker and make sure

that the landing gear selector is set to DOWN.
(6) If a tire/wheel change is performed check Refer to Section 32-10 - Adjustment of

minimum clearance between MLG tire and the the MLG wheel in retracted position.
lower wing shell / wheel bay cut-out.
(7) Carry out a test of the correct operation of the Refer to Section 32-30.

airplane.
airplane is clear.
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3. Remove/Install the Nose Wheel
A. Equipment
B. Remove the Nose Wheel
(1) Raise the nose of the airplane on an airplane

jack. Move the wing and rear fuselage trestle
into position to steady the airplane.
(2) Examine the wheel. Make sure that the wheel

can turn easily and quietly.
(3) Remove the nose wheel form the airplane: Refer to Figure 5.
S Remove the nut and washer that holds the

axle bolt in the wheel fork.
S Remove the axle bolt and flanged bushes. Support the nose wheel.
S Move the nose wheel clear of the airplane.
S Remove and retain the spacers and tubular

axle from the wheel.
(4) Examine the wheel bearings:
S Examine the wheel bearings for Look specially for sand, dust or similar
contamination. contaminants.
S Look for damage to the bearings. Signs of overheating or scoring. Replace

damaged bearings.
S Turn the bearing slowly and listen for noise Replace damaged bearings.
that may indicate wear of the bearings.
Make sure that the bearing turns freely and
quietly.
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Wheel Assembly
Spacer
Axle
Spacer
Bolt
Washer
Flanged Bush
Wheel Fork Washer
Nut
Flanged Bush
Figure 5: Remove/Install the Nose Wheel
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C. Install the Nose Wheel
(1) Install the wheel:
S Make sure that the tubular axle is clean and

install the axle into the wheel.
S Install the spacer bushes on the tubular

axle.
S Move the wheel into position in the fork.
S Install the flanged bushes.
S Install the axle bolt with washer through the

fork and wheel.
S Install the washer and nut that holds the Torque 16 Nm (11.8 lbf.ft.).
axle bolt into the fork.
(2) Make sure that the wheel turns freely and with No perceptible play in the bearings
no noise. allowed.
(3) Make sure that the nose gear leg is locked

down.
(4) Move the wing trestles and rear fuselage trestles

(5) Lower the nose of the airplane with the jack.
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4. Disassemble/Assemble Main/Nose Wheel
A. Disassemble the Main/Nose Wheel
WARNING: DEFLATE THE TIRE COMPLETELY BEFORE YOU DISASSEMBLE THE

WHEEL. IF YOU DO NOT DEFLATE THE TIRE COMPLETELY BEFORE
YOU DISASSEMBLE THE WHEEL YOU MAY GET INJURED.
(1) Remove the wheel from the airplane. Paragraph 2/3.
(2) Deflate the tire.
(3) Remove the bolts that hold the 2 halves of the Refer to Figure 1.
hub together.
(4) Remove the brake disk from the wheel. Main wheels only.
(5) Remove the hubs from the tire.
(6) Remove the inner tube from the tire.
(7) Remove the bearings from each hub of the

wheel:
S Remove the snap ring.
S Remove the grease seals from the hub. Note the order of the seals.
S Remove the bearing cones. Refer to Cleveland/Parker Maintenance

(8) Examine the wheel hubs, brake disc and the Main wheel only.
bearings for wear/damage.
Refer to Cleveland/Parker Maintenance
(9) Examine the wheel hubs and bearings for Refer to Cleveland/Parker Maintenance
wear/damage. Manual, latest revision.
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B. Assemble Main/Nose Wheel
(1) Install the bearings into each half of the wheel

hub:
S Make sure that the hub is clean.
S Grease and install the bearing cones. Refer to Cleveland/Parker Maintenance

S Install the grease seals. In the order note in Paragraph 4 A (7).
S Install the snap ring.
(2) Move the inner tube into position in the tire. Prior to mounting make sure tire bead is
clean. Apply talcum powder to the
outside of the inner tube.
(3) Assemble the main wheel:
S Move the main wheel hubs into position in

the tire.
S Move the brake disk into position at the

inner hub.
S Install the bolts that attach the brake disk

and the 2 hub halves.
S Install the washers and nuts onto the bolts. Torque according to Cleveland/Parker
Maintenance Manual, latest revision or
placard on rim.
(4) Assemble the nose wheel:
S Move the nose wheel hubs into position in

the nose tire.
S Install the bolts, washers and nuts that hold Torque according to Cleveland/Parker
the hub halves. Maintenance Manual, latest revision or
placard on rim.
(5) Inflate the tire. Refer to Section 12-10.
(6) Paint a red slip mark on the tire and on the hub.
(7) Install the wheel on to the airplane. Refer to Paragraphs 2 and 3.
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5. Remove/Install Brake System Components - General
This Section tells you how to remove and install the major components of the brake system. Refer to
the equipment manufacturer’s manuals for data about repairing the equipment in the workshop.
WARNING: RELEASE PRESSURE FROM THE WHEEL BRAKE SYSTEM BEFORE

YOU DO WORK ON THE SYSTEM. HYDRAULIC FLUID AT HIGH
PRESSURE CAN PENETRATE YOUR SKIN AND CAUSE DISEASE.

CAUSE SKIN DISEASE AND IT CAN DAMAGE CLOTHING.

FLUID CAN CAUSE DAMAGE TO THE AIRPLANE STRUCTURE AND IT
CAN REMOVE PAINT FROM COMPONENTS.
Note: Put caps on all open hydraulic connections to prevent contamination.
Note: Put a container below a connection before you release the connection to catch spilt
hydraulic fluid.
Note: If you open a brake system connection you must bleed the brake system after you
have remade the connection.
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6. Remove/Install a Brake Master Cylinder
A. Equipment
Hydraulic bleeding equipment. 1 Commercial.
Syringe for hydraulic fluid. 1 Commercial.
B. Material
Hydraulic fluid. A/R MIL-PRF-5606H

(for example,
Aeroshell Fluid 41).
C. Remove a Brake Master Cylinder


FLUID CAN CAUSE DAMAGE TO THE AIRPLANE STRUCTURE AND
IT CAN REMOVE PAINT FROM COMPONENTS.
(1) If necessary, remove the brake fluid reservoir: Co-pilot's pedals only.
S Remove the hose from lower hydraulic Use a container to catch spilt fluid.
connection.
S Remove the reservoir from the top hydraulic Put caps on all open connections.
connection.
(2) Disconnect the hoses from the upper and lower Pilot's pedals only. Use a container to
hydraulic connection. catch spilt fluid. Put caps on all open
connections.
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(3) Remove the upper clevis pin:
S Remove the cotter pin from the clevis pin.
S Remove the washer.
S Remove the clevis pin.
(4) Release the master cylinder from the lower

mounting spindle:
S Remove the cotter pin from the mounting

spindle.
S Remove the washer.
S Move the master cylinder clear of the pedal

assembly.
S Remove and retrain the spacer from the

lower mounting spindle.
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Brake Fluid Reservoirs

(Co-Pilots Pedals Only)
Brake Pedals
Upper Cotter Pin
Washer
Top Clevis Pin

Brake Master Cylinder Lower Mounting Spindle
Upper Hydraulic/Reservoir Connection

Spacer
Lower Hydraulic Connection
Washer
Lower Cotter Pin
Figure 6: Brake Master Cylinder Installation
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D. Install a Brake Master Cylinder
(1) Move the master cylinder into position at the

brake pedal assembly.
(2) Install the master cylinder onto the lower

mounting spindle:
S Install the spacer onto the lower mounting

spindle.
S Move the master cylinder into position on the

mounting spindle.
S Install the washer.
(3) Install the upper clevis pin:
S Align the top of the master cylinder with the

mounting on the brake pedal.
S Install the upper clevis pin.
S Install the washer onto the clevis pin.
(4) Install the hose onto the lower hydraulic Make sure that all blanking caps are
connection on the master cylinder. removed.
(5) Install the hose onto the upper hydraulic Pilot's pedals only. Make sure that all
connection on the master cylinder. blanking caps are removed.
(6) Install the hydraulic reservoir onto the upper Co-pilot's pedals only. Make sure that all
hydraulic connection of the master cylinder. blanking caps are removed.
(7) Bleed the brake system. Refer to Paragraph 9.
(8) Do a test for the correct operation of the brake

system.
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Attaching Bolt
Parking Brake Lever
To Right Brake Caliper

Swivel Fitting
Inlet for Right Brake System

To Left Brake Caliper
Cable Adjuster
Parking Brake Valve
Bowden Cable from Inlet for Left Brake System

Parking Brake Control
Lever
Control Bulkhead
Large Washer
Self Locking Nut
Figure 7: Parking Brake Valve Installation
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7. Remove/Install the Parking Brake Valve
A. Remove the Parking Brake Valve
(1) Remove the pilots’ seats. Refer to Section 25-10.


(2) Disconnect the Bowden cable: Refer to Figure 7.
S Loosen the screw in the swivel fitting.
S Pull the inner wire of the Bowden cable out

of the swivel fitting.
(3) Disconnect the 4 brake hoses from the parking Use a suitable container to catch spilt
brake valve. fluid. Install blanking caps on all open
connections.
(4) Remove the 2 nuts, bolts and washers that

attach the parking brake valve to its mounting.
(5) Move the valve clear of the airplane.
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B. Install the Parking Brake Valve
(1) Move the parking brake valve into position by its

mounting.
(2) Install the 2 bolts, washers and nuts that attach Use new self locking nuts.
the parking brake valve to its mounting.
(3) Connect the 4 brake hoses to the parking brake Remove all blanking caps.
valve.
(4) Connect the Bowden control cable to the parking

brake valve:
S Move the inner cable of the Bowden cable

through the swivel fitting.
S Make sure that the parking brake control

lever in the cockpit is set to RELEASE.
S Make sure that the operating lever on the

parking brake valve is set to the fully open
position.
S Tighten the screw of the swivel fitting.
(6) Do a test for the correct operation of the parking

brake system:
S Push and hold both brake pedals on the

pilot's rudder pedal assembly.
S Set the PARKING BRAKE to PARK.
S Both wheel brakes must stay on.
S Set the PARKING BRAKE to RELEASE.
S Both wheel brakes must release.
(7) Install the pilots’ seats. Refer to Section 25-10.
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8. Remove/Install a Brake Caliper
A. Remove a Brake Caliper

WARNING: MAKE SURE THAT THE PARKING BRAKE IS SET TO RELEASE

BEFORE YOU DISCONNECT THE HYDRAULIC HOSE TO THE BRAKE
CALIPER. HYDRAULIC FLUID AT HIGH PRESSURE CAN PENETRATE
YOUR SKIN AND CAUSE DISEASE.

(1) Disconnect the brake hose from the brake Refer to Figure 8. Use a suitable
caliper. container to catch spilt fluid. Put blanking
caps on all open connectors.
CAUTION: DO NOT OPERATE THE BRAKES WHILE THE CALIPER BACK

PLATES ARE REMOVED OR THE CALIPER IS REMOVED FROM THE
AIRPLANE. IF YOU DO OPERATE THE BRAKES, THE PISTONS BE
PUSHED OUT FROM THE CYLINDERS.
(2) Remove the backing plates from the brake

caliper:
S Remove the lock-wire from the 4 bolts that If bolts with drilled heads are used.
attach the back plates to the brake caliper.

the backing plate to the brake caliper.
S Remove the backing plates.
(3) Move the caliper inboard until the mounting Retain the pressure plate with the caliper.
spigots are clear of the torque plate, then move
the caliper clear of the airplane.
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Back Plate
Attaching Bolt
Washer
Brake Hose
Connector
Pressure Plate
Back Plates
Mounting
Spigots
Brake Torque Plate
LH installation shown,
RH installation similar
Figure 8: Brake Caliper Installation
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B. Install the Brake Caliper
(1) Make sure that the friction linings on both the Refer to Cleveland/Parker Maintenance
pressure plate and the back-plate are in good Manual, latest revision.
condition.
(2) Make sure that the mounting spigots on the

caliper are clean.
(3) Make sure that the spigot locating bushes on the

brake torque plate are clean.
(4) Move the caliper into position at the wheel. Make sure that the pressure plate is
Make sure that the mounting spigots engage correctly located within the caliper.
with the locating bushes of the torque plate.
(5) Install the back-plates:
S Move the back-plates into position at the

caliper.

the back-plates to the caliper, finger tight.
S Make sure that the wheel brake disk can

rotate freely between the caliper pressure
plate and the back-plates.
S Tighten the bolts that attach the back-plates Torque according to Cleveland/Parker
to the caliper. Maintenance Manual, latest revision or
placard on caliper.
(6) Connect the hydraulic brake hose to the

connection on the caliper.
(8) Do a test for the correct operation of the brake

system.
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9. Bleed the Wheel Brake System
A. Equipment
Pressure-hydraulic bleeding equipment. 1 Commercial.
Syringe. 1 Commercial.
B. Material
Hydraulic fluid. A/R MIL-PRF-5606H

(for example,
Aeroshell Fluid 41).
C. Bleed the Wheel Brake System
Use a pressure-hydraulic bleeding tool to bleed the wheel brake system.


(1) Remove the cap from the brake fluid reservoir. If On the co-pilot's brake pedals.
necessary remove fluid until the fluid level is at
Use a syringe.
MINIMUM.
(2) Set the parking brake to RELEASE. At the center console.
(3) Connect the brake bleeding tool to the caliper:
S Remove the blanking cap from the left brake

caliper bleed nipple.
S Connect the outlet hose of the hydraulic

bleeding tool to the bleed nipple of the left
brake caliper.
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(4) Bleed the left brake system:
S Open the bleed nipple on the brake caliper a Monitor the level of fluid in the left brake
small amount until fluid flows from the fluid reservoir. If necessary use a syringe
bleeding tool into the airplane brake system. to remove brake fluid.
S Let hydraulic fluid continue to flow into the

airplane brake system until no more air
bubbles can be seen in the airplane
reservoir.
S Close the bleed nipple on the brake caliper.
S Disconnect the outlet hose of the bleeding

tool from the nipple of the brake caliper.
S Install the blanking cap onto the nipple.
(5) Do steps 3 and 4 for the right wheel brake

system.
(6) Make sure that both brake fluid reservoirs are The MAXIMUM line on the reservoir.
filled to the correct level.
(7) Install both the left and right reservoir caps onto Use "vented caps".
the reservoirs.
(8) Do a test for the correct operation of the wheel

brake systems.
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10. Replace the Brake Friction Linings
A. Equipment
Drill bit 1/8". 1 Commercial.
Pin punch. 1 Commercial.
Cleveland brake riveting set. 1 Cleveland 199-1.
B. Material
Cleveland brake friction linings for 4 per brake. Cleveland 066-10500.

Brake Caliper 30-52Z.
Rivets. 8 per brake. Cleveland 105-00200.
C. Replace the Brake Friction Linings.
Note: For detailed instructions refer to Cleveland/Parker Maintenance Manual, latest

revision.
WARNING: DO NOT BREATHE THE DUST FROM BRAKE LININGS. THE DUST CAN
CAUSE DISEASE.
CAUTION: MAKE SURE THAT THE PARKING BRAKE IS SET TO RELEASE

BEFORE YOU RELEASE THE BRAKE CALIPER BACK-PLATE.
Note: For brake component limits refer to Cleveland/Parker Maintenance Manual, latest
revision.
(1) Remove the brake caliper from the wheel Refer to Paragraph 8.
assembly.
(2) Remove the pressure plate from the caliper. Refer to Figure 8.
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(3) Remove the brake friction lining from the

pressure plate:
S Drill out the rivets that attach the friction

lining to the pressure plate.
S Use pin-punch to remove the rivet stems.
(4) Remove the brake friction linings from the back

plates:
S Drill out the rivets that attach the friction

lining to the pressure plate.
S Use pin-punch to remove the rivet stems.
(5) Install the new friction linings onto the pressure Use only approved parts. Use the
plate and the back-plates. Cleveland rivet set to install the new
brake friction linings. Follow the
Cleveland rivet set Instruction Manual.
(6) Install the pressure plate into the caliper.
(7) Install the brake caliper. Refer to Paragraph 8.
(8) Do a test for the correct operation of the airplane

braking system.
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Section 32-50
Steering
1. General
The DA 42 NG has nose-wheel steering. The rudder pedals can turn the nose gear leg. The rudder
pedals connect to the nose gear leg with a steering rod. You can turn the nose wheel up to 9° using
the rudder pedals and up to 42° using a wheel brake.
This Section tells you about the nose-wheel steering system form the interface with the rudder controls
to the nose wheel leg. See Section 27-20 for more data about the rudder control system and see
Section 32-20 for more data about the nose gear leg.
Figure 1 shows the nose wheel steering system.
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Steering Arm Bracket
Linkage Buffer
Yolk Assembly on
Steering Control Bulkhead
Actuator
Lever Steering Linkage
Cardan Spring Assembly

Joint Bracket
Clamp
Tubular Steel Housing

Centering Unit Slider Plate
Roller
Tubular Steel Strut
Figure 1: Nose Wheel Steering
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2. Description
The nose wheel steering system has these major components:
A. Steering Linkage
One end of the steering linkage connects to the steering arm bracket on the rudder yoke assembly.
The rudder yoke assembly is located on the forward control bulkhead. The other end of the steering
linkage attaches to the steering actuator lever which is bolted to the top of the tubular strut of the
nose gear leg.
B. Linkage Buffer
A telescopic arm containing a compression spring makes the linkage buffer. When a force is
applied to one end of the telescopic arm the arm compresses the spring which then exerts a force
onto the other end of the telescopic arm. This allows the pilot to operate the rudder control system
when the nose wheel steering system has reached it’s limit of operation.
C. Centering Unit
A spring assembly which presses a roll against a slider plate makes the centering unit. The spring
assembly with the roller are attached to the tubular steel strut which does not rotate. The slider
plate is attached to the sliding tube guide which rotates about the leg axis when the nose wheel is
deflected.
When the nose wheel is deflected, the slider plate pushes the spring loaded roller up. The spring
creates a counter force which moves the nose wheel back into neutral position.
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3. Operation
When the pilot pushes the left rudder pedal when taxiing the airplane these events occur:
) The rudder cables from the rudder pedal turns the steering arm bracket of the yoke assembly on the
control bulkhead counter-clockwise.
) The steering linkage moves forward and turns the tubular steel strut of the nose gear leg to counter-
clockwise.
) The airplane will turn to the left.
When the pilot pushes the right rudder pedal when taxiing the airplane these events occur:
) The rudder cables from the rudder pedal turns the steering arm bracket of the yoke assembly on the
control bulkhead clockwise.
) The steering linkage moves aft and turns the tubular steel strut of the nose gear leg to clockwise.
) The airplane will turn to the right.
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Trouble-Shooting
1. General
This Section gives you the trouble-shooting data for the nose wheel steering components only. Refer
to Section 32-20 for trouble-shooting data on the nose gear leg and refer to Section 27-20 for trouble-
shooting data on the rudder control system.
Nose wheel steering Linkage buffer defective. Replace the steering linkage.
ineffective, the pilot must give
inputs to the rudder pedals to
steer the airplane.
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Maintenance Procedures
1. General
These Maintenance Procedures tell you how to remove/install the steering linkage and the centering
unit. It also tells you how to check the friction of the nose wheel steering. Refer to these Sections for
the related data:
) Section 32-10. Main landing gear.
) Section 32-20. Nose landing gear.
2. Remove/Install the Steering Linkage
A. Remove the Steering Linkage
(2) Disconnect the steering linkage from the Refer to Figure 1.

steering arm bracket at the yoke assembly:

attaches the steering linkage to the steering
arm bracket.
S Move the end of the steering linkage clear of

the steering arm bracket.
(3) Disconnect the steering linkage from the At the top of the nose gear leg.
steering actuator lever:

attaches the steering linkage to the steering
actuator.
S Move the steering linkage clear of the

steering actuator.
S Pull the steering linkage forward through into Note the orientation of the steering
the nose gear bay and clear of the airplane. linkage.
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B. Install the Steering Linkage
(1) Move the steering linkage into position through Make sure that you install the steering
the nose gear bay and into the fuselage. linkage in the correct orientation as noted
in Paragraph 2A.
(2) Connect the steering linkage to the steering arm

bracket at the yoke assembly:
S Move the end of the steering linkage into

position so that it aligns with the steering
arm bracket.
S Install the bolt, washer and nut that attaches Always use a new self-locking nut.
the steering linkage to the steering arm
bracket.
(3) Connect the steering linkage to the steering

actuator at the top of the nose gear leg:
S Move the end of the steering linkage into

position to align with the steering actuator
lever.
S Install the bolt, washer and nut that attaches Always use a new self-locking nut.
the steering linkage to the steering actuator
lever.
(4) Do a test for the correct operation of the rudder Refer to Section 27-20.
control system.
(5) If necessary for your Airworthiness Authority do

a duplicate inspection of the rudder control
system.
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3. Remove/Install the Centering Unit
Refer to Figure 1.
A. Remove the Centering Unit

ACCIDENTALLY.
(2) Remove the spring assembly:
S Remove the 4 bolts and washers which hold

the clamp to the leg.
S Move the clamp and spring assembly clear

of the leg.
(3) Remove the slider plate:
S Remove the 3 bolts and washers which Remove lock wire first, if bolts with drilled
attach the slider plate to the leg. heads are used.
S Move the slider plate clear of the leg.
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B. Install the Centering Unit
(1) Install the slider plate:
S Release the nose landing gear. Jack the airplane. Refer to Section 07-10.
S Move the slider plate in position on the leg.
S Install the 3 bolts and washers which attach Use Loctite 243 or lock wire if bolts with
the slider plate to the leg. drilled heads are used.
(2) Align the nose wheel to the center position.
(3) Install the spring assembly:
S Move the clamp and spring assembly in

position at the leg.
S Install the 4 bolts and washers which hold Use Loctite 243.
the clamp to the leg. Do not tighten the bolts.
S Align the spring so that the roller just Hold the spring assembly in this position.
contacts the lowest point on the slider plate.
S Turn the nose gear leg in one of its

maximum deflected positions.
S Move the spring assembly towards the slider The centering unit must be slightly pre-
plate so that 2.5 mm (0.1 inch) of bare piston stressed while in center position.
remain visible.
S Tighten the 4 bolts which hold the clamp to

the leg.
S Align the nose wheel to the center position.
(4) Remove the jacks from the airplane. Refer to Section 07-10.
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4. Nose Wheel Steering Friction Test

ACCIDENTALLY.
(1) Release the nose landing gear. Jack the airplane. Refer to Section 07-10.
(2) Check the strut extension of the nose landing Refer to Section 32-20. If necessary
gear damper. charge the damper assembly.
(3) Turn the nose wheel to its fully deflected position The counter force of the centering unit
left hand. must move the nose wheel back into
neutral position.
(4) Turn the nose wheel to its fully deflected position The counter force of the centering unit
right hand. must move the nose wheel back into
neutral position.
(5) Lower the airplane. Remove the jacks from the airplane.
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Section 32-60
Position and Warning
1. General
This Section tells you about the parts of the landing gear system that give the pilot position and
warning data. Refer to these Sections for the related data:
) Section 32-50. Nose wheel steering.
2. Description
The landing gear position and warning system has these functions:
) Landing gear control.
) Landing gear position.
) Landing gear warning.
) To give position data for the extension and retraction system.
The system has these components:
) A cockpit selector handle and indicators. The cockpit selector handle controls the position of the
landing gear. The indicators show the position/condition of the landing gear legs.
) Switches that sense 'weight-on-wheels'.
) Switches that sense 'folding-stay locked'.
) Switches that sense 'landing gear retracted'.
) Switches that sense the position of the engine power levers.
) Control relays and circuit breakers.
Figure 1 shows the landing gear electrical system schematic diagram.
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RELAY
GEAR
WARNING
+ -
GEAR ANNUN 5 2 THROTTLE
ELEV LIMIT TEST 1
SWITCHES
NOSE
5A
NOSE LDG GEAR DOWN
17
16
15
LH
LH LDG GEAR DOWN
47 21
L 48 28
H 49 22
M RH
A RH LDG GEAR DOWN
I 50 25
N 51 26
52 20
B
U
S
RELAY NOSE LDG GEAR UP
UNSAFE 25
24
LH LDG GEAR UP
S4
53 24
GEAR GEAR SELECTOR 54 23

UP RH LDG GEAR UP
5A
55 19
DOWN 56 27
SQUAT SWITCH LH
57 15
6 16
RELAY HYDRAULIC
1
EMERGENCY PUMP
RELEASE SWITCH M
40
NOSE LDG GEAR UP

44 21
45
Figure 1: Landing Gear Electrical Schematic Diagram
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AIRCRAFT
A. Landing Gear Selector
The landing gear selector is in the middle of the instrument panel. The gear selector has a handle
and can be set to UP or DOWN. Next to the gear selector are three green indicators and a red
indicator. There is also a push-to-test type TEST switch. Each landing gear has a related green
indicator. The green indicators will light if all the landing gear legs are down and locked when the
gear selector is set to DOWN. The green indicators will not light if all the landing gear legs are fully
up when the gear selector is set to UP. During the movement of the legs during extension or
retraction the red UNSAFE indicator will light and the green indicators will be off.
The red indicator will stay lit if one, or more, of the landing gear legs has not fully retracted when the
selector has been set to UP. The red indicator will stay lit if one, or more, of the landing gear legs
has not fully locked down when the selector has been set to DOWN. The related leg green indicator
will also not be lit.
Push the TEST switch to make sure that the red and green indicators are serviceable and to test
the landing gear audible warning horn.
B. Weight-on-Wheels Switches
The LH main landing gear leg has a weight-on-wheel switch (squat switch). When the airplane is
on the ground the weight of the airplane causes the trailing arm to move up and compress the
damper. This movement of the trailing arm causes the weight-on-wheels switch to open. With these
switches open the electrical power to the solenoid valves of the hydraulic supply and control system
is isolated. This over-rides the position of the landing gear selector handle and selects the landing
gear to the DOWN position when the airplane is on the ground.
C. Folding-Stay Switches
Each landing gear leg has a folding-stay. When the landing gear leg is fully down the folding-stay
will lock in the unfolded position to hold the leg locked down. When the folding-stay is locked the
related folding-stay switch (LDG GEAR DOWN) is closed and an electrical ground is supplied for
the related green indicator. The green indicator for the related gear leg will be illuminated.
D. Landing Gear Retracted Switches
Each landing gear leg has landing gear retracted switch (LDG GEAR UP) located in the top of the
landing gear bay. When the landing gear has fully retracted the switch will open and isolate the
electrical ground for the red UNSAFE indicator. If all three switches are open the red UNSAFE
indicator will not be illuminated.
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E. Engine Power Lever Switches
Switches sense the position of the left and the right engine power levers. When both engine power
levers are moved towards the IDLE position the engine power lever switches close. If both switches
are closed and the GEAR selector is set to UP the landing gear audible warning horn will operate.
If one or more engine power lever is moved towards TAKE-OFF or the GEAR selector is set to
DOWN the audible warning horn will not operate.
F. Control Relay and Circuit Breakers
The position and warning system has these relays and circuit breakers:
) UNSAFE control relay. The UNSAFE control relay is energized when the GEAR selector is set
to DOWN. When energized the relay gives an electrical ground for the red UNSAFE indicator
through the folding stay switch in the OPEN position (folding-stay not locked). When the GEAR
selector is set to UP the relay is de-energized. The de-energized relay gives an electrical ground
for the red UNSAFE indicator through the landing gear retracted switches in the CLOSED position
(landing gear not retracted).
) The GEAR and GEAR ANNUN. circuit breakers give circuit protection to the UNSAFE control
relay and the position indicating and warning systems.
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Trouble-Shooting
1. General
This table gives you the trouble-shooting data for the position and warnings system. Refer to Section
32-10 for trouble-shooting the main landing gear. Refer to Section 32-20 for trouble-shooting the nose
landing gear. Refer to Section 32-30 for trouble-shooting the extension and retraction system.
The red UNSAFE indicator One of the landing gear Replace the related landing
stays lit when the landing gear retracted switches is defective. gear retracted switch.
is retracted.
The red UNSAFE indicator Control relay defective. Replace the control relay.
stays lit when the landing gear
is down. All green indicators
are lit.
The red UNSAFE indicator The folding-stay switch is not Adjust the folding-stay switch
stays lit when the landing gear adjusted properly. properly.
is down. One of the 3 green
indicators not lit.
The folding-stay switch Replace the related folding-stay
defective for the landing gear switch.
leg for which the green
indicator is not lit.
The green indicator led is Check the light bulb and

unserviceable and the control replace as necessary. Replace
relay is defective. the control relay.
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1. General
This Section tells you how to remove/install the major components of the position and warning system.
It also tells you how to adjust some of the switches. Refer to these Sections for data about other landing
gear systems:
) Section 33-30. Extension and retraction system.
Refer to Chapter 92-00 for the wiring diagrams of the electrical circuits.
Figures 2 thru 4 show the locations of the position and warning switches.
2. Remove/Install an Engine Power Lever Switch
A. Remove an Engine Power Lever Switch
(1) Pull the GEAR and GEAR ANNUN/ELEV LIMIT Instrument panel. Right side.
circuit breakers.
(2) Release the engine control quadrant and lift it Refer to Chapter 76-00.
clear of the center console.
(3) Remove an engine power lever switch:
S Move both the engine power levers to To move the switch operating rod clear of
TAKE-OFF. the switches.
S Disconnect the electrical cables to the switch At the in-line connector.

that you will remove.
S Remove the 2 nuts, washers and bolts that Take care to retain the nuts, washers and
attach the switch that you will remove to the bolts. Hold the switch.
structure.
S Move the switch clear of the engine control

quadrant.
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To In-Line Connector
Microswitch Power Lever, RH

Nut
Washer
Nut Power Lever, LH
Washer
Screw To In-Line
Operating Rod Connector
Washer
Screw Screw
Microswitch
To In-Line Operating Washer
Connector Rod
Screw Nut
Washer
Nut
Screw
Washer
To In-Line Connector
Figure 2: Engine Power Lever Switch Installation
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B. Install an Engine Power Lever Switch
(1) Install the switch:
S Move the switch into position in the engine

control quadrant.

attach the switch to the structure.
S Connect the electrical cables for the switch.
(2) Install the engine control quadrant. Refer to Chapter 76-00.
(3) Reset the GEAR and GEAR ANNUN/ELEV Instrument panel. Right side.
LIMIT circuit breakers.
(4) Do a test of the landing gear position and Refer to Paragraph 5.

warning system.
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To In-Line
Connector
Landing Gear
Retract Switch
Switch To In-Line
Screw
Connector
Folding-Stay Switch
Screw
Plate Screw
Switch
To In-Line
Connector
Roller
Cover Bracket
Screw Weight-on-Wheels
Switch
Switch
Screw
Striker-Plate
Screw
Figure 3: Position and Warning Switches - Main Landing Gear
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3. Replace a Landing Gear Switch (Excluding the Nose Gear Folding Stay Switch)
Use this procedure for the following landing gear switches:
) Main gear folding stay switch.
) Main gear retract switch.
) Main gear weight on wheels switch.
) Nose gear differential switch.
) Nose gear retract switch.
The table will tell you where procedures are different for some switches.
A. Replace a Landing Gear Switch
circuit breakers.
(2) Locate the switch that you will replace. Refer to Figure 3.
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Landing Gear Retract Switch

Nut
Washer
To In-Line
Connector
Washer
Bolt Switch
Nut
Washer
Plate Differential Switch

Screw
Bolt
Washer
Screw
Switch
Nut
Washer
Mounting Bracket Washer

Nut
1st Folding-Stay Switch

Screw
Washer
Striker Plate Screw
Washer
Switch
To In-Line
Connector Screw
Washer
2nd Folding-Stay Switch Mounting Plate
Screw
Washer Washer
Screw To In-Line Connector
Switch
Mounting Plate
Washer
Striker Plate Screw
Figure 4: Position and Warning Switches - Nose Landing Gear
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(3) Replace the switch:
S Remove any cable-ties that may secure the Note the position of the cable-ties.
electrical cables for the switch to the
structure.
S Remove the protective cover for the switch.
S Disconnect the electrical cables for the

switch.
S Remove the 2 screws and washers that

attach the switch.
S Remove the roller bracket.
S Move the old switch clear of the mounting.
S Move the new switch into position in the

mounting.
S Install the roller bracket.
S Install the 2 screws and washers that attach

the switch.
S Adjust landing gear switch.
S Reconnect the electrical cables for the

switch.
S Install the cable-ties that attach the electrical

cables for the switch to the structure.
S Install the protective cover for the switch.

warning system.
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4. Replace a Nose Gear Folding Stay Switch
Use the following procedure for the nose gear folding stay switch.
A. Replace a Nose Gear Folding Stay Switch
circuit breakers.
(2) Locate the switch that you will replace. Refer to Figure 6.
(3) Replace the switch:
S Remove any cable-ties that may secure the Note the position of the cable-ties.
electrical cables for the switch to the
structure.
S Disconnect the electrical cables for the At the in-line connector.

switch.

attach the switch.
S Move the old switch clear of the mounting.
S Move the new switch into position.

the switch.
S Reconnect the electrical cables for the At the in-line connector.

switch.
S Install the cable-ties that attach the electrical At the positions noted.
cables for the switch to the structure.

warning system.
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5. Adjust Landing Gear Indication Micro Switches (Excluding Nose Gear Folding Stay Switch)
A. Equipment
The following landing gear switches can be adjusted with this procedure:
) Main gear folding stay switch (LH and RH).
) Main gear retract switch (LH and RH).
) Main gear weight on wheels switch (LH and RH).
) Nose gear differential switch.
) Nose gear retract switch.
B. Adjust Main/Nose Gear Retract Switches and Differential Switch

ACCIDENTALLY.
the airplane.

airplane.
(4) Remove the main/nose gear doors to get access Refer to Section 32-10 or 32-20.
to the landing gear.
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(5) Reset the GEAR circuit breaker.
(8) Adjusting the micro switches: Refer to Figure 3 and 4 to see where the
micro switches are located.
S Open the two screws which hold the micro
switch in position.
The gap of 1 - 2 mm (0.04 - 0.08 in)
S Adjust the micro switch so that the gap
ensures that the lever is far enough away
between the micro switch lever and the
from the switch point and that it is not
micro switch body is approx. 1 - 2 mm
overstretched which can cause the lever
(0.04 - 0.08 in).
to break.
S Tighten the two screws on the micro switch.
(9) Extend the landing gear. Refer to Section 32-30.
(11) Pull the GEAR circuit breaker.
(12) Install the main/nose gear doors. Refer to Section 32-10 or 32-20.

the airplane.
airplane is clear.
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C. Adjust Landing Gear Folding Stay and Weight on Wheel Switch
(2) This step is only necessary for adjusting the

weight on wheels switch:
S Raise the airplane on jacks and move the Refer to Section 07-10.
wing and rear fuselage trestles into position
to support the airplane.
(3) Adjusting of the micro switches:
S Open the two screws which hold the micro Refer to Figure 3 and 4 to see where the
switch in position. micro switches are located.
S Adjust the micro switch so that the gap For the weight on wheels switch remove
between the micro switch lever and the the protection cover. The gap of 1 - 2 mm
micro switch body is approx. 1 - 2 mm (0.04 - 0.08 in) ensures that the lever is
(0.04 - 0.08 in). far enough away from the switch point
and that it is not overstretched which can
S Tighten the two screws on the micro switch.
cause the lever to break.
(4) Move the wing and rear fuselage trestles clear of Make sure that the area around the
the airplane and lower the airplane with the airplane is clear.
jacks.
D. Cleaning and Maintaining the Micro Switches
Note: In case the landing gear indicators in the cockpit are not working properly it can be
that the micro switches are either not adjusted right or that the micro switches have
to be cleaned. Check the micro switches and their electrical connection for damage.
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6. Test the Landing Gear Position and Warning System
A. Equipment
B. Test the Landing Gear Position and Warning System
THE POSITION AND WARNING TEST. THE LANDING GEAR CAN
BE DAMAGED.
the airplane.
(2) Connect an external power supply to the Refer to Section 24-40

airplane.
(4) Set both engine power levers to 100%. Fully forward.
S Set the landing gear selector lever to UP and

you must have these indications:
S All 3 green (SAFE) leds switch off.
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gear warning horn:
S Move the left engine power lever to IDLE. The landing gear warning horn must
operate.
S Move the right engine power lever to IDLE. The landing gear warning horn must
operate.
S Move the left engine power lever to 100%. The landing gear warning horn must
operate.
(7) Extend the landing gear:
S Set the landing gear selector lever to DOWN

and you must have these indications:
S The landing gear extends.
S When all the landing gear legs are fully

extended and locked:
S All 3 green (SAFE) leds illuminate.
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CHAPTER 33
LIGHTS
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TABLE OF CONTENTS
CHAPTER 33
LIGHTS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 33-10
Lights - Flight Compartment
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Map/Reading Light Assembly (if MÄM 42-1024 is not installed)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Replace a Filament in a Map/Reading Light Assembly (if MÄM 42-1024 is not
installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Remove/Install a Map/Reading Light Assembly (if MÄM 42-1024 is installed) . 202
5. Replace a Filament in a Map/Reading Light Assembly (if MÄM 42-1024 is installed)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
6. Remove/Install a Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
7. Replace the Flood Light/Instrument Light Strip . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8. Remove/Install a Solid State Inverter for the Flood Light/Instrument Lights . . . . 210
Section 33-40
Exterior Lights
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Taxi Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Landing Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Remove/Install an Electronic Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5. Replace a Filament in the Wing Tip Light Unit (OÄM 42-222 is NOT installed)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6. Remove/Install a Wing Tip Light Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
7. Remove/Install a Strobe Power Unit in the Wing Tip (if OÄM 42-222 is NOT
installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
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CHAPTER 33
LIGHTS
1. General
This Chapter tells you about the cockpit and exterior lighting of the DA 42 NG. Section 33-10 tells you
about the flight compartment lighting and Section 33-40 tells you about the exterior lighting.
2. Description
Figure 1 shows the location of the lights.
The DA 42 NG has these flight compartment lights:
) Map/reading lights.
) Placard lights.
Some avionic equipment has internal lighting. Refer to the related Section and the equipment
manufacturers handbook for the equipment in your airplane. A combined ON/OFF and dimmer switch
for the placard lighting is located in the instrument panel, top left.
The DA 42 NG has these exterior lights in one light unit at each wing tip:
) Left and right position lights. The front part of the light has a red (left) or green (right) lens. The
light can only be seen from the front and the side. If OÄM 42-222 is installed, the lenses are
clear and the LEDs provide the coloration.
) Rear position lights. The aft part of each wing tip light unit has a clear lens. The lights can be
seen only from the rear of the airplane.
) Strobe light. The middle part of each wing-tip light unit has a clear lens. The filament gives a
high-intensity flash. The strobe light can be seen from all directions. If OÄM 42-222 is NOT
installed, a separate power unit for each strobe light is mounted in the wing-tip.
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Right Wing Tip

Light Assembly
Map/Reading Lights (3x)
Left Wing Tip

Light Assembly
Landing/Taxi Light Assy
Figure 1: Flight Compartment
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The DA 42 NG has these exterior lights mounted in a unit under the center fuselage:
) Landing light. The landing light has a clear lens and a 35 Watt HID Xenon bulb. It is located in a
recess located under the center fuselage, next to the taxi light.
) Taxi light. The taxi light has a clear lens and a 35 Watt HID Xenon bulb. It is located in a recess
located under the center fuselage, next to the landing light.
The switches for the landing and taxi lights are in the top left of the instrument panel. The landing and
taxi lights each have electronic controllers for the Xenon filaments. The electronic controllers are
located on the center section floor, below the pilots' seats.
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Section 33-10
Lights - Flight Compartment
1. General
This Section tells you about the flight compartment lights of the DA 42 NG airplane. Refer to
Chapter 92 for the wiring diagrams.
2. Description
The DA 42 NG has these flight compartment lights:
) Map/reading lights.
) Instrument panel flood lighting.
) Instrument lights (placard lights).
Some avionic equipment has internal lighting. Refer to the related Section and the equipment
manufacturers handbooks for the equipment installed in your airplane. Combined ON/OFF and dimmer
switches for the placard lights and the flood light are located in the instrument panel, top-left side.
A. Map/Reading Lights.
Map/reading lights are located in the roof of the cockpit. The two lights at the front are directed
towards the pilots' seats and the light at the rear is directed towards the passenger seats. Each light
assembly has an integral switch and a directional beam. The system is protected by a circuit
breaker located in the right side of the instrument panel.
Note: Map/Reading lights become very hot in service.
B. Instrument Panel Flood Lighting
A 115 V AC foil type light strip makes the instrument panel flood light. The intensity of the light is
controlled by a combined ON/OFF dimmer switch located on the top left of the instrument panel.
Turn the dimmer switch fully counterclockwise to turn the flood light off. Turn the dimmer switch
clockwise to turn the flood on and to set the level of lighting that you require. The strip light is held
in place under the instrument panel cover with double-sided pressure sensitive tape. A solid state
inverter supplies the 115 V AC current and the system is protected by a circuit breaker located on
the right side of the instrument panel.
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A A
BC
Reading Light
(Passengers)
Map/Reading Light
(Co-Pilot)
Map/Reading Light
(Pilot)
Dimmer Switch
Instrument Lights
(placard lights)
Dimmer Switch
Flood Lights
Flood Light (Foil Strip)
Figure 1: Flight Compartment Lights
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A A
BC
Locking Plates
Reading Light
(Passengers)
Map/Reading Light
(Co-Pilot)
Locking Plates
Map/Reading Light
(Pilot)
Dimmer Switch
Instrument Lights
(Placard Lights)
Dimmer Switch
Flood Lights
Flood Light (Foil Strip)
Figure 2: Flight Compartment Lights (if MÄM 42-1024 is installed)
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C. Instrument Lights (Placard Lights)
The DA 42 NG has placards that are etched onto panels. There are 8 placard panels on the
DA 42 NG instrument panel. Each placard panel has a dedicated light source. When the light
source is switched on the placards are illuminated. The intensity of the light sources are controlled
by a single ON/OFF dimmer switch located on the top left of the instrument panel. Turn the dimmer
switch fully counter clockwise to turn the placard lights off. Turn the dimmer switch clockwise to turn
the placard lights on and to set the level of lighting that you require.
All placard panels are attached to the instrument panel with screws. You can replace a placard
panel.
Refer to Section 11-30 for more data about the placard panels.
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Trouble-Shooting
1. General
This Section lists some defects you could have with the flight compartment lighting system. If you have
the trouble shown in the Trouble column read across to the Possible Cause column. Then do the repair
One of the map/reading lights Defective filament. Replace the filament.

does not operate.
Defective light unit. Replace the light unit.
The instrument panel flood Circuit breaker not set. Reset the circuit breaker.
light does not operate
Dimmer switch defective. Replace the dimmer switch.
correctly.
Solid state inverter defective. Replace the solid state
inverter.
Light strip defective. Replace the light strip.
Wiring defective.
Do a continuity test of the
diagrams.
The instrument lights (placard Circuit breaker not set. Reset the circuit breaker.
lights) do not operate correctly.
One or more light panels Replace defective light
One or more light panels not
defective. panel(s).
operating correctly.
Dimmer switch defective. Replace the dimmer switch.
Wiring defective. Do a continuity test of the

diagrams.
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1. General
These Maintenance Practices tell you how to remove/install the main components of the flight
compartment lighting system. Refer to Chapter 92 for the wiring diagrams.
2. Remove/Install a Map/Reading Light Assembly (if MÄM 42-1024 is not installed)
A. Remove a Map/Reading Light Assembly
(1) Pull the TAXI/MAP/ACL circuit breaker. Instrument panel, right side.
(2) Remove the light assembly:
S Release the spring clip that holds the light At the switch end of the assembly.
assembly in position.
S Lower the light assembly from the cabin At the in-line connector.
roof and disconnect the electrical cables.
S Move the light assembly clear of the

airplane.
B. Install a Map/Reading Light Assembly
(1) Move the light assembly into position in the Hold the light assembly.
airplane cabin.
(2) Connect the electrical cables to the light At the in-line connector.
assembly.
(3) Move the light assembly into position, lamp end Make sure that the light assembly is
first, then push the switch end up into position correctly installed and that the spring
until the spring clip engages. clip is fully engaged.
(4) Reset the TAXI/MAP/ACL circuit breaker.
(5) Do a test for the correct function of the light

assembly.
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3. Replace a Filament in a Map/Reading Light Assembly (if MÄM 42-1024 is not installed)
(2) Remove the light assembly. Refer to Paragraph 2A.
(3) Remove the filament holder from the back of the

light assembly.
(4) Replace the filament.
(5) Install the filament holder to the rear of the light

assembly.
(6) Install the light assembly. Refer to Paragraph 2B.

assembly.
4. Remove/Install a Map/Reading Light Assembly (if MÄM 42-1024 is installed)
A. Remove a Map/Reading Light Assembly
(2) Remove the light assembly:
S Loosen the three screws which hold the Slightly open the screws to prevent the
light assembly in position. locking plate from falling into the area
behind the map lights.
S Lower the light assembly from the cabin At the in-line connector.
roof and disconnect the electrical cables.
S Move the light assembly clear of the

airplane.
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B. Install a Map/Reading Light Assembly
(1) Open the screws, so that the threads of the Make sure that no locking plate falls
locking plates are just screwed in. down.
% (2) Install the map light seal (self adhesive) on the

% map light frame.
% (3) Move the light assembly into position in the Hold the light assembly.
airplane cabin.
% (4) Connect the electrical cables to the light At the in-line connector.
assembly.
% (5) Install the map light seal for emergency lever on

% the emergency exit lever that the recess in the
% frame is covered.
% (6) Move the light assembly into position. Make sure that the light assembly is
correctly positioned.
CAUTION: THE LOCKING PLATES MUST BE IN CORRECT POSITION
% (7) Tighten the screws to fully engaged.
% (8) Reset the TAXI/MAP/ACL circuit breaker.
% (9) Do a test for the correct function of the light

assembly.
5. Replace a Filament in a Map/Reading Light Assembly (if MÄM 42-1024 is installed)
(2) Remove the light assembly. Refer to Paragraph 4A.
(3) Open the black plastic cover. Loosen three screws (M3x10).
(4) Pull the cable with the socket out of the lamp.
(5) Open the nut and take out the LED lamp.
(6) Install a new LED lamp, tighten the nut and

connect the plug.
(7) Close the light cover.
(8) Install the light assembly. Refer to Paragraph 4B.
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assembly.
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6. Remove/Install a Dimmer Switch
Use this procedure for both the FLOOD light dimmer switch and the INSTRUMENT lights dimmer
switch.
A. Remove a Dimmer Switch
(3) Remove the knob from the dimmer switch that

you will remove:
S Loosen the grub screw that attaches the

knob to the switch spindle.
S Pull the knob off the switch spindle.
(4) Disconnect the electrical cables from the rear of Make a note of the connections.
the dimmer switch.
(5) Remove the placard panel. Refer to Section 11-30.
(6) Remove the nut and washer from the front of Hold the dimmer switch.
the dimmer switch.
(7) Move the dimmer switch forward and clear of

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B. Install a Dimmer Switch
(1) Move the dimmer switch into position in the From the forward side of the panel.
instrument panel. Make sure that the locating peg on the
switch engages with the hole in the
instrument panel.
(2) Install the washer and nut that attaches the Make sure that the dimmer switch is
dimmer switch to the instrument panel. installed with the correct orientation.
(3) Connect the electrical cables to the rear of the Refer to Chapter 92 for the wiring
dimmer switch. diagrams. Use the note that you made
at Paragraph 4A, step 4.
(4) Install the placard panel. Refer to Section 11-30.
(5) Install the knob to the front of the dimmer

switch:
S Align the flat on the switch spindle with the

flat in the bore of the knob.
S Push the knob onto the switch spindle.
S Tighten the grub screw that holds the knob

onto the switch spindle.
(8) Do a test for the correct operation of the dimmer

switch:
S Rotate the dimmer switch clockwise. The system light(s) must come on.
S Rotate the dimmer switch fully clockwise. The intensity of the light(s) must
increase.
S Rotate the dimmer switch fully counter- The light(s) must go off.
clockwise to the OFF position.
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7. Replace the Flood Light/Instrument Light Strip
You cannot remove the flood light/instrument light strip without causing damage to the strip. Only
remove the flood light/instrument light strip if it is defective.
(2) Remove the instrument panel cover and place Refer to Section 25-10.
on a clean work bench.
(3) Remove the light strip from the inside of the

instrument panel cover:
S Peel the light strip away from the panel

cover.
(4) Install the new flood light/instrument light strip to

the inside of the instrument panel cover:
S Make sure that the area where the light strip Use a commercial solvent. Obey the
attaches to the instrument cover is clean. solvent manufacturer’s directions.
S Apply double-sided tape to the back of the Use the tape specified in the DA 42 NG
light strip. Illustrated Parts Catalog or that is
supplied with the flood light strip.
S Position the flood light/instrument light strip

and firmly press into place.
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(7) Do a test for the correct operation of the flood

light/instrument light panel:
S Rotate the FLOOD light/INSTRUMENT light The light strip must come on bright.
dimmer switch fully clockwise.
S Rotate the FLOOD light/INSTRUMENT light The light strip must go dimmer.
dimmer switch a small amount counter-
clockwise.
S Rotate the FLOOD light/INSTRUMENT light The light strip must go off.
dimmer switch fully counter-clockwise.
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Screw
Nut
Washer
Solid State Inverter

(Flood Lights)
Screw
Washer Nut
Nut
Washer Washer
Nut
Solid State Inverter

(Placards / Instruments)
Figure 2: Solid State Inverters for the Instrument and Flood Lights
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8. Remove/Install a Solid State Inverter for the Flood Light/Instrument Lights
Use this procedure for both the flood light inverter and the instrument lights inverter.
A. Remove a Solid State Inverter
(3) Disconnect the electrical cables from the At the in-line connector.
inverter.
(4) For removal of the instrument light inverter, Refer to Section 31-40.
remove the PFD.
(5) Remove the inverter:
S Remove the 2 screws, washers and nuts

that attach the inverter to the instrument
panel floor.
S Move the inverter clear of the instrument

panel.
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B. Install a Solid State Inverter
(1) Install the inverter:
S Move the inverter into position on the

instrument panel floor.
S Install the 2 washers, screws and nuts that

attach the inverter to the instrument panel
floor.
(2) For the instrument light inverter, install the PFD. Refer to Section 31-40.
(3) Connect the electrical cables to the inverter. At the in-line connector.

inverter:
S Rotate the related dimmer switch clockwise. The system light(s) must come on.
S Rotate the related dimmer switch fully The intensity of the light(s) must
clockwise. increase.
S Rotate the dimmer switch fully counter- The light(s) must go off.
clockwise to the OFF position.
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Section 33-40
Exterior Lights
1. General
This Section tells you about the exterior lights of the DA 42 NG. The DA 42 NG has these exterior
lights:
) Position lights.
) Strobe lights.
) Landing light.
) Taxi light.
2. Description
The DA 42 NG has the position lights and the strobe lights in a single light unit in each wing tip. The
taxi and landing lights are located below the fuselage. Figure 1 and 2 show the wing tip light unit and
Figure 3 shows the landing and taxi lights.
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Screw
Strobe Light Power Unit
Screw
P-Clip
Washer
Nut
Rear Position Light
Bracket
In-Line Connector
Captive Nut
Clear Glass
Screw
Strobe Light
Filament
Screw
Front Position Light
0-Ring Seal
Colored Glass
Strobe Light Cover
Retaining Cover Screws
Figure 1: Wing Tip Light Unit and Strobe Power Unit
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Figure 2: Wing Tip-Light Unit (if OÄM 42-222 is installed)
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A. Position Lights (if OÄM 42-222 is NOT installed)
The DA 42 NG has left and right position lights. The front part of each light unit has a red (left) lens
or green (right) lens. The light can only be seen from the front or the side of the airplane.
Each light unit also has an aft light. Each aft light has a clear lens. The light can only be seen from
the rear of the airplane.
A switch on the top left of the instrument panel controls the position lights and a circuit breaker
protects the system.
B. Strobe Light (Anti-Collision Light - ACL), if OÄM 42-222 is NOT installed
The middle part of each wing tip light unit has a clear optic lens for a strobe light. The filament gives
a high intensity flash. This is followed immediately by a less bright flash. The double-flashes occur
about 50 times per minute. The strobe lights can be seen from all round the airplane.
A separate power unit for each strobe light is mounted in the wing tip. A switch on the top left of the
instrument panel controls both the strobe lights and the system is protected by a circuit breaker.
The power unit generates an electrical impulse of approximately 600 Volts. The pulse ionizes the
gas in the strobe light which causes a bright flash. A second less powerful pulse occurs
immediately after the main pulse to give the lower intensity second flash.
C. LED Position and Anti-Collision Light (if OÄM 42-222 is installed)
The DA 42 NG has left and right LED position and anti-collision light assemblies. The position and
anti-collision lights are installed on a base plate covered by a clear lens. The LEDs provide the
coloration. The forward position light is covered with red (left) or green (right) LEDs. The rear
position light is designed with two white LEDs. The anti-collision light is designed with 24 white
LEDs. If one of the LEDs fails, the unit must be replaced.
The position lights and the anti-collision lights are controlled by separate switches and are
protected by individual circuit breakers.
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D. Landing Light
The landing light is located in a housing below the center fuselage, on the right. The landing light
has a clear lens and Xenon filament. The landing light has an electronic controller located on the
wing center section floor, below the pilots’ seats. A switch on the top left of the instrument panel
controls the landing light and a circuit breaker protects the system.
E. Taxi Light
The taxi light is located in a housing below the center fuselage, on the left. The taxi light has a clear
lens and Xenon filament. The taxi light has an electronic controller located on the wing center
section floor, below the pilots’ seats. A switch on the top left of the instrument panel controls the
taxi light and a circuit breaker protects the system.
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Rubber Grommet
Taxi Light Switch

Landing Light Switch
Landing Light
Electronic Controller
Transparent Cover
Landing Light Shown, Taxi Light Similar
Figure 3: Landing and Taxi Light Installation
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Trouble-Shooting
1. General
This Section lists some defects you could have with the exterior lighting system. If you have the trouble
shown in the Trouble column read across to the Possible Cause column. Then do the repair given in
the Repair column.
Both position lights do not Circuit breaker not set or Reset/replace circuit breaker.
operate. defective.
Defective position light switch. Replace the switch.

Defective wiring. Do a continuity test of the
diagrams.
One position light does not Defective filament. Replace the filament.
operate.
diagrams.
Both strobe lights do not Circuit breaker not set or Reset/replace circuit breaker.
operate. defective.
Defective strobe light switch. Replace the switch.

diagrams.
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One strobe light does not Defective power supply unit (if Replace the power supply unit.
operate. OÄM 42-222 is NOT installed).
Defective strobe unit or LED. Replace the strobe unit or the

light assembly.
Defective wiring.
Repair/Replace the wiring.
Refer to Chapter 92 for the
wiring diagrams.
Strobe and position light does Connector at outer wing to Connect the connector.
not operate on one side. center section disconnected.
Landing light or taxi light does Defective light unit. Replace the defective light unit.
not operate.
Defective electronic controller. Replace the defective

electronic controller.
Circuit breaker not set or Reset/replace circuit breaker.

defective.
Defective landing light or taxi Replace the defective switch.

light switch.
Loose connector at the light Connect the connector

unit. correctly.

diagrams.
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1. General
These Maintenance Practices tell you how to remove/install defective filaments and light units. They
also tell you how to remove/install the major components of the exterior lighting system. Refer to
Chapter 92 for the wiring diagrams.
WARNING: DO NOT OPERATE THE STROBE LIGHTS WHEN PERSONS ARE

CLOSE TO THE AIRPLANE. DO NOT LOOK AT THE LIGHT WHEN IT
OPERATES. STROBE LIGHTS CAN CAUSE EYE DAMAGE.
WARNING: AFTER YOU SET THE AIRPLANE POWER OFF YOU MUST WAIT A
MINIMUM OF 5 MINUTES BEFORE YOU DO WORK ON THE STROBE
LIGHTS. THE POWER SUPPLIES TO THE STROBE LIGHTS GENERATE
HIGH VOLTAGES. HIGH VOLTAGES CAN CAUSE INJURY OR DEATH
TO PERSONS.
2. Remove/Install the Taxi Light
A. Remove the Taxi Light
(1) Set the ELECT. MASTER switch to OFF. Instrument panel.
(2) Set the TAXI light switch to OFF. Top left of instrument panel.
(3) Set the TAXI/MAP/ACL circuit breaker open. Pull.
(4) Remove the pilot's seat. Refer to Section 25-10.
(5) Remove the taxi light cover from below the Refer to Figure 3.
center fuselage:

attach the light cover to the housing.
S Move the light cover clear of the housing.
(6) Remove the 2 nuts, washers and bolts that

attach the taxi light unit to the structure.
(7) Hold the taxi light and move out a small way At the in-line connector.
from the housing and disconnect the electrical
cables. Move the taxi light clear of the housing.
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B. Install the Taxi Light
(1) Install the taxi light unit: Refer to Figure 3.
S Move the light unit into position by the

housing.
S Connect the electrical connections to the At the in-line connector.

light unit.
S Move the light unit fully into position in the

housing.
S Install the 2 bolts, washer and nuts that

attach the light unit to the structure.
(2) Install the light cover:
S Move the light cover into position below the

fuselage.

the light cover to the light housing.
(3) Reset the TAXI/MAP/ACL circuit breaker. Instrument panel, right side.
(4) Set the ELECT. MASTER switch to ON. Instrument panel.
(5) Do a test for the correct operation of the taxi

light:
S Set the TAXI light switch to ON.
S The taxi light must come on.
S Set the TAXI light switch to OFF.
S The taxi light must go off.
(7) Install the pilot's seat. Refer to Section 25-10.
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3. Remove/Install the Landing Light
A. Remove the Landing Light
(2) Set LANDING light switch to OFF. Top left of instrument panel.
(3) Set the LDG LT/START circuit breaker open. Pull.
(4) Remove the co-pilot's seat. Refer to Section 25-10.
(5) Remove the landing light cover from below the Refer to Figure 3.
center fuselage:

attach the cover to the light housing.
S Move the light cover clear of the housing.
(6) Remove the 2 nuts, washers and bolts that

attach the landing light unit to the structure.
(7) Hold the landing light and move out a small way At the in-line connector.
from the housing and disconnect the electrical
cables. Move the landing light clear of the
housing.
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B. Install the Landing Light
(1) Install the landing light unit: Refer to Figure 3.
S Move the light unit into position by the

housing.
S Connect the electrical connections to the At the in-line connector.

light unit.
S Move the light unit fully into position in the

housing.

attach the light unit to the structure.
(2) Install the light cover onto the housing:
S Move the light cover into position at the

housing.

the light cover to the light housing.
(3) Reset the LDG LT/START circuit breaker. Instrument panel, right side.
(4) Set the ELECT. MASTER switch to ON. Instrument panel.

light:
S Set the LANDING light switch to ON.
S The landing light must come on.
S Set the LANDING light switch to OFF.
S The landing light must go off.
(7) Install the co-pilot's seat. Refer to Section 25-10.
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4. Remove/Install an Electronic Controller
Use this procedure for both the landing light and taxi light electronic controllers. Refer to Figure 3.
A. Remove an Electronic Controller
(2) Set LANDING/TAXI light switch to OFF. Top left of instrument panel.
(3) Set the LDG LT/START or TAXI/MAP/ACL Pull. Right side of instrument panel.
circuit breaker open as necessary.
(4) Remove the pilot's/co-pilot's seat as required. Refer to Section 25-10.
(5) Remove the electronic controller: Refer to Figure 3.
S Disconnect the electrical cables form the

controller.
S Remove the nuts, washers, bolts and Note the position of the wire bonding
bonding wire lead that attach the controller lead.
to the structure.
S Move the controller clear of the airplane.
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B. Install an Electronic Controller
(1) Install the electronic controller:
S Move the controller into position under the

pilot's/co-pilot's seat.
S Install the 2 bolts, washers, wire bonding

lead and nut that attaches the controller to
the airplane structure.
(2) Connect the electrical cables to the controller. At the in-line connectors.

LANDING/TAXI light:
S Set the LDG LT/START or TAXI/MAP/ACL Push the circuit breaker in. Right side of
circuit breaker as necessary. instrument panel.
S Set the ELECT. MASTER switch to ON. Instrument panel, lower.
S Set the LANDING/TAXI light switch to ON. The related light must come on.
S Set the LANDING/TAXI light switch to OFF. The related light must go off.
(4) Install the pilot's/co-pilot's seat as required. Refer to Section 25-10.
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5. Replace a Filament in the Wing Tip Light Unit (OÄM 42-222 is NOT installed)
A. Replace a Position Light Filament in the Wing Tip
WARNING: AFTER YOU SET THE POWER TO OFF YOU MUST WAIT A MINIMUM
OF 5 MINUTES BEFORE YOU DO WORK ON THE STROBE LIGHTS.
THE POWER SUPPLIES TO THE STROBE LIGHTS GENERATE HIGH
VOLTAGE. HIGH VOLTAGE CAN CAUSE DEATH OR INJURY TO
PERSONS.
(2) Set these circuit breakers open:
S INST LT/NAV LT.
S TAXI/MAP/ACL.
(3) Remove the light unit cover and the lamp Refer to Figure 1.
glasses from the wing tip unit:
S Remove the 2 screws that attach the cover Hold the cover and glasses.
to the unit.
S Remove the cover.
S Remove the glasses and seals.
(4) Replace the defective filament.
(5) Install the lamp glasses and light unit cover:
S Move the glasses into position with the Make sure that the seals are correctly
seals. located.
S Move the light unit cover into position.

the light unit.
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(6) Set these circuit breakers:
S INST LT/NAV LT.
S TAXI/MAP/ACL.
(7) Do a test for the correct operation of the position

light:
S Set the POSITION light switch to ON. The position lights must all come on.
S Set the POSITION light switch to OFF. The position lights must all go off.
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B. Replace a Strobe Light Filament in the Wing Tip
PERSONS.
S INST LT/NAV LT.
S TAXI/MAP/ACL.
(3) Remove the light unit cover and the lamp Refer to Figure 1.
to the unit.
S Remove the cover.
(4) Replace the strobe light filament. Disconnect/connect the electrical cables
at the in-line connector.
seals. located.

the light unit.
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S INST LT/NAV LT.
S TAXI/MAP/ACL.
(7) Do a test for the correct operation of the strobe

light:
S Set the STROBE light switch to ON. The strobe lights must both operate.
S Set the STROBE light switch to OFF. The strobe lights must all go off.
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6. Remove/Install a Wing Tip Light Unit
A. Remove a Wing Tip Light Unit
PERSONS.
S INST LT/NAV LT.
S TAXI/MAP/ACL.
(3) Remove the light unit cover and the lamp Refer to Figures 1 and 2.
to the unit.
S Remove the cover.
(4) Remove the 3 light filaments (if OÄM 42-222 is Make sure that you disconnect the
NOT installed). strobe light filament at the connector.
(5) Remove the wing tip from the wing:
S Remove the screws that attach the wing tip

to the wing.
S Move the wing tip just clear of the wing and

disconnect the electrical connectors.
S Move the wing tip clear of the airplane.
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(6) Remove the light unit from the wing tip:
S Remove the nut, washer, bolt and P-clamp

that attach the bonding strip to the light unit.
S Remove the screws that attach the light unit

to the wing tip.
S Carefully move the light unit out from the

wing tip.
S Disconnect the 2 electrical in-line

connectors from the rear of the light unit.
S Move the light unit clear of the airplane.
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B. Install a Wing Tip Light Unit
(1) Install the light unit: Refer to Figure 1.
S Move the light unit into position at the wing

tip.
S Connect the 2 electrical connectors at the

rear of the light unit.
S Move the light unit into the wing tip.
S Install the screws that attach the light unit to

the wing tip.
S Install the P-clamp, bolt, washer and nut that

attach the bonding strip to the light unit.
(2) Install the filaments to the light unit (if

OÄM 42-222 is NOT installed).
seals. located.

the light unit.
(4) Install the wing tip onto the wing:
S Move the wing tip into position near the

wing.
S Connect the electrical connections to the At the connector.

wing tip.
S Move the wing tip fully into position and

install the screws that attach the wing tip to
the wing.
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S INST LT/NAV LT.
S TAXI/MAP/ACL.

CLOSE TO THE AIRPLANE AND DO NOT LOOK AT THE LIGHT
WHEN THE LIGHT OPERATES. HIGH INTENSITY STROBE LIGHTS
CAN CAUSE EYE DAMAGE.

light:

light:
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7. Remove/Install a Strobe Power Unit in the Wing Tip (if OÄM 42-222 is NOT installed)
A. Remove a Strobe Power Unit from the Wing Tip
PERSONS.
S INST LT/NAV LT.
S TAXI/MAP/ACL.
(3) Remove the wing tip from the wing:
S Remove the screws that attach the wing tip

to the wing.
S Move the wing tip just clear of the wing and

disconnect the electrical connectors.
S Move the wing tip clear of the airplane.
(4) Disconnect the electrical cables from the power At the in-line connector at the power
unit. unit.
(5) Remove the power unit from the wing tip:
S Remove the 4 screws that attach the power

unit to the structure.
S Move the power unit clear of the wing tip.
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B. Install a Strobe Power Unit into a Wing Tip
(1) Install the power unit into the wing tip:
S Move the power unit into position in the

wing tip.
S Install the 4 screws that attach the power

unit to the structure.
(2) Connect the power cables to the power unit. At the in-line connector at the power
unit.
(3) Install the wing tip onto the wing:
S Move the wing tip into position near the

wing.
S Connect the electrical connections to the At the connector.

wing tip.
S Move the wing tip fully into position and

install the screws that attach the wing tip to
the wing.

CLOSE TO THE AIRPLANE AND DO NOT LOOK AT THE LIGHT
WHEN THE LIGHT OPERATES. HIGH INTENSITY STROBE LIGHTS
CAN CAUSE EYE DAMAGE.
S INST LT/NAV LT.
S TAXI/MAP/ACL.
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light:

light:
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CHAPTER 34
NAVIGATION
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AIRCRAFT
TABLE OF CONTENTS
CHAPTER 34
NAVIGATION
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Section 34-10
Flight Environment Data
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install an ASI or Altimeter or Standby Attitude Module (if OÄM 42-270 is
installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Pitot Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Remove/Install an Altimeter Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5. Pitot and Static System Leak Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6. Clean the Pitot System and the Static System . . . . . . . . . . . . . . . . . . . . . . . . . . 212
7. Remove/Install the OAT Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Section 34-20
Attitude and Direction
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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Trouble-Shooting
1. Magnetic Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Attitude Gyro (Artificial Horizon), if OÄM 42-270 is NOT installed . . . . . . . . . . . 102
3. Standby Attitude Module, if OÄM 42-270 is installed . . . . . . . . . . . . . . . . . . . . . 102
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Magnetic Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Test/Adjust the Magnetic Compass (Compass Swing) . . . . . . . . . . . . . . . . . . . . 202
4. Remove/Install the Attitude Gyro (Artificial Horizon), if OÄM 42-270 is NOT
installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5. Remove/Install the Standby Attitude Module, if OÄM 42-270 is installed . . . . . . 205
Section 34-30
Landing and Taxiing Aids
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 34-40
Independent Position Determining
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 34-41
Stormscope System
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Page 2
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1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Stormscope Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Stormscope Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Test of the Stormscope System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Section 34-42
Traffic Advisory System
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practice
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the TAS Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Transponder Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Remove/Install a TAS Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Section 34-43
Garmin GWX 68 or GWX 70 Weather Radar System
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Garmin GWX 68 or GWX 70 Weather Radar System . . . . . 201
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Section 34-50
Dependent Position Determining
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Replace a Dependent Position Determining System Antenna . . . . . . . . . . . . . . 201
3. Used Types of Flexible Coaxial Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4. Sealant Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
5. Post-Installation Check of the ADF System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Section 34-56
Transponder (XPDR)
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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CHAPTER 34
NAVIGATION
1. General
This Chapter tells you about the navigation systems in the airplane. It only tells you about the
installation in the airplane. Refer to the equipment manufacturers’ manuals for more data about the
equipment and refer to the Wiring Diagrams in Chapter 92 for more data about the electrical wiring for
the navigation systems.
Refer to Section 23-10 for more data about the NAV system which is part of the speech
communication system.
The DA 42 NG has these navigation systems. Refer to these Sections for data about the systems:
) Section 34-10. Flight environment data (Pitot/static/OAT/flight instruments).
) Section 34-20. Attitude and direction (compass/artificial horizon).
) Section 34-30. Landing and taxiing aids (localizer).
) Section 34-40. Independent position determining.
) Section 34-50. Dependent position determining (VOR/transponder/altitude encoder/GPS).
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2. Description
A. Flight Environment Data
The DA 42 NG has the usual flight environment data systems. It has a Pitot system. The Pitot
system has a Pitot probe located under the left wing. The Pitot probe has an electric heater. The
heater is controlled by a switch on the left side of the instrument panel, at the bottom. Flexible
plastic hoses connect the Pitot probe to the airplane instruments. The static probe of the Pitot
system is not used in this installation.
The airplane has a static system. The normal static vents are located on the rear fuselage. An
alternate static vent is located in the cockpit, under the instrument panel, on the left side. The pilot
opens the alternate static vent by turning a valve on the vent.
The Pitot system and the static system connect to these flight instruments and systems:
) Altimeter (if OÄM 42-270 is NOT installed).
) Airspeed indicator (if OÄM 42-270 is NOT installed).
) Standby attitude module (if OÄM 42-270 is installed).
) Integrated cockpit system (ICS).
The DA 42 NG also has an electronic outside air temperature (OAT) indicator. The indicator is
integral with the ICS. Refer to Section 31-40 for more data about the ICS. The probe for the OAT
is located below the nose baggage compartment.
B. Attitude and Direction
The DA 42 NG has a magnetic compass mounted in the instrument panel, on the right side, at the
top. The airplane is also equipped with an attitude gyro (artificial horizon) or standby attitude
module (if OÄM 42-270 is installed) mounted at the top of the instrument panel, centrally arranged.
C. Landing and Taxiing Aids
The DA 42 NG has a localizer system which is part of the ICS. Refer to Section 31-40 for more data
about the landing and taxiing aids which are part of the ICS.
D. Independent Position Determining
The DA 42 NG may be equipped with the following independent position determining systems:
) Stormscope system, consisting of stormscope processor and stormscope antenna.
) Traffic advisory system, consisting of a processor, two antennas and a transponder coupler
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E. Dependent Position Determining
The DA 42 NG has these dependent position determining systems that are integral with the ICS:
) VOR/LOC.
) Global positioning system (GPS).
) Transponder.
) DME.
) ADF.
) Marker beacon receiver.
Refer to Section 31-40 for more data about the integrated cockpit system.
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Section 34-10
Flight Environment Data
1. General
This Section tells you about the Pitot system and the OAT sensor. It does not tell you about the OAT
indication. The OAT indication is integral with the ICS. Refer to Section 31-40 for more data about the
ICS.
Refer to Section 22-10 for information on the static pressure supplied to the autopilot system.
2. Description
) Figure 1 shows the Pitot and the static system schematic diagram.
) Figure 2 shows the component locations.
A. Pitot System
The Pitot system supplies Pitot pressure to the air data instruments and the ICS. A Pitot probe
mounted below the left wing senses the Pitot pressure. The static ports on the rear fuselage sense
the static pressure. An alternate static vent is located under the instrument panel, left side. The
alternate static vent is normally closed. The pilot can open the alternate static vent by operating a
valve-lever.
The Pitot probe has a heater element to prevent icing. A switch on the instrument panel controls
the Pitot heater and a circuit breaker protects the system. The Pitot heater status is shown on the
ICS.
Flexible hoses connect the Pitot probe and the alternate static vent to the air data instruments and
the ICS. Pitot hoses are green and the static hoses are blue/purple or red. Push fit plastic
connectors make the connections in the flexible hoses. Plastic T-pieces make junctions in the
hoses.
Both Pitot and static hoses have water traps at the lowest parts of the hose run (under the pilot’s
seat). T-pieces divide the hoses into 2 runs. The top runs go directly to the instruments. The bottom
runs form sumps before joining the top-runs at T-pieces.
If MÄM 42-462 is installed, the static pressure system has an additional water trap below the aft
baggage compartment. T-pieces at the static ports divide the hoses into 2 runs. The top runs go
directly to the instruments via the water trap below the pilot’s seat and the bottom runs from a sump
at the fuselage floor.
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Filter and
Orifice
Static Port
Static Port
Water Trap
Water Traps
To Air Data Instruments & ICS
Not In Use
Static Hose (Blue)
Pitot Hose (Green)
Pitot Probe
Figure 1: Pitot Probe and Static System Hoses
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B. Outside Air Temperature (OAT) Probe
The OAT indicator is integral with the ICS. The OAT sensor is located below the nose baggage
compartment. The ICS supplies the power for the OAT probe. Refer to Section 31-40 for more data
about the ICS.
C. Air Speed Indicator (ASI)
The DA 42 NG has the usual mechanical ASI with an analogue display an airspeed indicator
integral of the standby attitude module (if OÄM 42-270 is installed), as well as the speed indication
displayed on the G1000's PFD.
The mechanical ASI shows the speed of the airplane relative to the ambient airmass. It does not
show ground speed. Dynamic air pressure from the Pitot system acts on the inside of a bellows
assembly and ambient air pressure from the static system acts on the outside of the bellows
assembly. One end of the bellows assembly is fixed and the other end is connected to a gear drive
assembly. The movement of the bellows assembly is translated into rotary movement of indicator
arm(s) on the analogue display of the ASI. The indicator arms shows the airspeed of the airplane
in knots.
The airspeed indicator integral with the ICS or standby attitude module displays airspeed on a
rolling number gauge using a moving tape. Speed ranges, speed references and an airspeed trend
vector are also displayed on the PFD or SAM. Refer to the G1000 system or MD302 SAM
installation manual and the airplane flight manual for particular information on the ICS or SAM
implemented airspeed indicator.
D. Altimeter
The DA 42 NG has the usual mechanical altimeter with an analogue display an altimeter integral
of the standby attitude module (if OÄM 42-270 is installed) as well as the altimeter displayed on the
G1000's PFD.
The mechanical altimeter shows the relative altitude of the airplane above a defined pressure
altitude. The altimeter is a mechanical instrument. Pressure from the airplane static system acts
on a sealed bellows assembly. If the altitude of the airplane increases the static pressure
decreases and the bellows assembly expands. If the altitude of the airplane decreases the static
pressure increases and the bellows assembly contracts.
One end of the bellows assembly is fixed and the other end is connected to a gear drive assembly.
The movement of the bellows assembly is translated into rotary movement of indicator arm(s) on
the analog display of the altimeter. The indicator arms shows the relative altitude of the airplane
in feet. The initial setting of the altimeter can be adjusted by turning a small thumb-wheel located
on the front of the instrument. This allows the instrument to be compensated for regional barometric
variations and to be adjusted to indicate altitude above ground level or sea level.
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The altimeter integral with the ICS or standby attitude module displays barometric altitude values
on a rolling number gauge using a moving tape. Refer to the G1000 system or MD302 SAM
installation manual and the airplane flight manual for particular information on the ICS or SAM
implemented altimeter.
VOR Antenna
COM 1 Antenna
ADF Antenna
GPS Antenna
COM 2 Antenna
Marker Antenna
DME Antenna
Transponder Antenna
Figure 2: Flight Environment Data - Component Locations
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Trouble-Shooting
1. General
The table below lists the trouble you could have with the flight environment data system. If you have
the trouble detailed in the Trouble column read across to the Possible Cause column. Then do the
repair given in the Repair column. For more data about trouble-shooting the Standby Attitude Module
(if OÄM 42-270 is installed) refer to the Installation Manual of the MD302.
Altimeter lags or reads Faulty altimeter. Replace altimeter.

incorrectly. VSI (on ICS) reads
incorrectly.
Blocked or kinked static hose. Clear/straighten the hose.
Water in static system. Drain the static system.
Airspeed indication incorrect Faulty indicator. Replace ASI.

(low).
Blocked or kinked Pitot hose. Clear/straighten the hose.
Water in the system. Drain the Pitot system.
Leak in Pitot hose. Do a Pitot-static leak check.
Pitot heater does not operate. Pitot circuit breaker open. Close the circuit breaker. If the
circuit breaker opens again, do
a test for a short-circuit in the
Pitot heat wiring system.
Pitot circuit breaker defective. Replace the circuit breaker.
Pitot heat wiring open-circuit. Do a continuity test of the Pitot

heat wiring system. Repair or
replace defective wiring. Refer
to Chapter 92 for the Wiring
Diagrams.
Pitot probe defective. Replace the Pitot probe.
OAT indication (on ICS) OAT probe defective. Replace the OAT probe.
incorrect.
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1. General
These Maintenance Practices tell you how to replace the main components of the environmental data
system. It also tells you how to test the Pitot-static system. Refer to the equipment manufacturers’
manuals for more data about the equipment.
2. Remove/Install an ASI or Altimeter or Standby Attitude Module (if OÄM 42-270 is installed)
A. Remove an ASI or Altimeter or SAM

set to OFF.
(2) Remove the instrument panel cover. Refer to Section 25 -10.
(3) Disconnect the Pitot-static hose(s) from the rear

of the indicator.
(4) Disconnect the electrical connector from the

rear of the standby attitude module
(if OÄM 42-270 is installed).
(5) Remove the screws that attach the indicator to Hold the indicator!
(6) Remove the indicator from the instrument panel Fit dust caps to all open connections.
and clear of the airplane.
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B. Install an ASI or Altimeter or SAM
(1) Remove the dust-cover(s) from all open If necessary, install the dust covers from
connections. the new indicator onto the indicator that
you removed.
(2) If necessary, install Pitot-static hose Use the connections from the indicator
connections onto the new indicator. that you removed.
(3) Move the indicator into position at the Hold the indicator!
instrument panel.
(4) Install the screws that attach the indicator to the

instrument panel.
(5) Connect the Pitot-static hose(s) to the rear of

the indicator.
(6) Connect the electrical connector to the rear of

the standby attitude module (if OÄM 42-270 is
installed).
(7) Do a low-range static leak check. Refer to Paragraph 5.
(8) For the ASI only: Refer to Paragraph 5.
S Do a Pitot-static leak check.
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3. Remove/Install the Pitot Probe
A. Remove the Pitot Probe
(1) Make sure that the ELECT. MASTER switch is Instrument panel, left side.
set to OFF.
(2) Open the PITOT circuit breaker. Instrument panel, right side.
(3) Remove the Pitot probe access panel (with the Refer to Section 52-40.
Pitot probe) from the lower surface of the left
wing.
(4) Disconnect the electrical cables from the Pitot At the in-line connector.
probe.
(5) Disconnect the Pitot and static hose Identify the connections and install dust
connections. caps on the hoses.
(6) Disconnect the bonding-wire-assembly. Note the position of the bonding-wire-

assembly connection.
(7) Remove the Pitot probe:
S Remove the nuts and washers that attach Hold the probe!
the probe to the access panel.
S Move the probe clear of the airplane.
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B. Install the Pitot Probe
(1) Move the Pitot probe into position at the wing.
(2) Install the probe onto the access panel:
S Move the probe into position at the access

panel.
S Connect the bonding-wire-assembly. Install the bonding-wire-assembly at the

position noted in Paragraph 3 A, step 6.

attach the probe to the access panel.
(3) Connect the Pitot and static hoses to the probe. At the positions marked at
Paragraph 3 A, step 5.
(4) Connect the electrical cables to the probe. At the in-line connector.
(5) Install the Pitot probe access panel: Refer to Section 52-40.
S Move the panel up into position on the lower

surface of the wing.

the access panel to the wing.
(6) Do a test of the Pitot probe heat system:
S Set the ELECT. MASTER switch to ON. Instrument panel, left side.
S Reset the PITOT circuit breaker. Instrument panel, right side.
S Set the PITOT switch to ON: Instrument panel, left side.
S The Pitot probe must get warm.
S Set the PITOT switch to OFF:
S The Pitot probe must cool down.
(7) Do a Pitot leak test. Refer to Paragraph 5.
(8) Install a cover with a red pennant onto the Pitot

probe.
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Tube, Green Tube, Blue (not in use)

Thermal Switches
Plate
Thermal Cut-out
Bonding Wire Assy
Pitot Tube
Figure 3: Pitot Probe Installation
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4. Remove/Install an Altimeter Orifice
A. Remove an Altimeter Orifice
set to OFF.
(3) Remove the static hose (blue) from the rear of

the altimeter.
(4) Disconnect this part of static hose (blue) from Hold the T-fitting.
the next T-fitting.
(5) Carefully warm up the section around the Use a heat gun.
orifice.
(6) Use an edgeless object to press out the orifice. Use a screwdriver.
B. Install an Altimeter Orifice
(1) Carefully warm up 50 mm (2 in) from one end of Use a heat-gun.

the hose.
(2) Press the orifice in the static hose. Use a screwdriver to press in the orifice.
(3) Connect the hose to the static T-fitting. Hold the T-fitting.
(4) Connect the other end of the hose to the

altimeter.
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5. Pitot and Static System Leak Tests
Always do a Pitot leak-test after you do maintenance on the Pitot system and always do a low-range
static leak-test after you do maintenance on the static system.
CAUTION: OBEY THE FOLLOWING PRECAUTIONS WHEN YOU DO A PITOT OR

STATIC LEAK-TEST. IF YOU DO NOT OBEY THE PRECAUTIONS YOU
CAN DAMAGE THE AIR DATA INSTRUMENTS.
A. Precautions
) The pressure in the Pitot system must always be equal to (or greater than) the pressure in the
static equipment.
) Reversal of the Pitot and static hoses can cause damage to the air data instruments.
) The applied pressure (and the rate of change of pressure) must not be greater than the design
limits of the equipment that you will test.
) After doing the test, you must always return the system to usual operating conditions.
B. Equipment
Pitot-static probe adaptor. 1 PS 49742M-3-4,

or equivalent.
Pitot-static leak tester. 1 Commercial.
Static port adaptor. 2 SKA 100-4.
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C. Low-Range Static Leak Test
Follow the Pitot-static leak tester manufacturer’s instructions for the use of the test-set. Obey the
safety precautions for Pitot-static leak-testing at all times.
CAUTION: THE G1000 CONFIGURATION MODE CONTAINS CERTAIN PAGES

AND SETTINGS THAT ARE CRITICAL TO AIRPLANE OPERATION
AND SAFETY. THESE PAGES ARE PROTECTED AND CAN NOT BE
MODIFIED, UNLESS THE TECHNICIAN IS PROPERLY AUTHORIZED
AND EQUIPPED. HOWEVER, MOST PROTECTED PAGES ARE
VIEWABLE TO ALLOW SYSTEM AWARENESS FOR
TROUBLESHOOTING.
(1) Remove the blanking cap from the Pitot static Use the test set adaptor.
probe and connect the Pitot-static leak tester to
the probe.
(2) Make sure that the alternate static port is fully Under the instrument panel, left side.
closed.
(4) Block the static line. At the filter on top of the fuselage.
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(5) Prepare the G1000 system for the test: Only required for airplanes for which
14 CFR §91.411 and 14 CFR §91.411
S Allow the unit to warm up for 15 minutes
part 43 Appendix E is applicable.
before performing the following tests.
S Start the G1000 system in normal mode.
S Remove power to the PFD.
S Turn the PFD on in configuration mode by

pressing and holding the ENT key on the
PFD while applying power.
S Release the ENT key after ‘INITIALIZING

SYSTEM’ appears on the upper left corner
of the PFD.
S Using the outer FMS knob on the PFD turn

to the GRS page group, use the B ALT field
for all CFR Part 43 Appendix E tests for
G1000 altitude.
S Place the MFD in reversionary mode by

pressing the red ‘DISPLAY BACKUP’ button
% on the GMA 1347/1360 audio panel. Baro
settings can then be read from the MFD for
the CFR Part 43 Appendix E tests.
(6) Apply a partial vacuum to the static port until Note the altitude.
you get a pressure altitude of 1000 ft above the
ambient pressure altitude.
(7) Let the pressure stabilize.
(8) Monitor the system pressure. The system pressure change must not
be more than 100 ft/min.
(9) Compare the test equipment altimeter and the The indication error must be less than
airplane altimeter. shown in Table 1.
(10) Slowly adjust the system pressure to the

ambient pressure.
(11) Return both the MFD and PFD to normal mode. Only required for airplanes for which
14 CFR §91.411 and 14 CFR §91.411
part 43 Appendix E is applicable.
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(12) Disconnect the Pitot-static probe adaptor and

install a blanking cap, with pennant, onto the
airplane Pitot static probe.
(13) Remove the blockage of the static line. At the filter on top of the fuselage.
Table 1: Altimeter Indication Error
Altitude Permissible Error

-1000 ft.* ±20 ft.*
Sea level. ±20 ft.
4,000 ft. ±35 ft.
8,000 ft. ±60 ft.
12,000 ft. ±90 ft.
16,000 ft. ±110 ft.
20,000 ft. ±130 ft.
* Only required for airplanes for which 14 CFR § 91.411 and 14 CFR § 91.411 part 43 Appendix E
is applicable.
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D. Pitot Leak Test
Follow the Pitot static leak tester manufacturer’s instructions for the use of the test set. Obey the
safety precautions for Pitot static leak testing at all times.
(1) Remove the blanking cap from the Pitot-static Use the test-set adaptor.
probe and connect the Pitot-static leak tester to
the probe.
(2) Slowly apply a pressure to the Pitot port that

gives an indication of 150 kts on the ASI.
(3) Let the pressure stabilize.
(4) Monitor the system pressure. The leak rate must not be more than
10 kts/min.
(5) Compare the test equipment ASI and the The indication error must be less than
airplane ASI. shown in Table 2.
(6) Slowly release the system pressure.
(7) Disconnect the Pitot static probe adaptor and

install a blanking cap, with pennant, onto the
airplane Pitot-static probe.
Table 2: ASI Indication Error
Airspeed Permissible Error
160 kts ±4 kts
100 kts ±4 kts
40 kts ±1.7 kts
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6. Clean the Pitot System and the Static System
CAUTION: OBEY THE FOLLOWING PRECAUTIONS WHEN YOU CLEAN THE

PITOT STATIC SYSTEM. IF YOU DO NOT OBEY THE PRECAUTIONS
YOU CAN DAMAGE THE AIR DATA INSTRUMENTS.
A. Precautions
) Never apply pressurized air to the air data instruments. Always apply compressed air to the
hoses from the inboard end to the outboard end.
) Do not apply excessive pressure (above 1 bar/14.5 PSI) to the Pitot and static hoses.
) Do not use compressed air without oil separator.
) Reversal of the Pitot and static hoses can cause damage to the air data instruments.
) After cleaning the system, you must always return the system to usual operating conditions.
B. Equipment
Compressed air equipment with oil separator and 1 Commercial.

pressure regulator.
C. Cleaning Procedure

set to OFF.
(4) Remove the aft baggage compartment.
(5) Disconnect the Pitot static hoses from the rear

of the backup instruments.
(6) Disconnect the Pitot static hoses from the air

data computer (ADC).
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(7) Disconnect the Pitot static hoses from the water Two under the pilot’s seat, one below
traps. the aft baggage compartment.
(8) Blow compressed air through each of the Pitot Maximum pressure: 1 bar (14.5 PSI).
static hoses from the inboard end to the
outboard end.
(9) Check the water traps for dirt. Replace if

necessary.
(10) Reconnect the Pitot static hoses to the water Two under the pilot’s seat, one below
traps. the aft baggage compartment.
(11) Reconnect the Pitot static hoses to the Pitot

probe.
(12) Reconnect the Pitot static hoses to the air data

computer (ADC).
(13) Reconnect the Pitot static hoses to the rear of

the backup instruments.
(14) Do a low-range static leak test. Refer to Paragraph 5.
(15) Do a Pitot static leak test. Refer to Paragraph 5.
(16) Install the pilot’s seat and the aft baggage Refer to Section 25-10.
compartment.
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7. Remove/Install the OAT Probe
A. Remove the OAT Probe
set to OFF.
(2) Open the right nose baggage compartment

door.
(3) If the de-icing system is installed:
Remove the de-icing fluid tank.
(4) Remove the baggage compartment carpeting

and the rear access panel on the compartment
floor.
(5) Disconnect the electrical cables from the OAT At the in-line connector located on the
probe. instrument panel frame in the LH corner
below the nose baggage compartment.
(6) Remove the nut and the sealing washer that Located on the lower surface of the
attach the OAT probe to the airplane surface. fuselage nose, on the RH side of the
nose landing gear bay.
(7) Move the OAT probe clear of the nose baggage Note the position of the bonding wire.
compartment.
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Outside Air Temperature Probe
Washer
Nut
Figure 4: OAT Probe
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B. Install the OAT Probe
(1) Connect the bonding wire to the OAT Probe. Install the bonding wire as noted in
Paragraph 6 A, step 7.
(2) Move the OAT probe into position below the Slide the probe from the inside outwards
nose baggage compartment. though the hole beside the nose landing
gear bay.
(3) Install the sealing washer and the nut that On the lower surface of the fuselage
attach the probe to the airplane surface. nose, on the RH side of the nose
landing gear bay.
(4) Connect the electrical cables from the OAT At the in-line connector located on the
probe. instrument panel frame in the LH corner
below the nose baggage compartment.
(5) If the de-icing system is installed:
Install the de-icing fluid tank.
(6) Close the rear access hole on the nose

baggage compartment floor and install the
compartment carpeting.
(7) Set the ELECT. MASTER switch to ON. Instrument panel, left side.
(8) Do a nominal/actual value comparison with a Read the OAT indication on the ICS.
reliable digital or mercury thermometer to test
the serviceability of the OAT probe.
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Section 34-20
Attitude and Direction
1. General
This Section tells you about the attitude and direction systems installed in the DA 42 NG airplane. The
main attitude and direction systems are integral with the integrated cockpit system (ICS) that is
installed in the DA 42 NG airplane. Refer to Section 31-40 for more data about the ICS.
The DA 42 NG has the usual magnetic compass. The magnetic compass is installed in the instrument
panel at the top, on the right hand side. There is also an artificial horizon or standby attitude module
(OÄM 42-270) installed in the instrument panel at the top, arranged centrally.
A. Magnetic Compass
The magnetic compass shows the heading of the airplane related to magnetic north. Fluid in the
compass bowl gives damping. Each graduation of the compass is 5°.
A compass deviation card is located next to the compass on the instrument panel. You must do a
test for the correct operation of the compass (compass swing):
) After replacing a major component.
) After replacing the compass.
) After a major modification to the airplane.
) After a lightning strike has been reported.
) If the airplane has been parked for more than 90 days.
B. Attitude Gyro (Artificial Horizon), if OÄM 42-270 is NOT installed
The artificial horizon is an electrically powered gyroscopic instrument. It operates when the
RH MAIN BUS is powered and the AH circuit breaker is closed. It can also receive power from the
emergency battery, see Section 24-32. A warning flag drops into view to indicate that the gyro
motor is not receiving sufficient power to operate.
The artificial horizon incorporates a moving display that simulates the earth's horizon and provides
the pilot with a real time visual indication of the airplane pitch and roll attitude relative to the
indicator symbolic airplane. The instrument can function as a primary or standby indicator.
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The attitude gyro incorporates pitch and roll displays that are mechanically linked to a spinning
mass gyroscope. The horizon bar moves behind the symbolic airplane. Precession error is
corrected by the internal erection system or by pulling the PULL TO CAGE knob.
The artificial horizon employs an efficient electrically driven internal vertical gyroscope assembly
incorporating a special air erection mechanism. This mechanism simultaneously erects the pitch
and roll axes of the gyroscope. Movement of the airplane generates a reaction of the display that
simulates the visual reference seen by the pilot when looking outside at the earth's true horizon
line.
C. Standby Attitude Module, if OÄM 42-270 is installed
The left display of the standby attitude module MD302 represents the attitude indicator.
The background of the display consists of the representative white horizon line separating the ‘sky’
(blue) and ‘ground’ (brown).
The roll scale depicted as an arc of graduations representing bank angles of 0 (triangle), 10, 20,
30, 45 (small triangle) and 60. The roll scale can be configured during installation to be fixed to the
sky/horizon or fixed to the top of the display.
The roll pointer is the triangle just below the roll scale and represents the airplane in relation to its
bank angle. It is configured, by definition, to operate conversely to the roll scale behavior. That is,
a rotating scale produces a fixed roll pointer and a fixed roll scale produces a rotating roll pointer.
The pitch scale is depicted as a series of graduations representing pitch angles of every 5°, with
every 10° graduation extended and numbered.
The symbolic airplane will always remain in the center of the display, with the background elements
moving behind it to represent the aircraft’s relative position.
Refer to the manufacturer’s documentation for more information of the standby attitude module.
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Trouble-Shooting
1. Magnetic Compass
The table below lists the defects you could have with the magnetic compass. If you have the trouble
Magnetic compass damping Defective compass housing. Replace the compass.

fluid leaking.
Compass deviation more than Residual magnetism of a metal Do a test for residual
10°. component in the airplane. magnetism using a hand-held
compass. If necessary,
degauss the component.
Defective compass. Replace the compass.
Compass out of calibration. Do a compass swing.
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2. Attitude Gyro (Artificial Horizon), if OÄM 42-270 is NOT installed
The table below lists the defects you could have with the artificial horizon. If you have the trouble
Warning flag in view. AH circuit breaker open or Close or replace the circuit
defective. breaker.
Indication of instrument not Power supply wiring defective. Do a test for the correct voltage
reliable. at the instrument. Repair the
power supply wiring/connector.
Ground connection defective. Do a test for correct ground

connection. Repair the ground
wiring/connector.
Instrument defective. Replace the instrument.
Instrument is sluggish. Mechanism worn or dirty. Replace the instrument.
3. Standby Attitude Module, if OÄM 42-270 is installed
For data about troubleshooting the standby attitude module refer to the Installation Manual of the
MD302.
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1. General
This Section tells you how to remove/install the magnetic compass as well as the attitude gyro (artificial
horizon). It also tells you how to test and adjust the magnetic compass (compass swing).
2. Remove/Install the Magnetic Compass
A. Remove the Magnetic Compass
set to OFF.
(3) Disconnect electrical cables. At the in-line connector.
(4) Remove the 4 screws that attach the compass Hold the compass!
(5) Move the compass forward and clear of the Remove and discard the compass
instrument panel. deviation table.
B. Install the Magnetic Compass
set to OFF.
(2) Move the magnetic compass into position at the Hold the compass in position.
instrument panel.
(3) Install the 4 screws that attach the compass to

(4) Connect electrical cables. At the in-line connector.
(6) Do a compass swing. Refer to Paragraph 3.
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3. Test/Adjust the Magnetic Compass (Compass Swing)
You must do a test for correct operation of the compass (compass swing):
) After replacing a major component.
) After replacing the compass.
) After a major modification to the airplane.
) After a lightning strike has been reported.
) If the airplane has been parked for more than 90 days.
CAUTION: USE ONLY NON-MAGNETIC TOOLS TO ADJUST THE COMPASS.
CAUTION: DO NOT WEAR OR CARRY METALLIC OBJECTS (WATCHES,

BRACELETS ETC) WHEN YOU ADJUST THE COMPASS
COMPENSATING MAGNETS OR OPERATE THE LAND COMPASS.
METALLIC OBJECTS NEAR THE COMPASS CAN CAUSE ERRORS.
Note: If possible, use a compass swing area that has been tested for magnetic
interference. In any case, you must use a level area that is away from metal
structures, underground pipes, reinforced concrete, other airplane and
ground servicing equipment.
A. Equipment
Calibrated land compass. 1 Commercial.
B. Compass Swing
(1) Adjust the compensating magnets in the Refer to the compass manufacturer's
compass to a neutral position. instructions.
(2) Start the engine and set all electrical loads to Refer to the Airplane Flight Manual.
ON.
(3) Use the land compass to align the airplane to Adjust the N-S compensator magnet so
magnetic north. that the airplane compass indicates a
heading of 0°.
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(4) Use the land compass to align the airplane to Adjust the E-W compensator magnet so
magnetic east. that the airplane compass indicates a
heading of 90°.
(5) Use the land compass to align the airplane to Adjust the N-S compensator magnet to
magnetic south. remove half of the error between the
indicated heading and 180°.
(6) Use the land compass to align the airplane to Adjust the E-W compensator magnet to
magnetic west. remove half of the error between the
indicated heading and 270°.
(7) Turn the airplane through 360°, record the If large deviations occur when you
deviation at each 30° radial. Prepare a deviation operate electrical equipment/systems,
table that shows the corrections that must be the deviation table must also show the
applied to each of the 30° radials. corrections to apply to each 30° radial
when that particular equipment/system
is operating.
(8) Install the new deviation table in the compass

card holder next to the compass.
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4. Remove/Install the Attitude Gyro (Artificial Horizon), if OÄM 42-270 is NOT installed
CAUTION: GYROS ARE DELICATE AND CAN NOT WITHSTAND THE SHOCK OF
BEING DROPPED, JARRED OR STRUCK BY PIECES OF EQUIPMENT.
DO NOT PLACE GYROS ON ANY HARD SURFACE. PAD WITH
GENEROUS FOAM.
A. Precautions
To prevent damage to a gyro, the instrument should be transported to and from the airplane in its
original shipping container. If this is impractical, the gyro should be hand carried carefully in an
upright position.
A gyro should never be removed while it is spinning or running down. The instrument normally
operates at high RPM and may take 10 minutes or longer to run down. If it is removed while running
and tilted more than 20 degrees, the gyro can develop a gimbal lock. The gimbal will tumble and
start to spin. If gimbal lock occurs while the rotor is turning, the gimbal may spin fast enough to
damage the gimbal bearings, requiring overhaul.
A malfunctioning gyro should be handled with the same care given a new instrument. Most
malfunctioning instruments can be repaired and returned to service. Using proper handling
procedures during removal prevents additional damage and helps ensure possible reuse.
B. Remove the Attitude Gyro
(1) Pull the AH circuit breaker. Instrument panel, right side.
(3) Disconnect the connector at the rear of the

instrument.
(4) Remove the screws which attach the instrument Hold the instrument!
(5) Remove the instrument from the instrument Handle with care.
panel.
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C. Install the Attitude Gyro
(1) Insert the indicator into the instrument panel Upper instrument panel, arranged
cutout. centrally.
(2) Install the screws which attach the instrument to

(3) Connect the connector at the rear of the

instrument.
(5) Set the AH circuit breaker. Instrument panel, right hand side.
5. Remove/Install the Standby Attitude Module, if OÄM 42-270 is installed
Refer to Section 34-10, Maintenance Practices.
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Section 34-30
Landing and Taxiing Aids
1. General
This Section tells you about the landing and taxiing aids that can be installed in the DA 42 NG.
Refer to the equipment manufacturers' manuals for more data about other options of landing and
taxiing aids.
2. Description
The DA 42 NG has the following landing and taxiing aids:
) Localizer system, which is part of the G1000 integrated avionics system. Refer to Section 31-40
for more data about the G1000 integrated avionics system.
) Glideslope system, which is part of the G1000 integrated avionics system. Refer to Section 31-40
for more data about the G1000 integrated avionics system.
) Marker beacon receiver, which is part of the G1000 integrated avionics system. Refer to
Section 31-40 for more data about the G1000 integrated avionics system.
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Section 34-40
Independent Position Determining
1. General
This Section tells you about the independent position determining systems that can be installed in the
DA 42 NG. Refer to these Sections for data about the systems:
Section 34-41. Stormscope system (OÄM 42-057).
Section 34-42. Traffic advisory system (TAS) (OÄM 42-094).
Section 34-43. Enhanced vision system (EVS) (OÄM 42-214).
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Section 34-41
Stormscope System
1. General
This Section tells you about the stormscope system that can be installed in the DA 42 NG. Refer to
the manufacturer’´s manual for more data about the equipment.
The stormscope system consists of the following items:
) Stormscope processor.
) Stormscope antenna.
The WX-500 is a passive sensor that listens for electromagnetic signals with a receiving antenna. The
antenna detects intra-cloud, inter-cloud, or cloud-to-ground electrical discharges within a 200 nm
radius of the airplane and sends the resulting 'discharge signals' to the processor. The processor
digitizes, analyzes, and converts the discharge signals into range and bearing data. This information
is stored in the storm buffer.
A. Stormscope Processor
The stormscope processor is tray mounted and is located under the passengers’ seat.
The AVIONICS BUS power to the stormscope system. The ELECT. MASTER switch and the
AV. MASTER switch must be set to ON to supply power through the WX-500 circuit breaker to the
stormscope system.
The processor houses the lightning data acquisition circuitry as well as the circuitry necessary to
process heading information and communicate with the G1000 system. All WX-500 functions are
controlled through the MFD of the G1000 system.
B. Stormscope Antenna
The NY-163 stormscope antenna is located on the horizontal stabilizer. The antenna is a combined
cross-loop and sense antenna. The antenna is sealed against environmental extremes and is non-
repairable.
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Trouble-Shooting
1. General
The table below lists the defects you could have with the stormscope system. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair given in the
Repair column.
Stormscope does not operate. Circuit breaker not set. Set the circuit breaker.

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1. General
This Section tells you how to remove/install the components of the stormscope system. It also tells you
how to test the stormscope system.
2. Remove/Install the Stormscope Processor
A. Remove the Stormscope Processor
(1) Remove the passengers seat. Refer to Section 25-10.
(2) Open the WX-500 circuit breaker.
(3) Loosen the screw that attaches the processor to

its mounting tray.
(4) Remove the stormscope processor from the

mounting tray.
B. Install the Stormscope Processor
(1) Put the stormscope processor in position in the

mounting tray.
(2) Tighten the screw that attaches the processor to

its mounting tray.
(3) Install the passengers seat. Refer to Section 25-10.
(4) Close the WX-500 circuit breaker.
(5) Do a test of the stormscope system. Refer to Paragraph 4.
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3. Remove/Install the Stormscope Antenna
A. Remove the Stormscope Antenna
(1) Remove the horizontal stabilizer fairing. Refer to Section 55-10.
(2) Open the WX-500 circuit breaker.
(3) Remove the screws which attach the stormscope Hold the antenna!
antenna to the mounting bracket.
(4) Disconnect the connector of the stormscope

antenna.
(5) Remove the stormscope antenna from the

B. Install the Stormscope Antenna
(1) Put the stormscope antenna in position on the The arrow must point into flight
horizontal stabilizer. direction.
(2) Connect the connector of the stormscope

antenna.
(3) Install the screws which attach the stormscope

antenna to the mounting bracket.
(4) Close the WX-500 circuit breaker.
(5) Install the horizontal stabilizer fairing. Refer to Section 55-10.
(6) Do a test of the stormscope system. Refer to Paragraph 4.
4. Test of the Stormscope System
Perform the installation checkout as outlined in Goodrich Stormscope WX-500 Installation Manual
P/N 009-11500-001 Chapter 3 'Installation Checkout'.
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Section 34-42
Traffic Advisory System
1. General
This Section tells you about the traffic advisory system that can be installed in the DA 42 NG. Refer
to the manufacturer’s manual for more data about the equipment.
The TAS consists of the following items:
) Processor.
) Transponder coupler.
) Top antenna.
) Bottom antenna.
The Ryan/Avidyne traffic advisory systems (collectively know as TASs) are actively interrogating
on-board air traffic detection systems used to identify potential collision threats. The TAS computes
relative altitude and range of threats from nearby transponder-equipped airplanes. Airplanes with
non-Mode C transponders can provide range information. The TAS does not detect airplanes without
an operating transponder.
A. Processor
The TAS processor is tray mounted and is located behind the first ring frame.
The AVIONICS BUS supplies power to the traffic advisory system. The ELECT. MASTER switch
and the AV. MASTER switch must be set to ON to supply power through the TAS circuit breaker
to the traffic advisory system.
The TAS processor communicates to the Garmin G1000 system which indicates nearby traffic on
the MFD. All functions of the TAS are controlled through the MFD.
B. Transponder Coupler
The transponder coupler is mounted on the remote avionic box of the Garmin G1000 system. The
transponder coupler supplies the processor with a signal indicating the on-board transponder is
transmitting a reply.
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C. Antennas
The TAS has two directional antennas. The top antenna is located on top of the fuselage behind
the cabin between the COM and the ELT antennas, and the bottom antenna is located on the
fuselage bottom between the taxi - and landing lights.
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Trouble-Shooting
1. General
The table below lists the defects you could have with the traffic advisory system. If you have the trouble
TAS does not operate. Circuit breaker not set. Set the circuit breaker.

The TAS bearing shows The antenna co-axes for the Check antenna connections.
opposite to the traffic forward top antenna are backwards.
and aft, and it shows correctly
left and right.
The TAS bearing shows The antenna co-axes for the Check antenna connections.
opposite to the traffic left and bottom antenna are
right, and it shows correctly backwards.
forward and aft.
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Maintenance Practice
1. General
This Section tells you how to remove/install the components of the traffic advisory system.
2. Remove/Install the TAS Processor
A. Remove the TAS Processor
set to OFF.
(3) Open the TAS circuit breaker. Instrument panel, right side.
(4) Disconnect the connectors and antenna cables

from the TAS processor.
(5) Loosen the diagonal retaining screws that

attaches the processor to its mounting tray.
(6) Slide the TAS processor out of its mounting tray Along the rails.
and clear of the airplane.
B. Install the TAS Processor
(1) Slide the TAS processor into its mounting tray. Along the rails.
(2) Tighten the diagonal retaining screws that

attached the processor to its mounting tray.
CAUTION: WRONG CONNECTION OF THE ANTENNA CABLES WILL LEAD TO

A WRONG INDICATION.
(3) Connect the connectors and antenna cables to

the TAS processor.
(4) Close the TAS circuit breaker.
(5) Install the aft baggage compartment.
(6) Do a test of the traffic advisory system. Refer to the TAS Installation Manual,
latest revision.
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3. Remove/Install the Transponder Coupler
A. Remove the Transponder Coupler
set to OFF.
(4) Disconnect the antenna cables from the

transponder coupler.
(5) Remove the screws that attach the transponder Hold the transponder coupler!
coupler to the remote avionics box.
(6) Remove the transponder coupler from the remote Fit dust caps to all connections.
avionics box and clear of the airplane.
B. Install the Transponder Coupler
(1) Remove the dust-cover(s) from all connections. If necessary, install the dust covers
from the new transponder coupler onto
the transponder coupler that you
removed.
(2) Move the transponder coupler into position on the Hold the transponder coupler!
remote avionics box.
(3) Install the screws that attach the transponder

coupler to the remote avionics box.
(4) Connect the antenna cables to the transponder

coupler.
(5) Close the TAS circuit breaker.
latest revision.
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4. Remove/Install a TAS Antenna
A. Remove a TAS Antenna
set to OFF.
(3) Remove the aft baggage compartment if you will Refer to Section 25-50.
replace the top mounted antenna.
Remove both pilots’ seats if you will replace the Refer to Section 25-10.
bottom mounted antenna.
(4) Disconnect the coaxial cable from the antenna At the antenna.
that you will replace.
S Remove the 4 screws that attach the antenna Hold the antenna.
to the structure.
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B. Install a TAS Antenna
(1) Make sure that the contact surfaces of the

antenna and the ground plane where the
antenna will be installed are clean and free of
grease.
(2) Move the antenna into position.
(3) Install the 4 screws that attach the antenna to

the airplane.
(4) Seal the outer edge of the antenna where it Refer to 34-50, Paragraph 4 for an
contacts the airplane surface with sealant. approved sealant.
(5) Remove the excess sealant that has been

forced out of the joint between the antenna and
the airplanes surface.
CAUTION: WRONG CONNECTION OF THE ANTENNA CABLES WILL LEAD TO

A WRONG INDICATION.
(7) Install the aft baggage compartment or seat if Refer to Section 25-10 or 25-50.
necessary.
(8) Reset the TAS circuit breaker. Instrument panel, right side.
latest revision.
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Section 34-43
Garmin GWX 68 or GWX 70 Weather Radar System
1. General
This Section tells you about the weather radar system that can be installed in the DA 42 NG. Refer to
the manufacturer’s manual for more data about the equipment.
(1) Radar Nose Cone
The radar nose cone is made of GFRP and protects the GWX 68 or GWX 70 weather radar
system mechanically and is transparent for the transmitted microwaves. For lightning protection
4 strips are mounted to the surface and connected to the airplanes lightning protection system
with a lightning plate.
(2) Garmin GWX 68 or GWX 70 Weather Radar System
The Garmin GWX 68 or GWX 70 weather radar system provides information about precipitation
conditions ahead of the airplane. The system consists of a combined microwave transmitter and
receiver system in the nose cone, mounted to the radar bulkhead via the GWX 68 or GWX 70
bracket. The system is connected to the electrical system of the airplane via a circuit breaker
on the instrument panel. The processed data of the GWX 68 or GWX 70 system is displayed
on the Garmin G1000 MFD. Refer to the Garmin G1000 Pilot’s Guide for more information about
operation of the system.
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Lightning
Protection
Bracket
Screws 16 pieces GWX 68 /

Dimpled Washers 16 pieces GWX 70 Unit
Strips 4 pieces
GWX 68 / Radar Bulkhead
GWX 70 Bracket
Radar Bulkhead Cover
GWX 68 /
GWX 70
Attachment
Screws
Radar Nose Cone
Figure 1: Installation of the Garmin GWX 68 or GWX 70 Weather Radar System
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Trouble Shooting
1. General
The table below lists the trouble you could have with the Garmin GWX 68 or GWX 70 weather radar
system. If you have the trouble detailed in the trouble column read across to the possible cause
column. Then do the repair given in the repair column.
Weather radar does not Circuit breaker not set. Set the circuit breaker.
operate. Faulty cables / connectors. Do a test for continuity test of
the weather radar system.
Repair or replace defective
Weather radar shows poor Radome damaged / scratched. Replace radome.

image quality.
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1. General
These Maintenance Practices tell you how to replace the Garmin GWX 68 or GWX 70 weather radar
system. Refer to the equipment manufacturers’ manuals for more data about the equipment.
2. Remove/Install the Garmin GWX 68 or GWX 70 Weather Radar System
A. Remove the Garmin GWX 68 or GWX 70 Weather Radar System
Note: Special care must betaken to avoid any contact between tools that could become
magnetized and the magnetron. Use of non-magnetic tools (e.g. beryllium copper
or titanium) is recommended when installing or servicing the GWX 68 system.

set to OFF.
Note: The inner and outer surface of the radar nose cone (radome) effects the
function and image quality of the weather radar system significantly. Make sure
to avoid any scratches and contamination of the inner and outer surfaces of the
radome and do not touch the antenna face of the GWX 68 or GWX 70 unit.
(2) Remove the radar nose cone:
S Protect the surface of the fuselage and the

radar nose cone with a protective cover.
S Cut the sealant between the fuselage and Use a plastic spattle.
the radar nose cone.
S Clean the sealed gap between fuselage and

the radar nose cone.
S Remove the 16 screws which attach the Hold and support the radar nose cone.
radar nose cone to the fuselage.
S Move the radar nose cone straight forward.
(3) Disconnect the electrical connector.
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(4) Remove the GWX 68 or GWX 70 unit:
S Remove the 4 screws which attach the Hold and support the GWX 68 or
GWX 68 or GWX 70 unit to the GWX 68 or GWX 70 unit on the mounting plate. Do
GWX 70 bracket on the radar bulkhead. not touch the delicate radar antenna.
S Move the GWX 68 or GWX 70 unit free of

the airplane.
B. Install the Garmin GWX 68 Weather Radar System
Note: The inner and outer surface of the radar nose cone (radome) effects the
function and image quality of the weather radar system significantly. Make sure
to avoid any scratches and contamination of the inner and outer surfaces of the
radome and do not touch the antenna face of the GWX 68 unit.
(1) Install the GWX 68 or GWX 70 unit:
S Move the GWX 68 or GWX 70 unit in place Hold and support the GWX 68 or
in front of the GWX 68 bracket. GWX 70 unit on the mounting plate.
S Install the 4 screws which attach the Do not touch the delicate radar antenna.
GWX 68 or GWX 70 unit to the GWX 68 or
GWX 70 bracket on the radar bulkhead.
(2) Connect the electrical connector.
(3) Install the radar nose cone:
S Move the radar nose cone towards the Do not touch the delicate radar antenna.
fuselage.
S Install the 16 screws which attach the radar

nose cone to the fuselage.
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(4) Seal the joint between fuselage and the radar

nose cone:
S Apply thin red adhesive tape and the Refer to Figure 2.

masking tape on both sides of the joint.
S Fill the joint with sealant.
S Use plastic or rubber spattle to remove Use Terostat MS 9380 white sealant.
excess sealant. Maximum time for sealing process:
10 min.
S Spray the joint with water / cleaning solvent Use gloves to protect the skin.
solution and create smooth surface by hand.
S Remove all adhesive and masking tapes.
S Allow the sealant to cure for at least 12 hrs.
Note: Before energizing the equipment make sure microwave radiation safety
precautions including both fuel and personnel safety considerations are
observed. These include clearing all personnel to an area beyond the maximum
permissible exposure level (MPEL) boundary. The MPEL for the GWX 68 or
GWX 70 is 3 m (10 ft).
(5) Switch the ELECT. MASTER switch and the

AV. MASTER switch to ON and test the weather
radar system.
Refer to the manufacturer’s manual for more

information.
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Figure 2: Radar Nose Cone Sealed Joint
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Section 34-50
Dependent Position Determining
1. General
The DA 42 NG has an integrated cockpit system (ICS). The ICS has all the usual dependent position
determining systems. Refer to Section 31-40 for more data about the dependent position determining
systems that are integral with the ICS.
This Section tells you how to replace the antennas for the dependent position determining systems.
2. Description
The DA 42 NG has these dependent position determining systems and antennas:
) Transponder.
) DME.
) GPS (2x).
) ADF.
) Marker.
) VOR/G/S.
Flexible coaxial cables connect the antennas to their related equipment. You can replace the coaxial
cables. The antennas are all attached to the surface of the airplane and can be replaced.
Refer to Section 31-40 for more data about the dependent position determining systems and their
related displays.
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Figure 1: Antenna Locations
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Trouble Shooting
1. General
The table below lists the defects you could have with the dependent position determining system
antennas. Refer to Section 31-40 for trouble-shooting data for the dependent position determining
systems.
If you have the trouble listed in the Trouble column read across to the Possible Cause column. Then
ATC reports no transponder Low output power. Examine and repair/replace

reply. Transponder reply defective antenna connections.
symbol operates.
Replace antenna.
ATC reports no transponder Poor received signal. Examine and repair/replace

reply. Transponder reply defective antenna connections.
symbol not operating.
Replace antenna.
DME/GPS/ADF/MARKER/ Poor received signal. Examine and repair/replace

VOR/G/S systems give poor related defective antenna
performance. connections.
Replace related antenna.
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1. General
The Maintenance Practices in this Section tell you how to replace the antennas of the dependent
position determining systems. Refer to Section 31-40 for more data about the dependent position
determining systems. Refer to Paragraph 3 for more information on the used types of coaxial cables.
Further particulars on the antenna sealant are given in Paragraph 4.
2. Replace a Dependent Position Determining System Antenna
A. Replace the Transponder or DME Antenna
set to OFF.
(2) Open the XPDR/DME circuit breaker. Instrument panel, right side.
(3) Remove the pilot’s seat if you will replace the Refer to Section 25-10.
transponder antenna.
Remove only the co-pilot’s seat if you will

replace the DME antenna.
S Remove the 2 nuts and washers that attach Hold the antenna.
the antenna to the structure.
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S Make sure that the contact surfaces of the

antenna and the airplane surface where the
antenna will be installed are clean and free
of grease.
S Move the antenna into position under the

fuselage.
S Seal the outer edge of the antenna where it Use sealant. Refer to Paragraph 4.
contacts the airplane surface with sealant.

the antenna to the airplane structure.
S Remove the excess sealant that has been

forced out of the joint between the antenna
and the airplane surface.
(8) Install the seat(s) that you removed at step 3. Refer to Section 25-10.
(9) Reset the XPDR/DME circuit breaker. Instrument panel, right side.
(10) Do a test of the transponder. Only if you replaced the transponder

antenna.
(11) Do an operational test of the DME on the next Only if you replaced the DME antenna.
flight.
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A B
A
Nut
Connector
Washer
Nut
Connector
Washer
DME Antenna
Transponder
Antenna
Figure 2: Transponder and DME Antenna Installation
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Screw
Screw
GPS Antenna
Connector
Ground Plate
Washer
Nut
Washer
Nut
Figure 3: Replace a GPS Antenna
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B. Replace a GPS Antenna
set to OFF.
(2) Open the GPS/NAV1 and/or GPS/NAV2 circuit Instrument panel, right side.
breaker.
(3) Remove the reading/map light(s) as necessary Refer to Section 33-10.

to gain access to the antenna that you will
replace.
S Remove the 4 screws, nuts and washers Hold the antenna.

that attach the antenna to the airplane.
S Remove the ground-plate.
S If necessary, use a knife to carefully remove Take care not to damage the
the sealant that seals the antenna to the airplane surface!
S Move the antenna clear of the airplane. From the outside.

of grease.
S Move the antenna into position on the top of

the fuselage.
S Install the ground plate.
S Install the 4 screws, washers and nuts that Torque 2.5 ± 0.3 Nm (1.8 ± 0.22 lbf.ft.).
attach the antenna to the airplane.
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(8) Install the reading/map light(s) that you removed

at step 3.
(9) Set the GPS/NAV1 and/or GPS/NAV2 circuit Instrument panel, right side.
breaker.
(10) Do a test of the GPS system(s). Refer to Section 31-40.
C. Replace a Marker or ADF Antenna
set to OFF.
(2) Remove the passengers seats. Refer to Section 25-10.
S Remove the 3 screws, nuts and washers Hold the antenna.

that attach the antenna to the airplane.
S Remove the ground plate.
S Move the antenna clear of the airplane. From the outside.
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of grease.
S Move the antenna into position on the

bottom of the fuselage.
S Install the ground plate.

attach the antenna to the airplane.
(8) Do a post installation operational test of the Only if you replaced the ADF antenna.
ADF system. Refer to Paragraph 5.
(9) Do an operational test of the marker system on Only if you replaced the marker
the next flight. antenna.
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ADF Antenna
Bolt
Connector
Washer
Marker Antenna
Figure 4: Replace a Marker Antenna
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D. Replace a NAV/G/S Antenna (if OÄM 42-112 carried out)
set to OFF.
(2) Open the GPS/NAV1 and/or GPS/NAV2 circuit Instrument panel, right side.
breaker.
(3) Remove the rudder to gain access to the Refer to Section 27-20.
NAV G/S antenna via the hole in the stabilizer
spar.
S Remove the 4 nuts and washers that attach

the antenna to the airplane.
S If necessary, use a knife to carefully remove

the sealant that seals the antenna to the
(6) Install the rudder. Refer to Section 27-20
3. Used Types of Flexible Coaxial Cables
Antenna/Receiver Coaxial Cable
Transponder RG 142
DME RG 142
GPS RG 400
ADF RG 400
Marker RG 400
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4. Sealant Specification
Use an adhesive bonding compound on the basis of modified polymers or polyurethane to seal the
antennas to the airplane outer surface. Make sure the sealant is free of silicone and it is temperature
resistant from -40 °C ( -40 °F) to +60 °C (+140 °F).
5. Post-Installation Check of the ADF System
A. General
After installing the equipment, check the indicator reading is correct and determine whether or
not quadrantal error correction is necessary. If so, correction should be first carried out on the
ground, then in the air. It is also necessary to establish whether any equipment in the airplane
electrical system is generating interference.
B. Operational Check
(1) Locate the airplane on the correction platform

and using the bearing compass point the nose
of the airplane to a radio beacon in boundary
range.
(2) Switch on the ADF, adjust to the correct The indicator should read 0 relative
frequency and observe the indication in the bearing.
ADF operating mode.
(3) Turn the airplane about its vertical axis to a The indicator should move to the left.
larger heading.
(4) Turn the airplane about its vertical axis to a The indicator should move to the right.
smaller heading.
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Note: If the reading is incorrect or should the indicator move in the wrong direction,
check the wiring of the equipment for agreement with the wiring diagram and
correct if necessary.
Note: If the airplane is accurately aligned with the NBD beacon, but a relative bearing
reading of 0° is not indicated, this is an indication that the antenna has been
wrongly installed. Recheck the antenna for agreement with the centerline of the
airplane and correct if necessary.
Refer to the manufacturer’s manual for detailed information on the quadrantal error correction.
Note: It is obliging to proceed in accordance with FAA AC 43-13-1A and

FAA AC 43.13-2A requirements.
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Section 34-56
Transponder (XPDR)
1. General
The DA 42 NG has a transponder system which is an integral part of the Garmin G1000 system.
% Refer to the G1000 Maintenance Manual, Doc.No.190-00907-00, latest revision or to the G1000 NXi
% Line Maintenance Manual, Doc.No. 190-02631-00, latest revision for more details about the
transponder (XPDR) system of the DA 42 NG airplane.
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DA 42 NG AMM Oxygen System
AIRCRAFT
CHAPTER 35
OXYGEN SYSTEM
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TABLE OF CONTENTS
CHAPTER 35
OXYGEN SYSTEM
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 35-10
Pressure Gauge and Oxygen System
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Empty the Oxygen System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Remove/Install the Instrument Panel Pressure Gauge . . . . . . . . . . . . . . . . . . . . 203
5. Remove/Install the Oxygen Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
6. Remove/Install the Oxygen Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7. Remove/Install the Filling Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
8. Remove/Install the Pilot/Co-Pilot Outlet Manifold . . . . . . . . . . . . . . . . . . . . . . . . 209
9. Remove/Install the Passengers' Dual Outlet Manifold . . . . . . . . . . . . . . . . . . . . 210
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CHAPTER 35
OXYGEN SYSTEM
1. General
This Chapter tells you about the optional continuous flow oxygen system installed in the DA 42 NG
airplane. This Chapter contains general, trouble-shooting and maintenance information on the system.
2. Description
This oxygen system supplies supplemental oxygen which is required in an altitude above 12,500 ft.
Each pilot or passenger can connect a mask or cannula to the oxygen system via four outlet ports. The
operation of the oxygen system is controlled via a single ON/OFF switch installed below the instrument
panel on the pilot’s side. Information concerning the endurance of the system, which is in direct relation
to the cylinder pressure, is indicated on a pressure gauge installed on the upper right side of the
instrument panel.
A pressure gauge is installed on the RH side of the instrument panel. This gauge shows the amount
of remaining oxygen by means of the current oxygen pressure in the cylinder. Two marks (REFILL=red
color and FULL=green color) show the limits within which the system can be operated.
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Section 35-10
Pressure Gauge and Oxygen System
1. General
This oxygen system supplies supplemental oxygen which is required at altitudes above 12,500 ft. Each
pilot or passenger can connect a mask or cannula to the oxygen system via four outlet ports. The
operation of the oxygen is controlled via a single ON/OFF switch installed below the instrument panel
on the pilot’s side. Information concerning the endurance of the system, which is in direct relation to
the cylinder pressure, is indicated on a pressure gauge installed on the upper right side of the
instrument panel.
An oxygen system overview is given in Figure 1.
The system consists of five main sections:
) Pressure gauge on the instrument panel.
) Oxygen cylinder.
) Regulator valve assembly.
) Filling block.
) Outlet ports.
To enable proper ventilation the nose baggage compartment is divided into three vented
compartments:
) Battery/relay-box compartment.
) Oxygen compartment.
) De-icing compartment (including de-icing fluid tank; optional equipment).
Not shown in Figure 1:
) Instrument panel pressure gauge lighting.
) Interfaces: masks, cannulas.
The high pressure system components are connected with copper tubing (filling block to regulator
valve assembly; regulator valve assembly to instrument panel pressure gauge). The low pressure
system components are connected via PFA tubing.
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Lit Gauge
Battery
Relay Box Plug
TKS Fluid Tank
Oxygen Passenger Plugs
Vented Battery
Compartment
Batteries
Push-Pull Knob
Regulator
Fitting Block On-Off Cable

with Gauge Plug
Vented Oxygen
Compartment T-Fitting
Figure 1: AEROX Oxygen System
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2. Description
A. Pressure Gauge
The oxygen pressure gauge is installed on the RH side of the instrument panel. The gauge shows
the current pressure in the oxygen cylinder. The oxygen pressure is directly related to the remaining
amount of oxygen.
The lighting of the instrument panel pressure gauge is the only electrical item of the oxygen system.
There are no indications and warning lamps of the oxygen system connected to the Garmin G1000
system.
1000 2000
3000
PSI
OXYGEN USE NO OIL
DO NOT OPERATE SYSTEM

BELOW 200 PSI
Figure 2: Oxygen Pressure Gauge
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Instrument Panel Screw
Oxygen Indicator Frame
Oxygen Indicator
Washer
Nut O-Ring
Instrument Light
Clamp
Screw
High Pressure Line
Spiral Wrap
Figure 3: Pressure Gauge Installation on the Instrument Panel
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B. Oxygen Cylinder
The Kevlar oxygen cylinder is installed in the front baggage compartment in its own vented
compartment. The cylinder capacity is 10.7 liter (650 cu.in.), or 1419 liter (50.1 cu.ft.) of
compressed oxygen at 128 bar (1850 PSI).
C. Regulator Valve Assembly
The oxygen flow is controlled by a regulator valve assembly which is switched by a push/pull knob
Bowden cable assembly. The main task of the regulator valve is to reduce the oxygen pressure to
3.4 bar (50 PSI). Each mask or cannula is equipped with its own adjustable pressure regulator,
therefore each user can adjust the amount of supplemental oxygen.
D. Filling Block
Refilling of the oxygen cylinder, which is firmly installed in the airplane, is done via the filling block
assembly which is installed on the LH side of the oxygen compartment. It is accessible via a small
cover on the LH side of the oxygen compartment. It consists of a damper valve and a pressure
gauge. The cylinder is limited to a pressure of 128 bar (1850 PSI). The refilling of a fully depleted
oxygen cylinder takes approximately 3.5 min.
E. Outlet Ports
Each pilot and each passenger has his own outlet port to which the mask or cannulas including
their regulators can be connected. The outlet ports are interconnected via PFA-tubing to the low
pressure side of the regulator.
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3. Operation
CAUTION: OIL, GREASE OR OTHER LUBRICANTS IN CONTACT WITH OXYGEN

CREATES A SERIOUS HAZARD. SUCH CONTACT MUST BE AVOIDED
WHEN HANDLING OXYGEN EQUIPMENT.
A four-place oxygen system provides the supplementary oxygen necessary for continuous flight at high
altitude. An oxygen cylinder is located in the center section of the forward baggage compartment, in
its own enclosed, vented compartment. A combined pressure regulator/shut-off valve attached to the
cylinder automatically reduces pressure to the delivery pressure required for the operating altitude. The
oxygen cylinder filler valve is located on the LH side of the oxygen compartment next to the cylinder
in the forward baggage compartment.
The 50 cubic feet (1.41 cubic meter) capacity oxygen cylinder may be filled to 1850 PSI while installed
in the airplane. The system has a pressure gauge located next to the filler valve to indicate the amount
of oxygen in the cylinder. An identical gauge is located on the upper RH side of the instrument panel
(above the circuit breaker panel).The oxygen supply shut-off control is located on the LH side below
the instrument panel. It is cable connected to the oxygen regulator valve, controlling the oxygen system
by pulling the green control knob out for ON and pushing the same knob in for system supply OFF.
The system should be left OFF when not in use.
The oxygen ports are located (one each) in the map pocket recess for the pilot and co-pilot. The
passengers' oxygen ports are located overhead in the "roll-over bar" next to the cabin speaker. The
individual cannula or mask supply tubes are plug-in connected to each port and contain the individual
flow adjustments (flow meter-needle valve) for each occupant. Note that these ports are serviced
directly from the oxygen regulator valve.
The oxygen cylinder, when fully charged, contains 50 cubic feet (1.41 cubic meter) of aviator's
breathing oxygen under a pressure of 1850 PSI at 21°C (70 °F). Filling pressures will vary due to the
ambient temperatures in the filling area and the rise of temperature resulting from the compression of
the oxygen. Due to these factors merely filling the cylinder to 1850 PSI will not result in a properly filled
cylinder. Fill oxygen cylinders to the pressures indicated in the table shown below, based on the filling
area's ambient temperature.
The oxygen system pressure is limited and rated to 1850 PSI.
Ambient Filling Pressure Ambient Filling Pressure

Temperature Temperature
PSI PSI
o o o o
C ( F) C ( F)
-18 (0) 1650 10 (50) 1875

-12 (10) 1700 16 (60) 1925
-7 (20) 1725 21 (70) 1975
-1 (30) 1775 27 (80) 2000
4 (40) 1825 32 (90) 2050
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Trouble-Shooting
1. General
The table below lists the defects you could have with the oxygen system. If you have the trouble

No oxygen comes out of the False adjustment of flow Adjust.
connected masks and meter-needle valve.
cannulas.
Flow meter needle valve Replace valve.

defective.
Outlet port defective. Replace outlet port.
Regulator valve assembly Replace regulator valve

defective. assembly.
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1. General
These Maintenance Practices tell you how to perform an operational test of the oxygen system. They
also tell you how to remove and install the main components of the ice protection system.
2. Operational Test
(1) Fill up the oxygen cylinder to a max. pressure of Do not use oxygen with a lower purity
128 bar (1850 PSI). grade than prescribed by
MIL-PRF-27210.
(2) Check each plug-in outlet port. Use the flow meter-needle valve
assembly; open every needle valve
completely and make sure the ball floats
to the top of the flow meter. Make sure
that every plug in is fully opened.
(3) Check pressure gauges by comparing the one If the difference between both pressure
attached on the filling block with the pressure indications is more than 100 PSI
gauge installed in the instrument panel. exchange inaccurate pressure gauge.
Use a calibrated gauge, connected on
the filling valve to determine the
inaccurate gauge.
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3. Empty the Oxygen System
(1) Place airplane outside of hangar.
(2) Open the canopy.
(3) Check that the ON/OFF knob is in the OFF

position.
(4) Plug in one connection tube in the pilot’s outlet

port. Plug in only the connection tube including
the flow meter needle valve assembly.
(5) Pull ON/OFF knob in ON position and adjust the

needle valve to maximum flow.
(6) Confirm that the outlet of the flow meter needle

valve assembly does not point not towards oil or
grease (engine).
(7) The cylinder is depleted when the flow meter

ball shows no flow.
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4. Remove/Install the Instrument Panel Pressure Gauge
A. Remove the Instrument Panel Pressure Gauge
(1) Confirm that the oxygen cylinder is empty.
(2) Remove instrument panel cover.
(3) Disconnect the high pressure tube from the

pressure gauge.
(4) Remove the screws of the panel-overlay and

remove the placard.
(5) Remove the 2 nuts and washers from the rear

clamp sheet metal.
(6) Remove the clamp sheet metal and pull the

indicator backwards out of its frame.
(7) Remove the ring from the indicator.
B. Install the Instrument Panel Pressure Gauge
(1) Place the oxygen indicator in the frame.
(2) Attach the ring and the clamp sheet metal to the
rear of the indicator.
(3) Install this assembly in the designated cutout on Take care that no washer or nut falls
the RH side of the instrument panel. into the instrument panel.
(4) Install the RH panel overlay.
(5) Connect the high pressure copper tube to the

gauge.
(6) Fix the tube which surrounds the copper tube by Take care that the cable ties do not
using cable ties. clamp this plastic tube.
(7) Install the instrument panel cover.
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5. Remove/Install the Oxygen Cylinder
A. Remove the Oxygen Cylinder
(1) Empty the oxygen cylinder. Refer to Paragraph 3.
(2) Check both oxygen pressure gauges and check

the ON/OFF knob is in OFF position.
(3) Open both doors to the nose baggage

compartment.
(4) Remove the LH and RH oxygen compartment

cover.
(5) Remove one PFA tubing.
(6) Pull ON/OFF knob in ON position and confirm

that the cylinder is empty.
(7) Disconnect all other lines and the Bowden cable

from the regulator.
(8) Open the clamp which fixes the oxygen cylinder.
(9) Remove the LH battery cover. For easier removal of the oxygen
cylinder.
(10) Remove the cylinder.
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B. Install the Oxygen Cylinder
(1) Confirm that no oil, greases or any

accumulations of oil based substances are in or
near the oxygen compartment.
(2) Install the regulator on the cylinder. Seal the

thread with Teflon tape and a rubber ring.
(3) Install the cylinder in its designated position. Regulator points forward.
(4) Fix the cylinder by using the silicon protection

ring and a clamp.
(5) Connect all pressure lines and the Bowden

cable to the regulator.
(6) Install the LH battery cover and both oxygen

compartment covers.
(7) Perform an operational test.
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6. Remove/Install the Oxygen Regulator
A. Remove the Oxygen Regulator
(2) Check both oxygen pressure gauges; verify that

the ON/OFF knob is in the OFF position.

compartment.

cover.

(7) Disconnect all other lines and the Bowden cable

from the regulator.
(8) Open the clamp which fixes the oxygen cylinder.
(9) Remove the LH battery cover. For easier removal of the oxygen
cylinder.
(10) Remove the cylinder.
(11) Remove the regulator from the cylinder.
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B. Install the Oxygen Regulator
(1) Confirm that no oil, greases or any

accumulations of oil based substances are in or
near the oxygen compartment.
(2) Install the regulator on the cylinder. Seal the

thread with Teflon tape and a rubber ring.
(3) Install the cylinder in its designated position. Regulator points forward.
(4) Fix cylinder with the silicon protection ring and a

clamp.
(5) Connect all pressure lines and the Bowden

cable to the regulator.
(6) Install the LH battery cover and both oxygen

compartment covers.
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7. Remove/Install the Filling Block Assembly
A. Remove the Filling Block Assembly
(2) Check both oxygen pressure gauges and check

the ON/OFF knob is in OFF position.

compartment.

cover.

(7) Carefully disconnect the high pressure filling

copper line from the regulator.
(8) Remove filling block assembly screws and pull

out the filling block.
B. Install the Filling Block Assembly
(1) Thread in the high pressure copper filling line in Use a new compression ring in the fitting
the grommet installed in front of the forward of the regulator.
oxygen base. Mount the filling block assembly in
the forward base by using 4 screws.
(2) Install the LH battery compartment cover.
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8. Remove/Install the Pilot/Co-Pilot Outlet Manifold
A. Remove the Pilot/Co-Pilot Outlet Manifold
(1) Confirm that the oxygen system is switched

OFF.
(2) Remove the side pocket and disconnect the

PFA tubing from the outlet manifold.
(3) Open the threaded ring of the outlet manifold

and remove the outlet manifold.
B. Install the Pilot/Co-Pilot Outlet Manifold
(1) Remove the side pocket and install the outlet

manifold by using the threaded ring after
attaching the placard. Confirm that 2 PA rings
(one between the side pocket and the outlet
manifold and the other between the side pocket
and the placard) are on the manifold.
(2) Connect the outlet manifold to the PFA tubing.
(3) Install the side pocket and check operation of

the manifold.
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9. Remove/Install the Passengers' Dual Outlet Manifold
A. Remove the Passengers' Dual Outlet Manifold
(1) Confirm that the oxygen system is switched

OFF.
(2) Remove both forward lights and the speaker

from the roll-over bar.
(3) Remove both threaded rings of the dual outlet

manifold and push it in the roll-over bar.
(4) Remove the cable ties from the oxygen line and Take care that the PA rings on the outlet
pull on the oxygen line to extract the dual manifold do not fall into the roll bar.
manifold.
(5) Disconnect the PFA tubing from the dual outlet

manifold.
(6) Protect open end of the PFA tubing against

debris with tape.
B. Install the Passengers' Dual Outlet Manifold
(1) Put the 2 PA rings (one at each outlet) on the Use a small amount of adhesive to fix it.
dual outlet manifold.
(2) Place the dual outlet manifold in the roll bar

under the GPS antennas.
(3) Connect the PFA tubing with the outlet manifold.
(4) Place the outlet manifold in position and fix it

with 2 threaded rings. Clamp the oxygen
placard between the roll bar and the ring.
(5) Use cable ties to fix the oxygen line on the

bonding strip.
(6) Perform an operational check and reinstall the

forward cabin lights and the speaker.
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AIRCRAFT Practices/Structures
CHAPTER 51
STANDARD PRACTICES/STRUCTURES
51-TITLE
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TABLE OF CONTENTS
CHAPTER 51
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Types of Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Laminated Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Sandwich Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Bonded Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Repair Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section 51-10
Investigation
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Damage Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Types of Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Inspection Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Further Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Debris Protection Inspection (OÄM 42-088a, OÄM 42-089a, OÄM 42-090a) . . . . 4
Section 51-20
Repair Processes
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Center of Gravity Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Control Surface Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Drain/Vent Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5. Holding a Component During a Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6. Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7. Workshop Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Resin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Glass and Carbon Cloth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Core Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5. Laminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
6. Bonding Paste (Thickened Resin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
7. Curing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
8. Exterior Paint Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
9. Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Section 51-30
Materials
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Approved Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 51-40
Fasteners
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Replace a Quick Release Fastener Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 51-60
Control Surface Balancing
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Rudder Static Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3. Rudder Trim Tab Static Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4. Elevator Static Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. Elevator Trim Tab Static Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6. Aileron Static Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7. Wing Outer Flap Static Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8. Wing Inner Flap Static Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Section 51-80
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Test the Electrical Bonding System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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CHAPTER 51
1. General
The DA 42 NG is a twin engine, low wing monoplane of composite construction. The airplane has a
standard T-tail and vertical stabilizer with a tail skid. It has retractable tricycle landing gear with a nose
wheel that can be steered.
Two types of structural resin systems are in use, further designated as L285 and RIM 935 (refer to
Section 51-30 for detailed data). The resin system is clearly defined by a distinguished part number.
In addition the resin system for parts produced for S/N 42.N300/42.MN100 or above is stated on the
identification label of the part (refer to Figure 1). Composite parts with no resin system stated on the
identification label or on the part are made of L285.
Figure 1: Composite Part Identification Labels
The DA 42 NG fuselage has a semi-monocoque structure. Two carbon fiber reinforced plastic (CFRP)
half-shells make the fuselage skin. The fuselage shells have many layers of carbon cloth. Rigid foam
inserts give stiffness to the fuselage shells where necessary. All of the main structural components are
CFRP or GFRP rigid moldings. Many layers of carbon or glass cloth bond together to make each
molding. Carbon fiber cloth gives more strength and stiffness.
The vertical stabilizer is part of the fuselage. The aft part of the left and right fuselage shells make the
left and right shells of the vertical stabilizer.
The DA 42 NG has a wing center section and the left and right wings attach to the wing center section.
The wing center-section also supports the two engine nacelles. The wing center section is divided into
three areas, these are the engine nacelles, wing stubs and center section.
The flight loads from the wings are transferred to two spar bridges running laterally through the wing
center-section. The wings are connected to the center section with spar stubs that extend into the wing
center-section. Each wing is attached to the center section with four main bolts and two auxiliary bolts.
Each wing has top and bottom shells. It has front and rear spars and a wing root rib made in three
parts. Each shell has a carbon fiber reinforced plastic (CFRP) outer skin, a rigid foam core and a
GFRP inner skin.
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Each wing has two I-section spars. The front spar on one side is the same as the rear spar on the
other side. Many layers of uni-directional carbon fiber make the spar caps. The number of layers in
the spar caps decreases from root to tip. Each spar has a shear web. The shear web has GFRP skins
and a rigid foam core. Glass cloth fillets attach the spar caps to the shear web.
A rear web closes the trailing edge of the wing. An end rib closes the outboard end of the wing. A
removable winglet attaches to the wing shells and outer rib with screws.
The flaps and ailerons have top and bottom shells. Each shell has a mixture of CFRP and GFRP cloth.
The shells have rigid foam cores and bond together.
The horizontal stabilizer has top and bottom shells. Each shell has GFRP skins. The horizontal
stabilizer has a front spar and a rear spar. Three pairs of ribs give strength to the central area. The
elevator has top and bottom shells. Each shell has GFRP skins with a rigid foam core.
The rudder has left and right shells. Each shell has GFRP skins with a rigid foam core. The shells bond
together at a flange.
The canopy is a CFRP molding with inner and outer frames that bond together. The canopy has a
large one-piece acrylic transparency. The passenger door is a CFRP molding with inner and outer
frames. The frames bond together. The door has an acrylic transparency.
A polyurethane paint finish protects the outer skins of the airplane from ultraviolet rays and humidity.
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2. Types of Structure
The DA 42 NG is constructed from two main types of composite structure.
A. Glass Fiber Reinforced Plastic (GFRP)
GFRP is very thin glass fibers bonded together by resin. The glass fibers give most of the strength
and the resin maintains the shape. The resin also bonds to other structural components such as
metal attachment brackets or metal bushings.
The glass fibers are woven to make glass cloth. The orientation and the weave of the glass in the
cloth affects the structural strength of the cloth. A component can have many layers of cloth bonded
together with resin. This is called lamination.
GFRP has very good properties. It is strong and flexible. It is very resistant to chemical attack and
very little maintenance of GFRP laminates is necessary.
B. Carbon Fiber Reinforced Plastic (CFRP)
CFRP is very thin carbon fibers bonded together by resin. The carbon gives most of the strength
and the resin maintains the shape. The resin also bonds to other structural components such as
metal attachment brackets or metal bushings.
CFRP is very similar to GFRP. The main advantage of CFRP is that it is stronger and more rigid
than GFRP.
3. Laminated Components
A laminated component has two or more layers of glass/carbon cloth. The direction of the fibers in the
cloth give the properties of each layer. Extra layers are bonded to some areas to give more strength.
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4. Sandwich Construction
Many of the components in the DA 42 NG have a sandwich of two skins and a core. GFRP or CFRP
make the skins and rigid foam makes the core.
The skins must bond to the core of a sandwich structure completely. If the skins do not bond to the
core the component can fail.
5. Bonded Components
A number of components can bond together to make a larger component. Special thick resin bonds
these components together and fills the gap in a joint.
6. Repair Limitations
Repairs which are categorized as 'Class 1' in accordance with Section 51-10, Paragraph 2, may only
be carried out in accordance with a repair scheme which has been approved by Diamond Aircraft
Industries. Such repairs are not described in the Airplane Maintenance Manual (AMM).
Repair work on these components is not permitted:
) Radome (nose cone, if OÄM 42-119 or OÄM 42-273 is installed).
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Section 51-10
Investigation
1. General
This Section tells you how to assess the class of damage. It also tells you how to inspect glass fiber
reinforced plastic (GFRP), carbon fiber reinforced plastic (CFRP) composite structures and debris
protection composite and adhesive foil structures. Damage assessment and repairs must be carried
out by approved persons.
Refer to Section 51-00 for the types of structures used in the DA 42 NG and for repair limitations. Refer
to Section 51-20 for general repair procedures. Refer to Chapter 53 for more information about the
debris protection system.
2. Damage Classification
Damage is divided into the classes described below. If you are not sure about the classification of any
damage you must refer to the airplane manufacturer.
A. Class 1 Damage
% Any damage, that is not class 2 through 4 damage is counted among Class 1.
B. Class 2 Damage
Damage to primary structural components (fuselage, wings, empennage) and control surfaces
(dimensions for L285 <150 mm [5.9 in] or for RIM 935 <25 mm [1 in] in any direction) as well as
holes and cracks passing through both skins of a sandwich construction component. The core
damage must be able to be covered by a 75 mm (3 in) diameter circle for L285 or by a 13 mm
(0.5 in) diameter circle for RIM 935.
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C. Class 3 Damage
Small holes or cracks in the outer skin of primary structural components (fuselage, wings,
empennage) and control surfaces where there is no internal damage to the component, the
sandwich material or the inner skin.
D. Class 4 Damage
Minor scratches, abrasions or similar damage which is not a puncture or crack in the airplane skin
as well as any sort of damage to non-load-bearing structures (e.g. fairings, cowlings, carpetings,
canopies).
3. Types of Damage
There are two basic types of damage that can occur in composite structures and which can not be
readily found with visual examination:
) Disbonding.
) Delamination.
Disbonding is the failure of the bonding between two or more components. For example between the
wing skin and a wing rib. Or between a metal component and a composite component. Or between
a composite skin and a sandwich core material.
Delamination is the failure of a bond between one or more layers of glass/carbon cloth in a laminated
component.
There are also two main types of cracks that can occur in composite structures:
) Micro cracks.
) Major cracks.
Micro cracks occur in the surface of the resin and do not affect the integrity of the cloth.
Major cracks have broken fibers in the cloth. Major cracks do not occur with normal flight loads or
normal landing loads. You must carefully examine the areas around major cracks for indications of
further damage which can transmitted into other components.
You must repair all major cracks. If you are not sure how to proceed with further inspections of major
cracks you should contact the airplane manufacturer for advice.
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4. Inspection Techniques
A. Visual Examination
Use this method to find all types of damage to composites. Use a bright light to examine visually
the inside of a component. GFRP must be green or brown in color. If it has white areas, then it may
be damaged. Look specially where components bond to the GFRP.
CFRP must be black in color. Apply a small load to the area where you expect a damage, e.g. by
pushing slightly on it. Check for abnormal flexibility or noises. Broken lamination often crackles
under load. Look specially in areas where components bond to the CFRP.
Look carefully at the outer surface of a component. If the paint has cracks or bubbles, then the
composite below may be damaged. Refer to Paragraph 5 in this Section.
Also look for dents and deformation. Look specially in the areas where stones can hit the fuselage
and wings below the airplane. Look specially in the areas of the wing walkways.
B. Light Test
Use the light test to find delamination. Use this test on components which do not have rigid foam
cores.
CAUTION: DO NOT LET THE COMPOSITE GET HOT. HEAT CAN CAUSE
DAMAGE TO COMPOSITES.
Point a very bright light at the surface and look at the surface from the opposite side to the light
source. Damage usually shows as dark areas in the component. You can point the light from the
inside of the component or the outside of a component.
Note: You can use the light test on thick sections of GFRP but it is difficult to use
on CFRP.
C. Coin Tap Test
Use the coin tap test to find delamination and disbonding. Tap a coin on the laminate surface
across the area you will test. The sound of the coin tapping on the surface of the laminate will
change as you move the coin over damaged laminate.
Look specially in the area around the damage for secondary damage, which can remain
undetected.
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5. Further Inspection
If you find damage to the paint when you examine a composite structure then do this further inspection.
Find a way to see the inside of the structure or component. If necessary, remove panels (or other
components), or you can use remote viewing equipment. For example, remove a winglet to see inside
the wing. If you can see damage inside the component or structure you must do a repair.
Remove the paint coat in the area that you think is damaged. Remove the paint coat carefully, you
must not damage the surface under the paint coat.
Look carefully at the surface under the paint coat. Push the middle of the area to be tested with your
thumb. If you can feel the skin hitting against the core of the sandwich (or other layer/component) then
the skin is disbonded and you must repair the structure.
In some cases you may need to cut inspection holes in the structure to do the test correctly. If you
must make inspection holes then you must contact Diamond Aircraft Industries for advice.
6. Debris Protection Inspection (OÄM 42-088a, OÄM 42-089a, OÄM 42-090a)
A. Single and Triple Layer Adhesive Foil Debris Protection (OÄM 42-088a, OÄM 42-089a)
Even small holes or buckling deeper than 1.5 mm (0.06 in) in this layer have an adverse effect on
its tensile strength. A proper protection of the fuselage cannot be ensured and therefore the debris
protection must be replaced. Visually inspect the fuselage skin underneath during replacement.
Refer to Section 51-10 for classification and repair of a probable fuselage damage. Scratches and
little damages in the border area are acceptable. If damage occurs outside of the debris protection
check position or contact the airplane manufacturer.
A replacement by a composite debris protection is possible.
B. Composite Debris Protection (OÄM 42-090a)
The composite debris protection should be replaced if damage occurs. If damage exceeds 50 mm
(2 in) in diameter, the debris protection must be replaced and the fuselage skin underneath must
be inspected. Refer to Section 51-10 for classification and repair of a probable fuselage damage.
A replacement by adhesive foil debris protection is possible.
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Section 51-20
Repair Processes
1. General
Note: On certain serial numbers the engine cowlings are manufactured with a resin that
is different from the usual resin. Refer to Section 51-30.
This Section tells you how to repair composite structures. Repairs must be carried out by approved
persons. Refer to Section 51-00 for data about the types of structure. Refer to Section 51-10 for data
about the classification of damage and inspection techniques. Refer to Section 51-30 for data about
approved repair materials.
2. Center of Gravity Limits
When you repair an airplane you change the weight of the airplane. If you change the weight of an
airplane then you change the center of gravity. The further the distance of a repair from the center of
gravity, the greater the effect of the repair will have on the center of gravity. You must always weigh
the airplane after a large repair and calculate the center of gravity. Refer to Section 08-10 for data
about weighing the airplane and calculating the center of gravity.
3. Control Surface Balancing
When you repair a control surface it becomes heavier. Make an estimate of the new weight of the
control surface if you were to carry out the repair. (Weigh the materials that you will use to do the repair
and add the weight to the actual weight of the control surface). If the post repair weight is greater than
the permitted weight then do not do the repair. You must install a new control surface. Refer to Chapter
06-00 for data about the weight and balance of control surfaces.
When you repair a control surface and/or apply a new paint coat you must weigh the control surface
and check the balance of the control surface. Section 51-60 tells you how to check the balance of a
control surface. Refer to Chapter 06-00 for data about the weight and balance of control surfaces.
4. Drain/Vent Holes
You must keep all drain and vent holes in the structure of the DA 42 NG open. If you close a drain or
vent hole during a repair you must make a new hole in the same position after the repair is complete.
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5. Holding a Component During a Repair
You must hold a component in the correct position when you do a repair. If you do not hold a
component correctly it may move during the repair and cause further damage. It can also change the
airplane alignment.
Hold the component in a special device (jig/fixture) before you cut out the damaged area. If necessary,
lift the airplane on jacks and level the airplane. Refer to Section 07-10 for more data about lifting the
airplane on jacks and refer to Section 08-20 for data about leveling the airplane.
6. Safety Precautions
Moist resins can cause skin disease. When you use resins/hardeners use a protective barrier cream
on all exposed skin, specially your hands. You must always wear protective gloves.
WARNING: DO NOT GET RESIN ON YOUR SKIN. RESIN CAN CAUSE SKIN
DISEASE.
The resins, hardeners and solvents used for composite repairs are poisonous. You must not take food
or drinks into the work area. Use a mask to protect your face and use eye protection.
WARNING: DO NOT GET RESINS, HARDENERS OR SOLVENTS IN YOUR MOUTH

OR IN YOUR EYES. THESE CHEMICALS CAN CAUSE DISEASE.
When you grind composites you make small particles of composite dust. These particles can irritate
the skin and eyes. If you breathe these particle they can cause lung disease.
When you grind composite you must always use a protective cream on all exposed skin, specially your
hands. Wear overalls that seal; at the neck, sleeves and ankles. You must always wear protective
gloves and if necessary, change them often. Use a suitable mask to protect your face and lungs.
Always wear safety goggles to protect your eyes.
If your skin comes into contact with composite dust, then wash it off with clean flowing water. Do not
rub your skin while there is dust on it.
WARNING: DO NOT GET COMPOSITE DUST PARTICLES IN YOUR EYES, OR IN

YOUR MOUTH, OR ON YOUR SKIN. THESE PARTICLES CAN CAUSE
DISEASE.
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7. Workshop Conditions
Keep the workshop clean and free from dust. Remove grinding dust as it occurs. The working area
must not be affected by draughts.
The workshop temperature must be maintained:
) for L285 between 18 °C (65 °F) and 27 °C (80 °F).
) for RIM 935 between 18 °C (65 °F) and 23 °C (73 °F).
The temperature must not fall below 15 °C (59 °F).
The relative humidity during mixing, applying or curing resins must not be allowed to rise above 80%
for L285 or 65% for RIM 935.
Maintain the workshop temperature as near to 25 °C (77 °F) as possible during curing.
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1. General
These Maintenance Practices tell you about composite repair processes and how to repair Class 2,
3 and 4 damage to the composite structure. Refer to Section 51-10 for data about damage
% classification. Class 1 damage may only be repaired in accordance with a repair scheme which must
% be approved in accordance with the procedures established by the competent certifying authority. All
repairs must only be carried out by approved persons.
You must only use the materials approved by the manufacturer when repairing the airplane. Refer to
Section 51-30 for data about approved materials.
Inspect the damaged area(s). Look specially at the adjacent structure. Damage can go a long way
under the surface of a composite. Use the techniques given in Section 51-10.
You must take care to do the repair correctly. The outer shell of a composite structure is stressed.
% Improper repairs can cause structural failure.
2. Resin
You must use the correct quantity of mixed resin for the repair. Weigh all the cloth patches that you
will use for the repair. The ratio for glass cloth to resin mix is 100 : 70. For example, 100 grams of dry
cloth require 70 grams of mixed resin. The ratio for carbon cloth to mixed resin is 100 : 85. For
example, 100 grams of dry carbon cloth requires 85 grams of mixed resin.
Measure the quantities of resin and hardener accurately (± 0.5% by weight). Mix the resin and
hardener thoroughly before laminating, or adding fillers or other additives.
Always use clean containers for mixing resin and only mix as much resin as you can use within its
‘working life’.
When using large quantities of resin put it shallow containers. This will increase the ratio surface area
to volume which will reduce the risk of an exothermic reaction.
Two types of structural resin systems are in use, further designated as L285 and RIM 935 (refer to
Section 51-30 for detailed data). The part must be repaired with the same resin system as used during
manufacturing of the part. The resin system is clearly defined by a distinguished part number and is
stated on the identification label of the part. The resin system can also be specially defined for specific
% parts (e.g. cowlings). In case of doubt, contact the manufacturer.
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3. Glass and Carbon Cloth
You must always use the correct cloth for the repair. Refer to the lay-up drawing of the repair area for
data about the type of cloth you must use for the repair. The lay-up drawing will tell you:
) The correct type of cloth.
) The fiber direction.
) The dimensions of the layer.
Make sure that the fibers in each layer of cloth point in the direction given by the lay-up drawing. This
gives the correct strength to the laminate.
Only use sharp shears or scissors to cut the cloth to size. Make sure that the fibers in the cut cloth
point in the correct relative direction. Make sure that the fiber strands are not broken or damaged. The
cloth must be free of any damage or contamination.
4. Core Material
You must always use the correct sandwich core for the repair. Refer to the lay-up drawing of the repair
area for data about the core material that you must use.
Make sure that the core material is not damaged or contaminated.
Use a sharp knife to cut the core to the exact size for the repair. The edges of the cut must be clean
so that the core will bond correctly. You can profile the core by cutting or sanding.
Small damages of the core (diameter # ½ inch) may be repaired by resin thickened with micro balloons
or Q-Cell.
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5. Laminating
A prescribed stack of resin impregnated cloth makes a laminate. A laminate which is used to repair
an airplane becomes an integral part of the airplane structure once the laminate has hardened and
fully cured.
You can make a laminate in place on the airplane or you can make a laminate on a work bench and
then apply the wet laminate to the airplane repair. When you make the laminate on a work bench:
) It is easier to do.
) It is easier to control and correct the laminating process.
) You can make sure that the cloth layers in the stack are correct before you apply the resin.
) You can make the repair neater.
) You do not have to work upside down to make the laminate.
A. Laminating Directly on the Airplane
(1) Prepare the damaged area for laminating: Refer to the relevant repair procedure in
this Section.
S Make sure that the repair is clean and free of
contamination.
S Do not touch the area to be repaired.

Especially particles of skin protecting cream
on your hands may act as a separating agent
within the lamination.
(2) Identify type of resin used for the parts to be Find the parts label and note the resin
repaired. system used for this part.
For S/N below 42.N300/42.MN100:
if the parts label does not state a type of

resin, and this manual does not give
instructions on the resin system to be
used for the specific part, use L285 for
repair.
In case of doubt, contact Diamond

Aircraft for assistance.
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(3) Prepare the layers of cloth that you will use for Refer to the lay-up drawing.
the repair.
(4) Protect the area of the structure around the repair Use plastic/polythene sheeting held in
from contamination by the repair materials. place by self-adhesive tape.
DISEASE.
WARNING: DO NOT GET RESINS, HARDENERS OR SOLVENTS IN YOUR

MOUTH OR IN YOUR EYES. THESE CHEMICALS CAN CAUSE
DISEASE.
(5) Apply a thin coat of resin to the repair.
(6) Apply the first layer (the biggest one) of cloth to Make sure that the fibers in the cloth
the repair and trim to the correct size. point in the correct direction.
(7) Use a roller, squeegee and a stipple brush to

remove all trapped air. Make sure that the cloth is
completely impregnated with resin. If necessary,
add more resin.
(8) When the excess resin has been brought to the

surface with the rolling and stippling process.
Apply the next layer of cloth. Trim the cloth to the Make sure that the fibers in the cloth
correct size. point in the correct direction.
(9) Do steps 6 and 7 as necessary until all the layers

of cloth are in place.
(10) Use the roller and squeegee to remove the

excess resin.
(11) Put a layer of peel ply over the laminate.
(12) If necessary, apply a vacuum bag to the laminate. Refer to the lay-up drawing and/or
repair drawing.
WARNING: DO NOT PUT HOLLOW COMPONENTS COMPLETELY INTO A

VACUUM BAG. YOU MAY DESTROY THEM.
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B. Laminating on a Work-Bench
(1) Prepare the damaged area for laminating: Refer to the relevant repair procedure in
this Section.
S Make sure that the repair is clean and free
of contamination.
(2) Identify type of resin used for the parts to be Find the parts label and note the resin
repaired. system used for this part.
For S/N below 42.N300/42.MN100:
if the parts label does not state a type of

resin, and this manual does not give
instructions on the resin system to be
used for the specific part, use L285 for
repair.
In case of doubt, contact Diamond

Aircraft for assistance.
(3) Prepare the layers of cloth that you will use for Refer to the lay-up drawing.
the repair.
(4) Put a layer of clean transparent

plastic/polythene sheeting over the repair area
and hold in place with self-adhesive tape.
(5) Use an indelible ink marker to:
S Trace onto the plastic sheet the extreme The outer layer of the structure must be
outline of the repair. tapered to avoid stress risers and to give
a good finish.
S Trace onto the plastic sheet the contour
lines of each layer of cloth in the structure.
(6) Remove the transparent sheet from the repair

area and place it upside down on a work-bench.
Note: The cloth layers are laid in reverse order when you laminate on a table. You
must take care to put the cut cloth layers in the correct order and that the fibers
in each cloth layer point in the correct direction.
(7) Cut the layers of cloth to fit the contour lines that
you traced onto the transparent sheet.
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DISEASE.

DISEASE.
(8) Apply a thin coat of resin to the transparent

sheet.
(9) Apply the first inner layer of cloth to the Make sure that the fibers in the cloth
transparent sheet and trim to the correct size. point in the correct direction.
(10) Use a roller squeegee and a stipple brush to

remove all trapped air. Make suer that the cloth
is completely impregnated with resin. If
necessary, add more resin.
(11) When the excess resin has been brought to the

surface with the rolling and stippling process.
Apply the next layer of cloth. Trim the cloth to Make sure that the fibers in the cloth
the correct size. point in the correct direction.
(12) Do steps 9 and 10 as necessary until all the

layers of cloth are in place.
(13) Apply a thin coat of resin to the area of the

repair on the airplane structure where you will
attach the laminate patch.
(14) Put the laminate patch carefully into position on Make sure that the fibers in the cloths
the airplane structure using the transparent point in the correct direction.
sheet.
(15) Carefully remove the transparent sheet from the

patch.
(16) Use the roller and squeegee to remove the

excess resin.
(17) Put a layer of peel ply over the laminate.
(18) If necessary, apply a vacuum bag to the Refer to the lay-up drawing and/or repair
laminate. drawing.
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6. Bonding Paste (Thickened Resin)
CAUTION: FOR BONDING OF PARTS WHICH ARE MADE WITH SELF

EXTINGUISHING RESIN, THE BONDING PASTE MUST ALSO BE
MIXED FROM SELF EXTINGUISHING RESIN. REFER TO SECTION
51-30.
Use bonding paste to bond GFRP/CFRP components together and in the repair of sandwich cores.
Resin and thickening fillers make the bonding paste. Table 1 gives you the proportion by weight of
resin to thickening fillers.
Table 1 - Bonding Paste Mixing Proportions
Material Weight in Grams
Mixed Resin 50 100 150 200 250 300 350 400 450
Cotton Flakes 6.1 12.2 18.3 24.4 30.5 36.6 42.7 48.8 54.9
Sil Cell 300 or

3.9 7.8 11.7 15.6 19.5 23.4 27.3 31.2 35.1
Eurocell 300
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7. Curing
You must cure a composite structure to make it strong. If you do not cure a composite structure
correctly it may fail. Curing is a two part process, pre curing and post curing. The following procedure
gives a typical curing process. You must follow the resin manufacturers instructions for the resin that
you are using.
Curing and post curing depends on the resin system used for repair.
A. Curing with L285
(1) Maintain the temperature of the repair at If you do not have an oven or a warming
20 to 25 °C (68 to 77 °F) for at least 24 hours room you can make a temporary
to pre-cure the repair. enclosure around the repair to trap the
heat from a flame proof air heater.
CAUTION: DO NOT ALLOW THE TEMPERATURE TO GET TOO HIGH DURING

THE CURE. A TEMPERATURE THAT IS TOO HIGH CAN DAMAGE
THE COMPOSITE STRUCTURE.
(2) After 24 hours raise the temperature of the Monitor the temperature every
repair to at least 65 °C (149 °F) for a minimum 15 minutes for the first hour then hourly.
of 6 hours to complete the first stage of the
post-cure.
(3) After a minimum of 6 hours raise the The final stage post cure time can be
temperature of the repair to at least 80 °C divided into sections but you must make
(176 °F). Maintain this temperature for a sure that the repair has a minimum total
minimum of 14 hours to complete the final of 14 hours at post cure temperature.
post-cure.
CAUTION: DO NOT HEAT UP ABOVE 85 °C (185 °F). THE FOAM CORE MIGHT
BE DESTROYED.
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B. Curing with RIM 935
(1) Establish and maintain a temperature of the If you do not have an oven or a warming
repair area of 40 to 55 °C (104 to 131 °F) for at room you can make a temporary
least 10 hours to pre-cure the repair. enclosure around the repair to trap the
heat from a flame proof air heater.
CAUTION: DO NOT ALLOW THE TEMPERATURE TO GET TOO HIGH DURING

THE CURE. A TEMPERATURE THAT IS TOO HIGH CAN DAMAGE
THE COMPOSITE STRUCTURE.
(2) Gradually raise the temperature of the repair

area to 125 to 135 °C (257 to 275 °F) over a
minimum of 4 hours.
(3) Maintain this temperature for a minimum of Monitor the temperature every
14 hours to complete the final post-cure. 15 minutes for the first hour then hourly.
The post cure time can be divided into
sections but you must make sure that
the repair has a minimum total of
14 hours at post cure temperature.
(4) After min. 14 hours lower the temperature to

room temperature over a minimum of 4 hours.
CAUTION: DO NOT HEAT UP ABOVE 135 °C (275 °F). OTHERWISE THE FOAM
CORE MIGHT BE DESTROYED.
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8. Exterior Paint Finish
A. Paint Color Schemes
CAUTION: YOU MUST PAINT THE AIRPLANE TO THE PAINT COLOR SCHEME. IF
YOU DO NOT PAINT THE AIRPLANE TO THE PAINT COLOR SCHEME
YOU MAY CAUSE DAMAGE TO THE AIRPLANE STRUCTURE.
% If MÄM 42-1134 is installed, the painting scheme of the airplane at first delivery is stated on a
% placar on the floor in the RH nose baggage compartment according to Section 11-30-00.
Since full strength of the fiber composite structure has only been shown up to the most critical
climatic conditions expected in service with certain paint colors, the outer surface of the airplane
must be painted in accordance with a paint color scheme of a certain solar absorptivity. Refer to
Chapter 04 of this manual.
Refer to Figure 1 or Figures 2, 3 and the table for the details of the respective paint color scheme.
(1) For S/N below 42.N300/42.MN100:
Exceptions from the paint color scheme are registration markings, warning markings, trim or
striping, which are subject to the following restrictions (refer to Figure 1):
) Zone 1. No registration markings, warning markings, trim or striping may be applied here,
except for the placards in accordance with Section 11-20.
) Zone 1a. This zone has the same restrictions as Zone 1, except that registration markings may
be applied here which comply with the restrictions of Zone 2.
) Zone 2. Registration markings, warning markings, trim or striping may be applied here. They
may be any shape and color, provided that the average absorption coefficient of each
area measuring 200 mm by 200 mm (8 in by 8 in) does not exceed 0.5. Examples
which meet this criterion are:
• Registration markings, warning markings, trim or striping of any shape, provided

that colors with a solar absorptivity not exceeding 0.5 (e.g. light yellow or light
green) are used.
• Registration markings, warning markings, trim or striping of any color, provided

that no area measuring 200 mm by 200 mm (8 in by 8 in) is covered by more than
50%. One consequence is that the width of decoration stripes must not exceed
100 mm (4 in).
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) Zone 3. Registration markings, warning markings, trim or striping of any shape and color may
be applied here without restrictions. In addition color paint finish of any color may be
applied in this zone.
) Zone 4. It is mandatory to paint this zone (top of vertical stabilizer leading edge) in a color with
a solar absorptivity not exceeding 0.65.
If the Garmin GWX 68 or GWX 70 weather radar system (OÄM 42-119 or OÄM 42-273) is
installed, a special GFRP radar nose cone is installed. The radar nose cone is coated with a
special paint. You must replace the radar nose cone if the surface condition affects the weather
radar system’s image quality.
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Zone 1
Zone 1a
Zone 2
Zone 3
Zone 4
Figure 1: Paint Color Scheme S/N below 42.N300/42.MN100
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(2) For S/N 42.N300/42.MN100 and above:
Refer to Figures 2, 3 and Table 2 for further information on the paint color scheme.
) Zone 1. Colors coded A*** according to Table 2 have to be used on:
• the upper shell of the outer wings, from the engine nacelle to 1000 mm (40 in) outboard,
• 50 mm (2 in) radial distance from hinges on the upper shells of the aileron, the elevator,
the elevator trim tab and the outer flaps.
) Zone 2. This zone can either be painted with:
• colors coded A*** according to Table 2 or
• a combination of colors in patterns (e.g. stripes, squares, lines) with a maximum solar
absorptivity of 0.54 averaged over any 125 mm x 125 mm (5 in x 5 in) square. Examples
which meet this criterion are:
• Registration markings, warning markings, trim or striping of any shape, provided that
colors with a solar absorptivity not exceeding 0.54 are used.
• A stripe of any color on a white background (solar absorptivity 0.3) results in a

maximum width of the stripe of 50 mm (2 in) within the 125 mm x 125 mm (5 in x 5 in)
square.
) Zone 3. Color paint finish of any color may be applied in this zone.
) Zone 4. If the weather radar is installed, the radome has to be painted with colors coded N***
according to Table 2. Otherwise color paint finish of any color may be applied in this
zone.
For DA 42 M-NG external stores other than under fuselage the limitations of Zone 2 apply.
For DA 42 M-NG external stores under fuselage the limitations of Zone 3 apply.
Any color refers to any PU-based color. For suppliers other than MIPA, compatibility with the basis
paint layers must be verified.
The definition of the separation line between Zone 2 and 3 is shown in Figure 3 .
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Zone 3
Zone 4
Figure 2: Paint Color Scheme S/N 42.N300/42.MN100 and above, Part I
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Figure 3: Paint Color Scheme S/N 42.N300/42.MN100 and above, Part II
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Table 2: APPROVED BASE COAT COLORS

Base Coat Color Base Coat Color Number
CODE Supplier CODE Supplier
Number (Airplane) (Nose, Metal Free Colors)
A000 White PU-based color MIPA* N000 Use only approved white See
with a solar coating paints according to Section
absorptivity not Section 51-30-00, H(4)(a). 51-30
exceeding 0.3.
Examples: RAL 9016,
Mercedes D B 147,
BMW 218, Volvo
XG28, Volvo BC76,
Saab 5AC6, Alfa
Romeo 230.
A001 BC A-71061 RUMPF MIPA N001 BC A-71072 RADARNASE MIPA
SILBER MET SILBER PEARL
TOY-199 TOY-199
ANTHRAZIT ANTHRAZIT PEARL
TOY-1E5 TOY-1E5
A003 BC A-3819 MIPA N003 BC A-3819 MIPA
RADARNASE ROT RADARNASE ROT
PEARL TOY-3L6 PEARL TOY-3L6
BLAU MET BLAU MET
FEU-MLTC FEU-MLTC
GOLD MET GOLD MET
BMW-301 BMW-301
A006 BC A-50478 RUMPF MIPA N006 NOT AVAILABLE MIPA
BLAUGRÜN MET
BMW-288
A007 BC A-50474 MIPA N007 BC A-50474 MIPA
PANTONE 281c PANTONE 281c
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% A008 TSR-2655 MIPA N008 TSR-2655 MIPA
% LIGHT SUNSET LIGHT SUNSET
% ORANGE ORANGE
% DARK SUNSET DARK SUNSET
% ORANGE ORANGE
% FLAMENCO RED FLAMENCO RED
% SAN MARINO BLUE SAN MARINO BLUE
% A012 TSR-71229 AIR MIPA N012 TSR-71229 AIR MIPA
% SUPERIORITY GREY SUPERIORITY GREY
% GLOSS LEVEL MT GLOSS LEVEL MT
% A013 TSR-71229 AIR MIPA N013 TSR-71229 AIR MIPA
% SUPERIORITY GREY SUPERIORITY GREY
% GLOSS LEVEL SM GLOSS LEVEL SM
% LIGHT BLUE LIGHT BLUE
% AURORA GOLD AURORA GOLD
% A016 BC A-71062 RUMPF MIPA N016 BC A-71071 RADARNASE MIPA
% ANTHRAZIT ANTHRAZIT
% TOY-1E5 TOY-1E5
% GLOSS LEVEL MIT GLOSS LEVEL MT
% A017 A-90641 MIPA N017 A-90641 MIPA
% CREME WHITE CREME WHITE
% PEARL** PEARL**
* For Suppliers other than MIPA, compatibility with the basis paint layers must be verified.
% ** This base coat includes a base coat and subsequent effect coat. For application obey manufacture’s
% instructions.
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% Following clear coats have to be used:
% ) for gloss level MT: MIPA 2K-HS-Klarlack matt
% ) for gloss level SM: MIPA 8010-12-349-6040 (stumpfmatt)
% ) for all other base coats: MIPA 2K-MS-Klarlack C 75
B. Painting a Large Repair Area
This procedure must be followed when the diameter of the area which must be painted is larger
than 200 mm (8 in).
(1) Carefully scarf the edges of the existing paint Refer to Figure 4. Do not sand through
finish. the existing antistatic filler.
Minimum scarf length: 25 mm (1 in).

To ensure the at the antistatic filler of
the existing paint is electrically
connected to the antistatic filler of the
new paint.
WARNING: DO NOT GET ACETONE, FILLER, OR PAINT ON YOUR SKIN.

ACETONE, FILLER, AND PAINT CAN CAUSE SKIN DISEASE.
WARNING: DO NOT BREATHE ACETONE, FILLER, OR PAINT FUMES.

ACETONE, FILLER, AND PAINT FUMES CAN CAUSE DISEASE.
CAUTION: THERE MUST BE NO GREASE OR DUST ON THE REPAIR AREA.

GREASE AND DUST PREVENT A GOOD BOND.
(2) Make sure that the area to be repaired is clean If necessary, use acetone and re-sand
and free from any contaminants. the area.
(3) Apply HS filler to the repair area. Obey the filler manufacturer's
instructions.
(4) Allow the HS filler to cure. 2 hours at 45 °C (113 °F).
(5) Lightly sand the HS filler with 320 grit sanding

paper.
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(7) Apply two layers of anti-static spray filler to the Obey the filler manufacturer's
repair area. instructions.
(8) Allow the anti-static filler to dry. At 60 °C (140 °F).
(9) Carefully sand the HS filler with 320 grit sanding Remove as little antistatic filler as
paper. possible. Do not sand through the
edges.
(11) Apply the paint coat. Obey the paint manufacturer's

instructions.
(12) Allow the paint coat to dry. 90 minutes at 45 °C (113 °F), then 2
days at 20 °C (68 °F).
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> 200mm (8,0in)
Scarfing 25mm ± 5mm

(1in ± 0.2in) Anti-static Filler
Repair Area
Scarfing 25mm ± 5mm

(1in ± 0.2in)
Coating Paint
Anti-static Filler
Figure 4: Scarfing the Paint Coat
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C. Painting a Small Repair Area
This procedure must be followed when the diameter of the area which you will paint is 200 mm
(8 in) or less.
WARNING: DO NOT GET ACETONE, FILLER, OR PAINT ON YOUR SKIN.

ACETONE, FILLER, AND PAINT CAN CAUSE SKIN DISEASE.
WARNING: DO NOT BREATHE ACETONE, FILLER, OR PAINT FUMES.

ACETONE, FILLER, AND PAINT FUMES CAN CAUSE DISEASE.

(2) Apply 2 layers of HS filler to the repair area. Obey the filler manufacturer's
instructions.
(3) Allow the HS filler to cure. 2 hours at 45 °C (113 °F).
(4) Lightly sand the HS filler with 320 grit sanding

paper.
(6) Apply the paint coat. Obey the paint manufacturer's

instructions.
(7) Allow the paint coat to dry. 90 minutes at 45 °C (113 °F), then
2 days at 20 °C (68 °F).
D. Coated Safety Walk Repair (OÄM 42-187 carried out)
(1) Equipment
Safety walk substrate sprinkler. 1 DAI-9011-20-03_LV.
Plastic spattle. 1 Commercial.
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(2) Material
Safety walk cover LH. 1 D60-1120-20-01_LV.
Safety walk cover RH. 1 D60-1120-20-02_LV.
Fill-in 2 K 400 ml RAL 7038. 3 22101980.
Safety walk substrate. 0.5 kg DAI-9011-20-03.
(3) Repair Procedure
WARNING: WHEN HANDLING CHEMICALS ALWAYS OBSERVE HEALTH AND

SAFETY REGULATIONS GIVEN BY THE MANUFACTURER OF THE
CHEMICALS.
(1) Clean the entire area between fuselage and Refer to Section 12-30.
nacelle. Use water to remove dirt from the
surface. If necessary, add a mild cleaning
agent.
(2) Use a commercial solvent to remove grease

from the surface. The surface must be
totally clean from grease or dirt.
(3) Place the safety walk cover on the center Refer to Figure 5.
wing and mark the position with a pencil on
the middle wing surface.
(4) Make sure that the safety walk cover

orientation is parallel to flight direction.
(5) Remove the protective layer from the safety

walk cover.
(6) Place the safety walk cover corresponding

to the marks on center wing (don’t use soap
water) and remove the transfer foil
smoothly.
(7) Remove air bubbles from the edges of the

cutouts with a plastic spattle.
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(8) Prepare the surface at the cutouts of the

safety walk cover:
S Carefully roughen the paint with

sandpaper (grit 320), for the ends of
strips use red Scotch-Brite.
(9) Clean the surface at the safety walk cutouts

with a vacuum cleaner and silicon remover.
(10) Cover the airplane’s surface around the

safety walk cover.
(11) Prepare lacquer P/N 22101980 in acc. with

the technical information sheet.
Shake 2 minutes before and after operating

the red button.
Press red button with the ball of your hand

until stop is reached.
(12) Spray a thick film at the cutouts of the safety

walk cover.
(13) Use safety walk substrate sprinkler to apply

safety walk substrate evenly over cutouts.
(14) Apply a second layer of lacquer:
S Make sure the whole substrate is evenly

covered with a sufficient amount of
paint.
(15) Carefully pull off the safety walk cover

starting from one edge. Remove the cover in
direction of the strips within 15 minutes.
(16) Let the system dry for 12h in a dry and

weather protected area at temperatures
from 20 to 30°C (68 to 86 °F).
(17) Remove the cover from the airplane surface.
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Place front edge of Place rear edge of

Safety Walk Cover Safety Walk Cover
100mm away from 175mm away from
fuselage wall fuselage wall
Place Safety
Walk Cover
to trailing edge
Figure 5: Safety Walk Cover Positioning
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9. Repairs
A. Class 4 Repairs
The repair of minor scratches, abrasions or similar damage which is not a crack or a puncture in
the skin.
WARNING: DO NOT GET ACETONE, FILLER OR PAINT ON YOUR SKIN.

ACETONE, FILLER AND PAINT CAN CAUSE SKIN DISEASE.
WARNING: DO NOT BREATHE ACETONE, FILLER OR PAINT FUMES.

ACETONE, FILLER AND PAINT FUMES CAN CAUSE DISEASE.
(1) Sand the repair area with 150 grit sanding paper.
(2) Make sure that the area to be repaired is clean If necessary, use acetone.
and free from any contaminants.
(3) Apply putty to the repair area to fill any damage. Obey the putty manufacturer's
instructions.
Fill to the original contour of the

structure.
(4) Allow the putty to cure. 5 to 20 minutes.
(5) Lightly sand the putty with 150 grit sanding paper.
(6) Apply filler(s) and paint coat. Refer to Paragraph 8.
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AIRCRAFT
B. Class 3 Repairs
Small holes or cracks in the outer skin where there is no internal damage to the component, the
sandwich material, or the inner skin.
Refer to Figure 6 for an example of a typical Class 3 repair scheme.
(1) Make sure that the area around the damage is

clean.
(2) Carefully examine the area around the damage. Do a coin tap test to find the extent of
Look specially for disbonding between the inner any disbonding or delamination.
laminate layers and any core material.
(3) Remove damaged/loose laminate until the edges Refer to Figure 6.

of the laminates are bonded together and to any
Use a sharp knife or grinding disk.
core material.
(4) Scarf the edges of the repair area with a grinding Scarf glass cloth at 50:1 (50x cloth
disk or block. thickness) minimum and carbon cloth at
100:1 (100x cloth thickness) minimum.
(5) Count the layers of fabric that you will need to Refer to the lay-up drawing for the
replace. related structure for data about the cloth
type and orientation.



(6) Clean the area of the repair. If you use acetone to remove any
grease or dirt then you must lightly
re-sand the repair area.
51-20-00
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Standard
DA 42 NG AMM
Laminate
Foam Core
Laminate
Remove Damaged /Loose Laminate
Scarf
Scarf the Edges of the Repair Area
New Laminate
Repair the Laminate
New Laminate
Contour the Laminate
Figure 6: Typical Class 3 Repair
51-20-00
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AIRCRAFT
DISEASE.

DISEASE.
(7) Repair the laminate. Use one of the 2 methods given in

Paragraph 5, step 7.
(8) Pre-cure the repair. Refer to Paragraph 7.
(9) Post-cure the repair. Refer to Paragraph 7.
(10) When the repair is fully post cured, remove the

peel ply and sand smooth the surface of the
repair.
(11) Contour the repair so that the final surface level Use 150 grit sanding paper.
of the repair is slightly lower than the original
To allow for the paint coat.
surrounding area.
(12) Apply filler(s) and paint coat. Refer to Paragraph 8.
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Standard
DA 42 NG AMM
Laminate
Foam Core
Laminate
Remove Damaged/Loose Laminate
Scarf Scarf
20 mm 20 mm
Remove Damaged Foam Core and Scarf Laminate
Foam Insert
Laminate
Insert the Laminate and Foam Core Into the Repair with Bonding Paste
Foam Insert
Laminate
Profile the Foam Core Insert
Laminate
Repair the Laminate

Laminate
Contour the Laminate
Figure 7: Typical Class 2 Repair
51-20-00
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AIRCRAFT
C. Class 2 Repairs
Holes and cracks passing through both skins of a sandwich construction component. The core
damage must be able to be covered by a 75 mm (3 in) diameter circle.
Refer to Figure 7 for an example of a typical Class 2 repair scheme.
(1) Make sure that the area around the damage is

clean.
(2) Carefully examine the area around the damage. Do a coin tap test to find the extent of
Look specially for disbonding between the inner any disbonding or delamination.
laminate layers and any core material.
(3) Remove damaged/loose laminate until the Refer to Figure 7.

edges of the laminates are bonded together and
Use a sharp knife or grinding disk.
to any core material.
(4) Remove the damaged foam core. Remove sufficient foam core to give a
minimum of 20 mm (0.8 in) edge around
the outside of the damaged area. Refer
to Figure 7.
(5) Scarf the edges of the external laminate repair Scarf glass cloth at 40:1 (40x cloth
area with a grinding disk or block. thickness) minimum and carbon cloth at
60:1 (60x cloth thickness) minimum.



(6) Clean the area of the repair. Use acetone only if any grease or dirt
comes to the surface of the repair.
(7) Cut and shape a piece of foam core to replace Use a sharp knife to cut the foam.
the damaged foam core that you removed in
step 4.
51-20-00
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DA 42 NG AMM
(8) Prepare the layers of cloth that you will need to Refer to the lay-up drawing for the
laminate on the inner surface of the foam core. related structure for data about the cloth
type and orientation.
DISEASE.

DISEASE.
(9) Prepare the foam core for inserting in the repair:
S Apply a thin coat of resin to the foam core.
S Apply a coat of thickened resin to the foam Refer to Paragraph 6.

core.
S Laminate the inner layers of cloth onto the Use one of the 2 methods given in
inner surface of the foam core. Make sure Paragraph 5.
that the fibers of the cloth point in the correct
direction.
(10) Apply a thin coat of resin to the area to be

repaired.
(11) Put the foam core and inner laminate into

position in the repair.
(12) Pre-cure the repair. Refer to Paragraph 7.
(13) Use a sanding disk or block to contour the foam Refer to Figure 7.
core of the repair.
(14) Clean the repair.
(15) Apply a coat of thickened resin to the foam core

of the repair.
(16) Apply a thin coat of resin to the scarfed edges of

the outer laminate of the repair.
(17) Repair the outer laminate. Use one of the 2 methods given in
Paragraph 5.
(18) Pre cure the repair. Refer to Paragraph 7.
51-20-00
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AIRCRAFT
(19) Post cure the repair. Refer to Paragraph 7.
(20) When the repair is fully post cured, remove any

peel ply and sand smooth the surface of the
repair.
(21) Contour the repair so that the final surface level Use 150 grit sanding paper.
of the repair is lower than the original To allow for the paint coat.
surrounding area.
51-20-00
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DA 42 NG AMM
Section 51-30
Materials
1. General
You must only use approved materials from approved sources to repair the DA 42 NG airplane.
2. Approved Materials
A. Resin Systems
(1) L285
Resin : L285
Hardener : H286
Mixture : 100 parts resin and 40 ± 2 parts of hardener (by weight)
Supplier : Hexion Specialty Chemicals Stuttgart GmbH

Am Ostkai 21/22
D-70327 Stuttgart, Germany
Phone: +49-711-389800-0
Fax: +49-711-389800-11
(2) RIM 935
Resin : RIM 935

Hardener : RIMH937
Supplier : Hexion Specialty Chemicals Stuttgart GmbH

Am Ostkai 21/22
D-70327 Stuttgart, Germany
Phone: +49-711-389800-0
Fax: +49-711-389800-11
51-30-00
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AIRCRAFT
B. Self- Extinguishing Resin System
CAUTION: THE SELF-EXTINGUISHING RESIN SYSTEM MAY ONLY BE USED

FOR THE REPAIR OF ENGINE COWLINGS WHICH WERE MADE WITH
THAT RESIN SYSTEM (OÄM 42-061).
Resin : L940
Hardener : H286
Supplier : Hexion (see above)
C. Glass Fiber Cloth
(1) L285
WLB No. Weave Weight per Interglas Type Porcher Type

unit area
(German
[g/m²]
Aviation
Standard)
8.4548.60 2/2 twill 163 92110 917
8.4551.60 2/2 twill 280 92125 3063
8.4554.60 2/2 twill 390 92140 1989
8.4520.60 UD 220 92145
8.4525.60 UD 425 92146
All cloth types consist of alkali free E-glass with I 550 or PT 55 finish and comply with LN9169
(German Aviation Standard).
51-30-00
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Standard
DA 42 NG AMM
(2) RIM 935
WLB No. Weave Weight per Interglas Type Porcher Type

unit area
(German
[g/m²]
Aviation
Standard)
8.4548.60 2/2 twill 163 917
8.4551.60 2/2 twill 280 3063
8.4554.60 2/2 twill 390 1989
8.4520.60 UD 220 92145
8.4525.60 UD 425 92146
Plain 49 2037
All cloth types consist of alkali free E-glass with K 506 or FK 144 finish and comply with LN9169
(German Aviation Standard).
Supplier for Interglas cloth : Interglas

P-D Interglas Technologies GmbH
Benzstraße 14
D-89155 Erbach, Germany
Phone: +49(0)-7305955-0
Fax: +49(0)-7305955-513
Supplier for Porcher cloth : Porcher Industrietextilien GmbH

Holzgraben 13/15
D-52062 Aachen, Germany
Phone: +49-241-48225
Fax: +49-241-48229
51-30-00
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Rev. 5 22 Dec 2021
Standard
AIRCRAFT
D. Carbon Fiber Cloth
(1) L285
WLB No. Weave Mass per Interglas ECC Type SGL Type
unit area Type
(German
[g/m²]
Aviation
Standard)
8.3520.80 2/2 twill 200 98141 CCC 452
2/2 twill
with 220 CCC 459 Al

aluminum
fibers
Sigratex
UD tape 380
KDU 1034
(2) RIM 935
WLB No. Weave Mass per ECC Type SGL Type J.H. vom
unit area Baur Type
(German
[g/m²]
Aviation
Standard)
2/2 twill 200 CCC 452
2/2 twill
with 220 CCC 459 Al

aluminum
fibers
Sigratex
UD tape 380 16563
KDU 1034
UD cloth 280 CCC 796
plain 80 CCC 461
51-30-00
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22 Dec 2021 Rev. 5
Standard
DA 42 NG AMM
The cloth complies with LN9169 (German Aviation Standard).
Supplier for Interglas cloth : Rudolf Usner GmbH (Refer to Paragraph 2(C))
Supplier for Cramer cloth : ECC GmbH + CoKG

Weberstrasse 21
D-48619 Heek-Nienborg, Germany
Phone: +49-2568-3883-34
Fax: +49-2568-3883-97
Supplier for Vom Baur : J.H. vom Baur Sohn GmbH & CoKG
Marktstraße 34
D-42369 Wuppertal, Germany
Phone: +49(0)-20224661-0
Fax: +49(0)-2024660033
Supplier for SGL tape : SGL Technik GmbH

Werner von Siemens-Str. 8
D-86405 Meitingen, Germany
Phone: +49-8271-832152
Fax: +49-8271-831427
E. Peel Ply
Type : PA20-63, compliant with LN98690
Supplier : Strübel Vertriebs GbR

Herrlingerstr. 36/1
D-89081 Ulm, Germany
Phone: +49-731-388577-1, -2
Fax: +49-731-39387353
51-30-00
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Standard
AIRCRAFT
F. Sandwich Core Material
Type : Airex C71.55
Manufacturer : AIREX AG
Supplier : Polychem HandelsgesmbH

Markt Allhau Nr. 463
A-7411 Markt Allhau, Austria
Phone: +43-3356-20444
Fax: +43-3356-20445
E-Mail: chemie@polychem.at
G. Fillers for Resin
Type : Cotton flakes FB1/035
Supplier : Rudolf Usner GmbH (see above)
Type : Silcell 300
Supplier : Joh. Klinglhuber & Söhne Handelsgesellschaft mbH

Wallgasse 21
A-1060 Vienna, Austria
Phone: +43-1-5974712-0
Fax: +43-1-5974712-16
Type : Aerosil 380
Supplier : Polychem HandelsgesmbH

Markt Allhau Nr. 463
A-7411 Markt Allhau, Austria
Phone: +43-3356-20444
Fax: +43-3356-20445
E-Mail: chemie@polychem.at
51-30-00
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DA 42 NG AMM
H. Exterior Painting Materials
(1) Putty
Type : Sikkens Polysoft
Manufacturer : Akzo Nobel
Supplier : Akzo Nobel Coatings GesmbH

Baudißg.10
A-1110 Vienna, Austria
Phone: +43-1-7674488
Fax: +43-1-7674488-33
Type : ICI P551-1052
Manufacturer : ICI Paints, Berkshire, Great Britain
Supplier : ICI Autocolor der PPG Austria Handels GmbH

Siezenheimerstrasse 31
A-5020 Salzburg, Austria
Phone: +43-1-662-420425-0
Fax: +43-1-662-435640
(2) EP Filler
Type : ICI P580-2100
Supplier : ICI Autocolor (see above)
Type : MIPA EP 103-20, gelb lasierend
Manufacturer : MIPA Professional Coating System AG
Supplier : MIPA Professional Coating System AG

Am Oberen Moos 1
D-84051 Essenbach, Germany
51-30-00
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AIRCRAFT
(3) Anti-Static Filler
Type : Streicolor 2K PU ESD-Leitlack, matt
Manufacturer : Streicolor AG
Supplier : Streicolor AG
Niederwil
CH-8502 Frauenfeld, Switzerland
Phone: +41–52-7232150
Fax: +41-52-7232169
Type : MIPA PU 191-20-1001 ESD Füller
Supplier : MIPA Professional Coating System AG (see above)
(4) Coating Paint
(a) White
Type : PPG Turbo Plus 493; Color 6-KVW (white)
Manufacturer : PPG Deutschland
Supplier : Nexa Autocolor der PPG Austria Handels GmbH

Siezenheimerstrasse31
A-5020 Salzburg, Austria
Phone: +43-662-420425-0
Fax: +43-662-435640
Type : MIPA PUR HS
Type : Dupont Imron AF400
Manufacturer : E.I. DUPONT DE NEMOURS & CO
Supplier : E.I. DUPONT DE NEMOURS & CO

WILMINGTON, DE 19898
USA
51-30-00
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Standard
DA 42 NG AMM
Type : Dupont Imron 5000
Manufacturer : E.I. DUPONT DE NEMOURS & CO
Supplier : E.I. DUPONT DE NEMOURS & CO (see above)
Type : BASF UNO
Manufacturer : BASF
Supplier : BASF CANADA INC.

10 Craig Street
Brantfort, Ontario
Canada
(b) Other Colors
Type : Refer to Section 51-20
51-30-00
Doc # 7.02.15 Page 9
Rev. 5 22 Dec 2021
Standard
AIRCRAFT
I. Interior Painting Materials
(1) Putty
Type : Sikkens Polysoft
Manufacturer : Akzo Nobel
Supplier : Akzo Nobel Coatings GesmbH (see above)
Type : ICI P551-1052.
Supplier : ICI Autocolor der PPG Austria Handels GmbH (see above)
(2) Coating Paint
Glare shield : Nuvovern DS 10/1 + Nuvovern ACR
Inst. Panel cover : Nuvovern DS 10/1 + Nuvovern ACR
General : Nuvovern DS 10/1
Manufacturer : Mäder Lacke AG, Killwangen, Switzerland
Supplier : Walter Mäder GmbH

Wiener Str.99
A-2514 Traiskirchen, Austria
Phone: +43-2252-53038
Fax: +43-2252-52297
51-30-00
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DA 42 NG AMM
J. Fire Retardant Paint
(1) PPG Aerospace
Fire retardant paint : Wiedoflugat N 56582/T508 (white)
Finishing varnish : PU 2K- Klarlack 423511-2-035
Hardener : PU-Härter FN39-1327
Supplier : PRC-DeSoto Deutschland GmbH

PPG Aerospace
Hein-Saß- Weg 29
D-21129 Hamburg, Germany
Phone: +49-40-742193-10
Fax: +49-40-742139-69
(2) Hensel
Fire retardant paint : Hensotherm 2 KS (white)
Coating paint : Hensotop 84f
Supplier : Rudolf Hensel GmbH

Lack- und Farbenfabrik
Lauenburger Landstrasse 11
D-21039 Börnsen, Germany
Phone: +49-40-72106210
Fax: +49-40-72106252
K. Acrylic Glass Cement
Acrylic glass cement : Polymerization Cement Acrifix 92
Manufacturer : Röhm
D-64275 Darmstadt, Germany
Phone: +49-6151-1801
Fax: +49-6151-1802
Supplier : Röhm Austria GmbH & Co. KG

Lamezanstrasse 17
1239 Wien, Austria
Phone: +43-1616-7510-0
Fax: +43-1616-7510-33
51-30-00
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AIRCRAFT
51-30-00
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Standard
DA 42 NG AMM
Section 51-40
Fasteners
1. General
This Section tells you about the fasteners used to attach panels and cowlings on the DA 42 NG
airplane.
2. Description
The DA 42 NG uses two main types of fasteners. It has quick release camloc fasteners for panels
which you remove often, for example, engine cowlings, and it has screws for all other access panels.
Figure 1 shows the quick release camloc fastener. The fastener has three parts, a receptacle with a
cam track, a grommet and a stud. Rivets attach the receptacle to the structure or base panel. A spring
ring attaches the stud assembly to the access panel and a compression spring holds the stud in the
stud assembly.
The T shaped end of the stud locates in the slot of the receptacle. When you turn the stud clockwise
through 90° it engages the cam-track in the receptacle and pulls the access panel into position. When
the stud is turned fully 90° clockwise the T-shaped end of the stud engages in a small indent in the
cam-track. The compression spring in the stud assembly holds the stud in position in the detent.
There are different length studs. Short studs for thin panels and longer studs for thicker panels. Not
all airplane serial numbers have the same length studs in the same positions. This is because
composite structures and components can vary in thickness. If you must replace a fastener, make sure
that the new fastener that you install has the correct length stud. You can replace a stud in a stud
assembly.
51-40-00
Doc # 7.02.15 Page 1
Rev. 5 22 Dec 2021
Standard
AIRCRAFT
Receptacle
Spring Ring Access Panel
Rivet
Grommet
Stud
Figure 1: Quick Release Fastener Assembly
51-40-00
Page 2 Doc # 7.02.15
22 Dec 2021 Rev. 5
Standard
DA 42 NG AMM
1. General
This Section tells you how to replace a quick release fastener stud in an access panel.
2. Replace a Quick Release Fastener Stud
A. Equipment
Stud pliers. 1 Camloc 4 P 3.
B. Procedure
(1) Remove the damaged stud assembly: If installed.
S Turn the stud 90° counter clockwise to

release it from the receptacle.
S Move the U-jaw of the stud pliers into Refer to Figure 1.

position under the rim of the stud assembly.
S Compress the stud assembly with the stud Turn the stud assembly approximately
pliers and remove the stud assembly from 30° off-axis.
the grommet.
(2) Install the new stud assembly:
S Select the correct length stud assembly.
S Put the stud assembly into the U jaw of the

stud pliers.
S Compress the stud assembly and move the Turn the stud assembly approximately
stud assembly into position in the grommet 30° off-axis.
and then release the stud assembly.
S Engage the stud in the receptacle and turn Make sure that the panel is pulled fully
the stud 90° clockwise to lock the stud. into position and that the stud is in the
detent of the receptacle.
51-40-00
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AIRCRAFT
51-40-00
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DA 42 NG AMM
Section 51-60
Control Surface Balancing
1. General
% This Section tells you how to weigh and measure the residual moment of the control surfaces. Figure 1
% thru 8 show typical Weights and Residual Moments Reports for the DA 42 NG airplane.
WARNING: YOU MUST WEIGH AND CHECK THE BALANCE OF A CONTROL

SURFACE AFTER ANY WORK WHICH COULD AFFECT ITS WEIGHT
OR ITS BALANCE. AN OUT OF BALANCE CONTROL SURFACE CAN
FLUTTER AND CAUSE STRUCTURAL FAILURE.
Correct control surface balance is critical to flight safety. You must remove a control surface to weigh
it and check its balance after:
) Any repair to the control surface.
) Painting the control surface.
) Any report of control vibration or flutter in flight.
You can use any convenient method to weigh a control surface. If you use anything to connect the
control surface to the weighing device then you must weigh the device, (for example, a sling)
separately and deduct its weight from the total value. For example, you use a rope sling to weigh an
aileron with a spring balance:
) Weight of aileron and the rope sling = 3.8 kg (8.378 lb).
) Weight of rope sling = 0.7 kg (1.543 lb).
) Weight of aileron = (3.8 kg - 0.7 kg) = 3.1 kg (6.835 lb).
When you do a test for the correct balance of a control surface, the pivot angle of the control must be
as shown in the Weights and Residual Moments Report.
We recommend that for balancing the flaps, aileron, elevator and elevator trim tab, you put a suitable
size rod through the hinge bearings. Support the rod at two points to keep it horizontal.
To balance the rudder it must be supported at the top pivot pin and the bottom mounting bracket. The
center line of the rudder must be horizontal.
51-60-00
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Standard
AIRCRAFT
DA 42 NG Elevator Trim
Rudder Rudder Trim Elevator
SN: Tab
mass balance
Weight incl.
Limits [kp] 6.6 to 8.25 0.28 to 0.39 5.3 to 6.35 0.28 to 0.39
Actual [kp]
Upper Rudder Horn Centre:
Mass Balance [kg] Push Rod:

Lower Rudder Horn
L: R:
P [kp]
r [cm]
Static Moment
Limits [kp cm] 23.0 to 33.1 1.3 to 2.15 1.0 to 7.6 1.0 to 1.5
Actual [kp cm]
Center-line horizontal Center-line horizontal

M = P*r
P in [kp]
r in [cm] P r P P
r P
r Typ: 13cm r
Typ: 52.4cm Typ: 31cm Typ: 10cm
Rudder trim tab and push rod Elevator trim tab and push rod
Figure 1: Typical Weights and Residual Moments Report DA 42 NG Airplane

(if MÄM 42-600 is NOT installed) - Sheet 1 (Metric Dimensions)
51-60-00
Page 2 Doc # 7.02.15
22 Dec 2021 Rev. 5
Standard
DA 42 NG AMM
SN: Tab
mass balance
Weight incl.
Actual [kp]
Mass Balance [kg] Push Rod:

Lower Rudder Horn
L: R:
P [kp]
r [cm]
Static Moment
Limits [kp cm] 53.9 to 69.2 1.5 to 2.4 1.0 to 7.6 1.0 to 1.5
Actual [kp cm]

M = P*r
P in [kp]
r in [cm] P r P P
r P
r Typ: 13cm r
Typ: 52.4cm Typ: 31cm Typ: 10cm

(if MÄM 42-600 is installed) - Sheet 1 (Metric Dimensions)
51-60-00
Doc # 7.02.15 Page 3
Rev. 5 22 Dec 2021
Standard
AIRCRAFT
% DA 42 NG Elevator Trim
% Rudder Rudder Trim Elevator
SN: Tab
%
%
%
%
if MÄM 42-1041
mass balance
Weight incl.
% is installed: 6.17 to 7.50 0.41 to 0.51 5.3 to 6.35 0.28 to 0.39

% Limits [kp]
%
Actual [kp]
%
%
%
% Push Rod:
Mass Balance [kg]
% Lower Rudder Horn
% L: R:
%
%
%
P [kp]
%
%
r [cm]
%
%
% Limits [kp cm] 53.9 to 69.2 1.5 to 2.4 1.0 to 7.6 1.0 to 1.5
%
Static Moment
% if MÄM 42-1041
is installed: 53.9 to 75.0 1.3 to 2.0 1.0 to 7.6 1.0 to 1.5
%
Limits [kp cm]
%
% Actual [kp cm]
%
% Center-line horizontal Center-line horizontal
%
M = P*r
% P in [kp]
% r in [cm] P r P P
r P
r Typ: 13cm r
% Typ: 52.4cm Typ: 10cm
Typ: 31cm
% Rudder trim tab and push rod Elevator trim tab and push rod
%

(if MÄM 42-600 and MÄM 42-885 are installed) - Sheet 1 (Metric Dimensions)
51-60-00
Page 4 Doc # 7.02.15
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Standard
DA 42 NG AMM
SN: Tab
mass balance
Weight incl.
Limits [lbf] 14.6 to 18.2 0.62 to 0.86 11.7 to 14.0 0.62 to 0.86
Actual [lbf]
Mass Balance [lb] Push Rod:

Lower Rudder Horn
L: R:
P [lbf]
r [in]
Static Moment
Limits [lbf in] 20.0 to 28.7 1.13 to 1.87 0.87 to 6.60 0.87 to 1.30
Actual [lbf in]

M = P*r
P [lbf]
r [in] P r P P
r P
r Typ: 5.1 in r
Typ: 20.63 in Typ: 12.2 in Typ: 3.94 in

(if MÄM 42-600 is NOT installed) - Sheet 1 (Imperial Dimensions)
51-60-00
Doc # 7.02.15 Page 5
Rev. 5 22 Dec 2021
Standard
AIRCRAFT
SN: Tab
mass balance
Weight incl.
Limits [lbf] 12.4 to 14.4 0.68 to 0.93 11.7 to 14.0 0.62 to 0.86
Actual [lbf]
Mass Balance [lb] Push Rod:

Lower Rudder Horn
L: R:
P [lbf]
r [in]
Static Moment
Actual [lbf in]

M = P*r
P [lbf]
r [in] P r P P
r P
r Typ: 5.1 in r
Typ: 20.63 in Typ: 12.2 in Typ: 3.94 in
Elevator trim tab and push rod Elevator trim tab and push rod

(if MÄM 42-600 is installed) - Sheet 1 (Imperial Dimensions)
51-60-00
Page 6 Doc # 7.02.15
22 Dec 2021 Rev. 5
Standard
DA 42 NG AMM
%
%
SN: Tab
%
%
% Limits [lbf] 13.6 to 15.6 0.90 to 1.24 11.7 to 14.0 0.62 to 0.86
%
if MÄM 42-1041
%
mass balance
is installed:
Weight incl.
13.6 to 16.5 0.90 to 1.12 11.7 to 14.0 0.62 to 0.86

% Limits [lbf]
%
% Actual [lbf]
%
% Upper Rudder Horn Centre:
%
% Mass Balance [lb] Push Rod:
Lower Rudder Horn
%
L: R:
%
%
% P [lbf]
%
%
% r [in]
%
Static Moment
%
%
%
if MÄM 42-1041
% is installed: 46.8 to 65.1 1.13 to 1.73 0.87 to 6.60 0.87 to 1.30
% Limits [lbf in]
%
% Actual [lbf in]
%
% Center-line horizontal Center-line horizontal
% M = P*r
% P [lbf]
r [in] P r P P
% r P
r Typ: 5.1 in r
% Typ: 20.63 in Typ: 12.2 in Typ: 3.94 in
% Elevator trim tab and push rod Elevator trim tab and push rod

(if MÄM 42-600 and MÄM 42-885 are installed) - Sheet 1 (Imperial Dimensions)
51-60-00
Doc # 7.02.15 Page 7
Rev. 5 22 Dec 2021
Standard
AIRCRAFT
%
% DA 42 NG Aileron Outer Flap Inner Flap
% SN: Left Right Left Right Left Right
%
mass balance
Weight incl.
% Limits [kp] 2.28 to 2.77 3.4 to 3.96 2.3 to 2.84

%
%
Actual [kp]
%
%
%
% Mass Balance [kg]
%
%
%
%
P [kp]
%
%
% r [cm]
%
%
Static Moment
% Limits [kp cm] 0 to 2.5 24.5 to 33.1 25.5 to 32.6

%
%
%
Actual [kp cm]
%
Upper surface horizontal Upper surface horizontal Upper surface horizontal
%
% M = P*r
% P in [kp]
r in [cm] P P P
% r r r
% Typ: LH 17cm Typ: 23cm Typ: 30cm
Typ: RH 19cm
%
%
%
Figure 7: Typical Weights and Residual Moments Report
DA 42 NG Airplane - Sheet 2 (Metric Dimensions)
51-60-00
Page 8 Doc # 7.02.15
22 Dec 2021 Rev. 5
Standard
DA 42 NG AMM
%
DA 42 NG Aileron Outer Flap Inner Flap
%
% SN: Left Right Left Right Left Right
%
mass balance
Weight incl.
% Limits [lbf] 5.03 to 6.10 7.50 to 8.73 5.07 to 6.26

%
% Actual [lbf]
%
%
%
% Mass Balance [lb]
%
%
%
% P [lbf]
%
%
% r [in]
%
%
Static Moment
%
Limits [lbf in] 0 to 2.17 21.3 to 28.7 22.1 to 28.3
%
%
Actual [lbf in]
%
%
Upper surface horizontal Upper surface horizontal Upper surface horizontal
%
M = P*r
%
P [lbf]
% r [in] P P P
r r r
%
Typ: LH 6.7 in Typ: 9.1 in Typ: 11.8 in
% Typ: RH 7.5 in
%
%
Figure 8: Typical Weights and Residual Moments Report
DA 42 NG Airplane - Sheet 2 (Imperial Dimensions)
51-60-00
Doc # 7.02.15 Page 9
Rev. 5 22 Dec 2021
Standard
AIRCRAFT
2. Rudder Static Balance
% Refer to Figure 1 to 6 for the weight and residual moment.
Use any suitable method to support the rudder horizontally at the pivot axis. The rudder must be able
to rotate freely around the pivot axis.
Remove the stop bolts from the lower mounting bracket before weighing and balancing.
The residual moment is tail heavy.
Mass Balance
Weights Spring
Balance
Moment Arm
Horizontal
Tape
Pivot Axis Lower Mounting Bracket
Lower Mounting Bracket

Without Stop Bolts.
Top Pivot
Pivot Axis
Moment Arm
% Figure 9: Rudder Static Balance
51-60-00
Page 10 Doc # 7.02.15
22 Dec 2021 Rev. 5
Standard
DA 42 NG AMM
3. Rudder Trim Tab Static Balance
Refer to Figure 1 to 6 for the weight and residual moment.
Use any suitable method to support the trim horizontally at the pivot axis. The trim tab must be able
Spring
Balance
Tape
Horizontal
Pivot Axis
Moment Arm
Pivot Axis
Moment Arm
% Figure 10: Rudder Trim Tab Static Balance
51-60-00
Doc # 7.02.15 Page 11
Rev. 5 22 Dec 2021
Standard
AIRCRAFT
4. Elevator Static Balance
Use any suitable method to support the elevator horizontally at the pivot axis. The elevator must be
able to rotate freely around the pivot axis.
The balance includes the trim tab, trim tab control rods and horn.
Spring Balance
Tape
Horizontal
Pivot Axis
Moment Arm
Balance Weight Balance Weight

Balance Weight Pivot Axis
% Figure 11: Elevator Static Balance
51-60-00
Page 12 Doc # 7.02.15
22 Dec 2021 Rev. 5
Standard
DA 42 NG AMM
5. Elevator Trim Tab Static Balance
Use any suitable method to support the elevator trim tab horizontally at the pivot axis. The elevator trim
tab must be able to rotate freely around the pivot axis.
Spring
Balance
Tape
Horizontal
Pivot Axis
Moment Arm
Pivot Axis
Moment Arm
% Figure 12: Elevator Trim Tab Static Balance
51-60-00
Doc # 7.02.15 Page 13
Rev. 5 22 Dec 2021
Standard
AIRCRAFT
6. Aileron Static Balance
Refer to Figure 7 or 8 for the weight and residual moment.
Use any suitable method to support the aileron horizontally at the pivot axis. The aileron must be able
The balance includes the horn, trim plate and hinges.
Spring
Balance
Tape
Pivot Axis
Horizontal
Mass Balance
Moment Arm
Mass Balance Weight
Pivot Axis
Hinges
Moment Arm
Horn Trim Plate

% Figure 13: Aileron Static Balance
51-60-00
Page 14 Doc # 7.02.15
22 Dec 2021 Rev. 5
Standard
DA 42 NG AMM
7. Wing Outer Flap Static Balance
Use any suitable method to support the outer flap horizontally at the pivot axis. The outer flap must be
The balance includes the horn and hinges.
Spring
Balance
Moment Arm
Horizontal
Pivot Axis
Horn Hinges Pivot Axis
Moment Arm
% Figure 14: Wing Outer Flap Static Balance
51-60-00
Doc # 7.02.15 Page 15
Rev. 5 22 Dec 2021
Standard
AIRCRAFT
8. Wing Inner Flap Static Balance
Use any suitable method to support the inner flap horizontally at the pivot axis. The inner flap must be
The balance includes the horn and hinges.
Spring
Balance
Moment Arm
Horizontal
Pivot Axis
Hinges Horn Pivot Axis
Moment Arm
% Figure 15: Wing Inner Flap Static Balance
51-60-00
Page 16 Doc # 7.02.15
22 Dec 2021 Rev. 5
Standard
DA 42 NG AMM
Section 51-80
1. General
Lightning protection for the DA 42 NG is provided by the airplane bonding system. A special bonding
system is necessary for the composite structure of the DA 42 NG. Without this special system, the
composite structure would not sufficiently conduct electricity.
Refer to Section 23-60 for data about the static discharge wicks.
2. Description
Figure 1 shows the simplified bonding system schematic diagram.
The lightning conductor system is the main part of the bonding system. High capacity aluminum alloy
tubes and strips make the basis of the lightning conductor system.
The lightning conductor system has a longitudinal system and a lateral system. The longitudinal
system runs from the front rib of the fuselage, through both sides and center of the wing center section,
through the left side of the rear fuselage and up into the vertical stabilizer. From the vertical stabilizer
aluminum strips and braids connect to the horizontal stabilizer, the elevator and trim tab.
The lateral system runs from the wing tips, through the front of the wing, across the engine nacelles
and through the center wing section where it connects to the longitudinal system. Aluminum strips and
braids connect the propellers, engines, fuel tanks and other metal components installed along the
wings to the main lateral system.
51-80-00
Doc # 7.02.15 Page 1
Rev. 5 22 Dec 2021
Standard
AIRCRAFT
Fuel Sel. DME

Instrument Ant. Upper RH Step
Panel Console COMM #2 Antenna Vert. Tube
Strip
COMM #1 Antenna
ADF Antenna
Relay Box XPDR LH Step
Mounting Bolts GPS Ants.
Ant. MKR Antenna
Engine
Mounting
Bolts
MLG Lightning
Jumpers Engine Trim System Electrode
Bracket Horizontal
Mount Stabiliser
Main Bracket
Engine Horizontal
Harness Stabiliser
Overbraid
Vert. Tube
Aileron Lever
Pitot Tube
Bracket Rudder
Figure 1: Lightning Protection System Schematic Diagram
51-80-00
Page 2 Doc # 7.02.15
22 Dec 2021 Rev. 5
Standard
DA 42 NG AMM
The following design features also add to the lightning protection system:
) The aluminum tubes of the lightning protection system also provide the conduit system for electrical
cables.
) Carbon fiber material is used for parts of the wing and fuselage skins. Carbon fiber material is
conductive and is used to form part of the lightning protection system.
) Carbon fiber material with interwoven aluminum fibers is used on the upper wing skin, the fuselage
and the engine cowlings. Carbon fiber material with interwoven aluminum fibers is conductive.
) A lightning conductor strip is integrated into the horizontal stabilizer.
) The propeller blades are non-conductive (except for the blade sheaths), therefore currents cannot
flow in structural parts of the propeller. The propeller spinner is made from aluminum and is
connected to electrical ground.
51-80-00
Doc # 7.02.15 Page 3
Rev. 5 22 Dec 2021
Standard
AIRCRAFT
51-80-00
Page 4 Doc # 7.02.15
22 Dec 2021 Rev. 5
Standard
DA 42 NG AMM
1. General
This Section tells you how to do a test of the electrical bonding system.
2. Test the Electrical Bonding System
The resistance measurements on the DA 42 NG are divided into 3 categories:
) Very low ohms measurements for conduits in the direct lightning path and electrical power grounds.
) Low ohms resistance measurements for bonding of controls and canopy.
) High resistance measurements for antistatic precipitation i.e. static wicks.
Do the low resistance bonding measurements with a milliohmmeter and Kelvin probes. The test current
must be approximately 2 amps.
Do the high resistance measurements with a high voltage megaohmmeter. Measure the static
discharge wicks and the precautions against static charge of the airplane.
All measurements are referenced to the negative terminal of the airplane main battery. The airplane
must be serviceable during the tests and the engine cowlings must be removed.
A. Very Low Resistance Measurements
Max Measured
Item Attachment Point Allowable L/R Passed
(mΩ) (mΩ)
ENGINE COMPARTMENTS
Firewall. 6.0 /
Engine mount. 6.0 /
Engine. Propeller bearing, front 6.0 /
Heat exchanger. Case 6.0 /
Oil cooler. Case 6.0 /
Water cooler. Case 6.0 /
Intercooler. Case 6.0 /
Engine breather. Tube 10.0 /
Engine to firewall. Engine block - firewall 3.0 /
2nd Alternator LH (optional) Case 10.0
51-80-00
Doc # 7.02.15 Page 201
Rev. 5 22 Dec 2021
Standard
AIRCRAFT
Max Measured
(mΩ) (mΩ)
NACELLE COMPONENTS
Electrical junction box fwd. Sheet metal 5.0 /
Electrical junction box aft. Sheet metal 10.0 /
Fuel cooler. Mounting screw 10.0 /
Fuel pumps. Mounting bracket 10.0 /
Aux fuel tank (optional). Drain 10.0 /
Aux fuel tank refill (optional). Tube 10.0 /
Nacelle fuel filter. Mounting bracket 10.0 /
FUSELAGE
COMPONENTS
External power connector. Outer large pin 5.0
Instrument panel. Above co-pilot’s left 3.0

knee
Taxi light. Mounting screw 4.0
Landing light. Mounting screw 4.0
Remote avionic box. Case 4.0
Hydraulic module. Sheet metal 4.0
Nose LDG gear door hinge. LH/RH front hinge 10.0 /
Nose baggage door lock. LH/RH front lock 10.0 /
TKS spray bar (optional). Center 5.0
Radar nose cone lightning Mounting screws 8.0

strips (4 pieces, optional).
51-80-00
Page 202 Doc # 7.02.15
22 Dec 2021 Rev. 5
Standard
DA 42 NG AMM
Max Measured
(mΩ) (mΩ)
EXTERNAL CONDUCTIVE
PARTS
LH step. Grounding point 5.0
RH step. Grounding point 5.0
OAT sensor. 10.0
Front LDG gear. Yoke exposure 10.0

mounting screw
Main LDG gear LH. Axle mounting screw 10.0
Main LDG gear RH. Axle mounting screw 10.0
RACC outlet scoop Tube 10.0 /

(optional)
RACC inlet cap (optional) Tube 15.0
ANTENNAS
COM 1 antenna (top). Mounting screws 6.0
COM 2 antenna (bottom). Mounting screws 6.0
ELT antenna. Mounting screws 6.0
Top TAS antenna (optional). Mounting screws 6.0
Bottom TAS antenna Mounting screws 5.0

(optional).
Iridium antenna (optional) Mounting screws 5.0
STABILIZER
Vertical lightning protection Upper end 7.0

tube.
LH horizontal stabilizer Tip 15.0

lightning strap.
RH horizontal stabilizer Tip 15.0

lightning strap.
Rudder hinge. Rudder side 10.0
51-80-00
Doc # 7.02.15 Page 203
Rev. 5 22 Dec 2021
Standard
AIRCRAFT
Max Measured
(mΩ) (mΩ)
Vertical stabilizer fairing. Front left-side 12.0

attachment screw
Vertical stabilizer fairing. Front right-side 12.0

attachment screw
Horizontal stabilizer. Front bracket 10.0
Horizontal stabilizer. Rear bracket 10.0
Horizontal stabilizer TKS LH inner panel section 15.0

panel (optional).
Horizontal stabilizer TKS LH outer panel section 15.0

panel (optional).
Horizontal stabilizer TKS RH inner panel section 15.0

panel (optional).
Horizontal stabilizer TKS RH outer panel section 15.0

panel (optional).
Vertical stabilizer TKS panel Upper panel section 25.0

(optional).
Vertical stabilizer TKS panel Bottom panel section 25.0

(optional).
TKS low pressure switches Mounting plate 20.0

(optional).
LH WING
Fuel tank drain. Drain 5.0
Tank refill. Ring 5.0
Tank vent. Plate 10.0
Pitot tube base. Tube base 6.0
Tip light assembly. Base plate 8.0
Aileron push-rod Bonding strap 50.0

attachment. connection
Outer flaps push-rod Bonding strap 50.0

51-80-00
Page 204 Doc # 7.02.15
22 Dec 2021 Rev. 5
Standard
DA 42 NG AMM
Max Measured
(mΩ) (mΩ)
Inner flap push-rod Bonding strap 50.0

Stall warning switch. Mounting screw 10.0
Inner TKS panel (optional). Inner panel section 15.0
Outer TKS panel (optional). Inner panel section 15.0
Outer TKS panel (optional). Outer panel section 10.0
RH WING
Fuel tank drain. Drain 5.0
Tank refill. Ring 5.0
Tank vent. Plate 10.0
Pitot tube base. Tube base 6.0
Tip light assembly. Base plate 8.0
Aileron push-rod Bonding strap 50.0

Outer flaps push-rod Bonding strap 50.0

Inner flap push-rod Bonding strap 50.0

Inner TKS panel (optional). Inner panel section 15.0
Outer TKS panel (optional). Inner panel section 15.0
Outer TKS panel (optional). Outer panel section 10.0
51-80-00
Doc # 7.02.15 Page 205
Rev. 5 22 Dec 2021
Standard
AIRCRAFT
B. Low Resistance Measurements in Control System
Max Measured
Item Attachment Point Allowable (mΩ) Passed
(mΩ)
Pilot stick. Tube 50.0
Co-pilot stick. Tube 50.0
Trim wheel assembly. Frame 10.0
Levers. Frame 50.0
Pilot pedal assembly. 150.0
Co-pilot pedal assembly. 150.0
Canopy hinge LH. Tube tip 100.0
Canopy hinge RH. Tube tip 100.0
RACC system (optional) Bracket 100.0
C. High Resistance Measurements
Use a wet sponge to get a constant electrical connection to the static dischargers.
Max Measured
Item Attachment Point Allowable (MΩ (500V) Passed
(MΩ) IN/OUT)
STATIC DISCHARGE
WICKS
LH wing tip. 200.0 /
RH wing tip. 200.0 /
Rudder. 200.0
Horizontal stabilizer, LH. 200.0
Horizontal stabilizer, RH. 200.0
TIRES
Nose wheel. 100.0
LH main wheel. 100.0
RH main wheel. 100.0
51-80-00
Page 206 Doc # 7.02.15
22 Dec 2021 Rev. 5
DA 42 NG AMM Doors
AIRCRAFT
CHAPTER 52
DOORS
Doc # 7.02.15 Page 1

Doors DA 42 NG AMM
AIRCRAFT
Page 2
22 Dec 2021 52-TITLE Doc # 7.02.15
Rev. 5
DA 42 NG AMM Doors
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 52
DOORS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 52-10
Canopy and Passenger Door
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Canopy Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Passenger Door Description and Operation ............................. 7
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Canopy Door Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Remove/Install the Gas Spring Strut for the Canopy . . . . . . . . . . . . . . . . . . . . . 205
5. Remove/Install the Passenger Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6. Remove/Install the Passenger Door Locking Mechanism (if MÄM 42-687 is
installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
7. Remove/Install the Gas Spring Strut for the Passenger Door . . . . . . . . . . . . . . 211
8. Test the Canopy and Access Door Warning Lights . . . . . . . . . . . . . . . . . . . . . . 212
9. Examine the Carbon Hinges on the Passenger Door . . . . . . . . . . . . . . . . . . . . . 213
10. Inspection of the Door Locking and Safety Hook Mechanisms . . . . . . . . . . . . . 217
11. Replace a Passenger Door Carbon Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
12. Remove/Install the Passenger Door Handle (if MÄM 42-097 is installed) . . . . . 219
13. Remove/Install the Door Handle Compression Gas Spring (if MÄM 42-097 is
installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
14. Test the Passenger Door Handle Compression Gas Spring (if MÄM 42-097 is
installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
15. Canopy Jettison System (if OÄM 42-194 is installed) . . . . . . . . . . . . . . . . . . . . . 223
Doc # 7.02.15 Page 1

Doors DA 42 NG AMM
AIRCRAFT
Section 52-30
Front Baggage Compartment Doors
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation ...................................................... 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Front Baggage Compartment Door . . . . . . . . . . . . . . . . . . . . . 201
3. Remove, Install and Adjust a Front Baggage Compartment Micro Switch (if MÄM
42-1129 is installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Section 52-40
Access Panels
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Page 2 Doc # 7.02.15

DA 42 NG AMM Doors
AIRCRAFT
CHAPTER 52
DOORS
1. General
The DA 42 NG has three types of doors. Section 52-10 tells you about the canopy and the passenger
access door. Section 52-30 tells you about the front baggage compartment doors and Section 52-40
tells you about the maintenance access panels.
2. Description
The canopy is a CFRP molding with inner and outer frames. The frames bond together. The canopy
has a large one-piece acrylic glass window. The window has direct vision panels on both sides. You
can open the direct vision panels in flight. Refer to Chapter 56 for data about the window.
The canopy attaches to a tubular steel frame at the front. The frame attaches to two hinges on the rear
face of the instrument panel frame. The canopy moves up and forward to open.
A handle on the left of the canopy operates two locking bolts. The handle is red on the inside of the
canopy and red on the outside. The locking bolts are at the bottom rear corners of the canopy.
The passenger door is a CFRP molding with inner and outer frames. The frames bond together. The
door has a acrylic glass window.
Two hinges attach the door to the top of the fuselage near the center-line. A gas strut attaches to the
rear of the door and the fuselage. The gas strut holds the door open.
A handle on the left of the door operates two locking bolts. The handle is black on the inside of the
door and red on the outside. The locking bolts are at the bottom front and rear corners of the door.
The DA 42 NG has a large baggage compartment in the nose of the airplane. An access door on each
side of the airplane gives access to the baggage compartment. The baggage compartment doors have
hinges at the top and locking handles at the bottom. Gas struts hold the doors up when they are in the
open position.
The DA 42 NG has a small number of access panels. Panels which must be used often (for example,
engine cowlings) have quick release fasteners. Other panels have the usual screws.
Doc # 7.02.15 Page 1

Rev. 5 52-00-00 22 Dec 2021
Doors DA 42 NG AMM
AIRCRAFT
Page 2 Doc # 7.02.15

22 Dec 2021 52-00-00 Rev. 5
DA 42 NG AMM Doors
AIRCRAFT
Section 52-10
Canopy and Passenger Door
1. General
This Section tells you about the structure, operation and maintenance of the canopy and the
passenger door. Refer to Chapter 56-00 for data about the windows in the canopy and the passenger
door.
An optional Canopy Jettison System can be installed with OÄM 42-194.
2. Canopy Description and Operation
Figure 1 shows the canopy installation.
The canopy is a CFRP molding with inner and outer frames. The frames bond together with thickened
resin. Each part of the frame has layers of carbon cloth and one layer of glass cloth. Areas of high
stress have extra layers of carbon cloth. Mounting bushes for the handle and locking bolts bond to the
inside of the frame with thickened resin.
The canopy has a large one-piece acrylic glass window. A special flexible adhesive bonds the window
to the canopy frame. A flexible filler seals the small gap between the edge of the window and the
frame.
The window has a direct vision panels on each side. You can open the direct vision panels in flight.
Refer to Chapter 56-00 for data about the window.
The canopy attaches to a tubular steel frame at the front (the hinge frame). The frame attaches to two
hinges on the rear face of the instrument panel frame. A gas spring strut attaches to the hinge frame
and the bottom of the instrument panel frame. The canopy moves up and forward to open. The gas
spring strut holds the canopy open.
The canopy has two tubular brackets on the front edge of the canopy frame. Two bolts attach each
bracket to the canopy frame. You can remove the canopy by removing these bolts.
Doc # 7.02.15 Page 1

Rev. 5 52-10-00 22 Dec 2021
Doors DA 42 NG AMM
AIRCRAFT
Hinge Frame
Firewall
Hinge Frame
Hinges to
Firewall
Gas Spring Pedal assy

Strut
Figure 1: Canopy Installation
Page 2 Doc # 7.02.15

22 Dec 2021 52-10-00 Rev. 5
DA 42 NG AMM Doors
AIRCRAFT
% A. MÄM 42-097 not installed
% Figure 2 shows the canopy locking mechanism.
% A handle on the left of the canopy operates two locking bolts. The handle has a spring assisted
% over-center lock which holds the handle in the closed position. The locking bolts are at the bottom rear
% corners of the canopy.
% The handle has two parts. The inner handle is red and has a black double lever. The outer handle is
% red and attaches to the inner handle with two roll pins. A connecting rod attaches to the rear of the
% double lever. The other end of the connecting rod attaches to the inside of the left canopy locking bolt.
% A teleflex cable attaches to the front of the double lever. The teleflex cable goes inside the front of the
% canopy frame to the right canopy locking bolt. If you pull the canopy handle away from the canopy
% frame, these things happen:
% ) The double lever turns to pull the connecting rod and the teleflex cable.
% ) The connecting rod pulls the left canopy locking bolt forward. The forward movement of the
% locking bolt operates the door unlocked warning micro-switch in the left side fuselage shell.
% ) The teleflex cable pulls the right canopy locking bolt forward.
% The canopy can be pushed up and forward to open.
% With the canopy fully closed, push the canopy handle towards the canopy frame. This engages the
% locking bolts in the fuselage holes. The spring assisted over-center lock holds the handle in the closed
% position. The left canopy locking bolt operates the micro-switch for the DOOR warning caption. When
% the handle is flush with the canopy frame, the canopy is locked. Push up on the rear of the canopy
% frame to make sure that it is locked. A key operated lock can be used to secure the canopy in the
% closed position, when the airplane is parked.
% B. MÄM 42-097 installed
% Figure 2 shows the canopy locking mechanism with MÄM 42-097 installed.
% A handle on the left of the canopy operates two locking bolts. The handle has a spring assisted
% over-center lock which holds the handle in the closed position. The locking bolts are at the bottom rear
% corners of the canopy.
% The handle has two parts. The inner handle is red and has a black double lever. The outer handle is
% red and attaches to the inner handle with a roll pin. A connecting rod attaches to the rear of the double
% lever. The other end of the connecting rod attaches to the inside of the left canopy locking bolt.
% A teleflex cable attaches to the front of the double lever. The teleflex cable goes inside the front of the
% canopy frame to the right canopy locking bolt. It can be removed. If you pull the canopy handle away
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% from the canopy frame, these things happen:
% ) The double lever turns to pull the connecting rod and the teleflex cable.
% ) The connecting rod pulls the left canopy locking bolt forward. The forward movement of the
% locking bolt operates the door unlocked warning microswitch in the left side fuselage shell.
% ) The teleflex cable pulls the right locking bolt forward.
% The teleflex cable pulls the right locking bolt forward.
% With the canopy fully closed, push the canopy handle towards the canopy frame. This engages the
% locking bolts in the fuselage holes. The spring assisted over-center lock holds the handle in the closed
% position. The left canopy locking bolt operates the microswitch for the door unlocked warning light
% (DOOR or DOORS). When the handle is flush with the canopy frame, the canopy is locked. Push up
% on the rear of the canopy frame to make sure that it is locked. A key operated lock can be used to
% secure the canopy in the closed position when the airplane is parked.
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%
%
%
%
%
%
%
%
%
%
%
%
Canopy
% Frame
Locking Bolts
%
%
%
Connecting Rod to
% Teleflex Cable to Left Locking Bolt
Right Locking Bolt
%
%
%
% Canopy
Fuselage
% Handle
Shell
% Locking Clip
% Inner Canopy Handle Connecting
Rod
% Fork
End-Fitting
%
% Canopy PTFE
% Teleflex Frame Block
Cable
%
%
Locking Bolt
% To Right
Locking Bolt PTFE Bush
%
Spring Box Canopy Frame
% Outer Canopy
Handle
%
%
%
% Figure 2: Canopy Locking Mechanism (MÄM 42-097 not installed)
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%
%
%
%
%
%
%
%
Locking Bolt, RH
%
%
% Canopy Frame
Grub Screw
% Blanking Plug
%
%
%
Locking Bolt, LH
%
% Teleflex Cable to Connecting Rod to
Right Locking Bolt Left Locking Bolt
%
%
%
%
Canopy
% Handle
Fuselage
Shell
%
Inner Canopy Handle PTFE
% Fork Connecting
Rod Block
End-Fitting
% Countersunk Screw
with Internal Hex. Head
%
% Canopy Frame
%
Teleflex
% Cable Locking Bolt
Lock Plate
%
PTFE Bush
% To Right
Locking Bolt
% Canopy Frame
% Lock Tab Outer Canopy Handle

Lock Assy
%
% Figure 3: Canopy Locking Mechanism (MÄM 42-097 installed)
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3. Passenger Door Description and Operation
% A. MÄM 42-097 not installed
% Figure 4 shows the passenger door installation and locking mechanism.
% The passenger door is a CFRP molding with inner and outer frames. The frames bond together with
% thickened resin. Each part of the frame has layers of carbon cloth and one layer of glass cloth. Areas
% of high stress have extra layers of carbon cloth. Mounting bushes for the handle and locking bolts bond
% to the inside of the frame with thickened resin.
% The door has a acrylic glass window. A special flexible adhesive bonds the window to the door frame.
% A flexible filler seals the small gap between the edge of the window and the frame.
% Two hinges attach the door to the top of the fuselage near the center-line. The hinges bolt to the door
% frame. The front hinge can be removed from inside of the cabin in an emergency. With the front hinge
% removed, the passenger door can be forced open from the top. A gas strut attaches to a bracket at the
% rear of the door and to the fuselage. The gas strut holds the door open. A door unlocked warning
% caption on the ICS display operates when the door is unlocked.
% A handle on the left of the door operates two locking bolts. The locking bolts are at the bottom front
% and rear corners of the door.
% The handle has two parts. The inner handle is black and has a double lever. The outer handle is red
% and attaches to the inner handle with two roll pins. A long connecting rod attaches to the rear of the
% double lever. The other end of the long connecting rod attaches to the inside of the rear locking bolt.
% A safety lock is fitted to prevent accidental movement of the handle.
% You must lift the safety handle before you can operate the black handle from inside the passenger
% compartment. To operate the red handle from the outside you must push the button next to the red
% handle to lift the inner safety lock.
% A short connecting rod attaches to the front of the double lever. The short connecting rod goes to the
% front locking bolt. If you pull the canopy handle away from the canopy frame, these things happen:
% ) The double lever turns to pull the both of the connecting rods.
% ) The long connecting rod pulls the rear locking bolt forward.
% ) The short connecting bolt pulls the front locking bolt aft. The aft movement of the locking bolt
% operates a micro switch for the warning caption located on the ICS.
% The door can be pushed up and out to open.
% With the door fully closed, push the door handle towards the door frame. This engages the locking
% bolts in the fuselage holes. The forward locking bolt operates the door unlocked micro switch. When
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% the handle is flush with the door frame, the door is locked. Push outwards on the bottom of the door
% frame to make sure that it is locked. A key operated lock can be used to secure the door in the closed
% position when the airplane is parked.
% B. MÄM 42-097 is installed
% Figure 5 shows the passenger door installation and locking mechanism. The passenger door is a
CFRP molding with inner and outer frames. The frames bond together with thickened resin. Each part
of the frame has layers of carbon cloth and one layer of glass cloth. Areas of high stress have extra
layers of carbon cloth. Mounting bushes for the locking bolts bond to the inside of the frame with
thickened resin.
The door has an acrylic glass window. A special flexible adhesive bonds the window to the door frame.
A flexible filler seals the small gap between the edge of the window and the frame.
Two hinges attach the door to the top of the fuselage near the center-line. The hinges bolt to the door
frame. The front hinge can be removed from inside of the cabin in an emergency. With the front hinge
removed, the passenger door can be forced open from the top. A gas strut attaches to a bracket at the
rear of the door and to the fuselage. The gas strut holds the door open. A door unlocked warning
caption on the ICS display operates when the door is unlocked.
A handle on the left of the door operates two locking bolts. The locking bolts are at the bottom front
and rear corners of the door.
The handle has two parts. The inner handle is red and has a double lever. The outer handle is red and
attaches to the inner handle with two roll pins. A long connecting rod attaches to the rear of the double
lever. The other end of the long connecting rod attaches to the inside of the rear locking bolt. A safety
lock is fitted to prevent accidental movement of the handle.
You must lift the safety handle before you can operate the red handle from inside the passenger
compartment. To operate the red handle from the outside you must push the button next to the red
handle to lift the inner safety lock.
A short connecting rod attaches to the front of the double lever. The short connecting rod goes to the
front locking bolt. If you pull the canopy handle away from the canopy frame, these things happen:
) The double lever turns to pull the both of the connecting rods.
) The long connecting rod pulls the rear locking bolt forward.
) The short connecting bolt pulls the front locking bolt aft. The aft movement of the locking bolt
operates a micro switch for the warning caption located on the ICS.
The door can be pushed up and out to open. With the door fully closed, push the door handle towards
the door frame. This engages the locking bolts in the fuselage holes. The forward locking bolt operates
the door unlocked micro switch. When the handle is flush with the door frame, the door is locked. Push
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22 Dec 2021 52-10-00 Rev. 5
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outwards on the bottom of the door frame to make sure that it is locked. A key operated lock can be
used to secure the door in the closed position when the airplane is parked.
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%
%
%
%
%
Gas Spring Strut
% Hinges
%
%
%
%
%
%
%
%
%
Door Safety Lock Rear Locking Bolt
%
% Passenger Door
%
%
% Front Locking Bolt Door Handle
%
%
% Locking Clip Fuselage Shell
Inner Long
% Connecting Rod PTFE Block
Door Handle Fork
% End-Fitting
% Door
% Frame
Short
% Connecting Rod
Locking Bolt
% Rear
% PTFE Bush
% Locking Clip
Door Frame
% Front Fork Outer Door
% Locking Bolt End-Fitting Handle
% PTFE Bush
%
PTFE Block
%
%
% Figure 4: Passengers Door (MÄM 42-097 not installed)
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Hinges
%
%
Gas Spring Strut
%
%
%
% Rear Locking Bolt
%
%
% Passenger Door
%
% Door Handle
% Front Locking Bolt

Child Safety Lock
%
%
Door-Closed Switch
%
Fuselage Shell
% Fork End-Fitting
Inner PTFE Block
% Countersunk Screw
Door Handle
Long Connecting Rod
with Internal Hex. Head
%
% Door Frame
%
% Short Connecting Rod
Locking Bolt
%
PTFE Bush
%
Locking Clip Door Frame
%
%
PTFE Bush Outer Door Handle Lock Plate
Fork End-Fitting
%
% Front Locking Bolt
%
Lock Tab
%
Door-Closed Microswitch Lock Assy
%
%
%
% Figure 5: Passengers Door (MÄM 42-097 is installed)
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Rev. 5 52-10-00 22 Dec 2021
Doors DA 42 NG AMM
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Hinges
Gas Spring Strut
Child Safety Lock
Rear Locking Bolt

Passenger Door
Inner Door
Handle
Rear Connecting Rod
Fork End-Fitting
Front Locking Bolt
Rod Guide Lever
Anti Vibration Spacers Fuselage
Door-Closed Switch Long Connecting Rod Shell
Inner Ball Joint

Countersunk Screw PTFE Block
with Internal Hex. Head Door Handle Fork End-Fitting
Door Frame
Short Connecting Rod

PTFE Bush
Locking Bolt
Locking Clip Door Frame
Fork End-Fitting
Outer Door Handle Lock Plate
Fork End-Fitting
Front Locking Bolt
PTFE Bush Lock Tab

Lock Assy
Door-Closed Microswitch
% Figure 6: Passengers Door (if MÄM 42-687 is installed)
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Trouble-Shooting
1. General
The table below lists the defects you could have with the canopy and passenger door. If you have the
trouble detailed in the Trouble column, read across to the Possible Cause column. Then do the repair
Canopy/door is difficult to Canopy/door frame damaged. Replace the canopy/door.

move.
Canopy/door hinges damaged. Replace the damaged parts.
Gas spring strut defective. Replace the gas spring strut.
Canopy/door handle is difficult Locking bolts damaged. Replace the damaged bolt.
to move.
Handle bushes damaged. Replace the canopy/door.
Canopy handle is difficult to Teleflex cable defective. Replace the teleflex cable.
move.
Incorrect operation of door Canopy/door micro switch Adjust canopy/door micro

warning caption on the ICS incorrectly adjusted. switch.
display.
Canopy/door micro switch Replace defective micro

defective. switch. Do a continuity test of
the wiring. Refer to Chapter 92
Defective wiring.
Red button operating the Poor lubrication. Lubricate.

safety hook mechanism is Refer to Section 12-20.
stuck in pushed position.
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1. General
These Maintenance Practices tell you how to remove and install the canopy and the passenger door.
They also tell you how to adjust and test the locking mechanism.
2. Remove/Install the Canopy
A. Remove the Canopy
% (1) Open the canopy: Refer to Figure 2 or 3.
S Pull the canopy handle away from the

canopy frame.
S Lift the canopy open.
(2) Remove the 2 nuts, 4 washers and 2 bolts on Refer to Figure 1. Note the position of
either side that attach the canopy tubular the bonding wire cable.
brackets to the hinge frame.
Hold the canopy!
(3) Lift the canopy clear of the airplane. 2 persons needed.
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B. Install the Canopy
(1) Move the canopy into position on the airplane. 2 persons needed.
(2) Align the canopy mountings with the canopy

frame and:
S Install the 2 nuts, 4 washers and 2 bolts on Refer to Figure 1.

either side that attach the canopy tubular
brackets to the canopy frame.
S Install the bonding wire cable onto the At the location noted in Paragraph 2.
canopy.
(3) Close the canopy.
(4) Operate the canopy lock:
S Hold the canopy closed.
S Push the canopy handle towards the canopy When the canopy is locked, the canopy
frame. handle must be flush with the canopy
frame.
S Push up on the rear of the canopy frame.
To make sure that the canopy is locked.
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% 3. Remove/Install the Canopy Door Handle (if MÄM 42-097 is installed)
A. Remove the Canopy Door Handle
(1) Remove the canopy. Refer to Paragraph 2.
(2) Put the canopy on a stable surface and secure it Protect the canopy surface.
against movement.
(3) Remove the outside door handle:
S Open the inside door handle for access to

the spring pin.
S Push the spring pin through the inside door Use punch 4 mm (0.16 in).
handle.
S Pull the outside door handle out.
(4) Remove the 4 screws from the inside door

handle.
(5) Pull out the handle and disconnect the front fork
head from the slide axle. Remove the circlip and
move the axle out.
(6) Disconnect the rear fork head from the inside

lever.
(7) Remove the inside door handle from the canopy

shell.
(8) Remove the spring pin from the canopy door

handle.
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B. Install the Canopy Door Handle
(1) Install the inside door handle to the canopy door

shell:
S Pre fit the door handle.
S Connect the rear fork head to the inside

lever.
(2) Connect the front fork head. Install the slide axle
and secure the axle with circlip.
(3) Install the inside handle. Install the 4 screws.
(4) Install the outside door handle:
S Push the outside door handle into the door

shell to the inside door handle.
(5) Install the spring pin through the inside door Use punch 4 mm (0.16 in).
handle.
(6) Install the canopy. Refer to Paragraph 2.
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4. Remove/Install the Gas Spring Strut for the Canopy
A. Remove the Gas Spring Strut for the Canopy
(1) Remove the canopy. Refer to Paragraph 2.
(2) Remove the nut and washer that attach the strut Refer to Figure 1.
to the hinge frame.
WARNING: MAKE SURE THAT THE STRUT IS FULLY EXTENDED BEFORE YOU
DISCONNECT IT FROM THE HINGE FRAME.
(3) Pull the top of the strut away from the hinge Remove and retain the bush and second
frame. washer.
(4) Remove these items that attach the bottom of

the strut:
S Nut washer and bolt.
S Bush.
S Two spacers.
(5) Remove the strut from the airplane.
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B. Install the Gas Spring Strut for the Canopy
(1) Move the strut into position in the airplane. The cylinder goes to the top.
(2) Install the bolt, washer and self-locking nut at Torque 6.4 Nm (4.7 lbf.ft.).
the bottom attachment to the instrument panel
Use a new self-locking nut.
frame.
(3) Put the washer and bush into position on the

hinge frame.
(4) Move the top eye end of the of the strut over the
bush on the hinge frame.
(5) Install the washer and self-locking nut onto the Torque 6.4 Nm (4.7 lbf.ft.).
hinge frame.
Use a new self-locking nut.
(6) Install the canopy. Refer to Paragraph 2.
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5. Remove/Install the Passenger Door
A. Remove the Passenger Door
% (1) Open the passenger door: Refer to Figure 3, 4 or 5.
S Push and hold the safety button next to the

door handle.
S Pull the door handle away from the door

frame.
S Lift the door open.
(2) Remove the gas strut: Hold the door!
S Remove the locking clips from the gas strut

top and bottom ball end fittings.
S Pull the gas strut off the ball end fittings on

the fuselage and clear of the airplane.
(3) Remove the passenger reading light assembly For access to the front door hinge. Refer
from the top of the cockpit. to Section 33-10.
(4) Remove the bolts and washers which attach the Hold the door!
front and rear door hinges to the fuselage.
(5) Lift the door clear of the airplane.
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B. Install the Passenger Door
(1) Put the door in position in the fuselage.
(2) Install the bolts and washers which attach the

front and rear door hinges to the fuselage.
(3) Install the passenger reading light assembly. Refer to Section 33-10.
(4) Install the gas strut:
S Push the gas strut ball end fittings onto the

fuselage gas strut mounts.
S Install the locking clips which lock the ball

end fittings in place.
(5) Close the door.
(6) Operate the door lock: When the door is locked, the door
handle must be flush with the door
S Hold the door closed.
frame.
S Press the safety button next to the door
handle and push the door handle towards
the door frame.
S Push outwards on the bottom of the door

frame.
(7) Do a test for correct operation of the DOOR Refer to Paragraph 8.

warning caption. In the ICS display.
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6. Remove/Install the Passenger Door Locking Mechanism (if MÄM 42-687 is installed)
A. Remove the Passenger Door Locking Mechanism
(1) Remove the door handle.
(2) Remove the 4 bolts from the rod guide base.
(3) Remove the lever bolt from the guide base.
(4) Remove the guide base.
(5) Pull the long connecting rod and the guide lever
with the locking bolt to the door handle cut out.
B. Install the Passenger Door Locking Mechanism
(1) Install the long connecting rod and the guide

lever into the door handle cutout.
(2) Install the rear locking bolt into the PTFE bush.
(3) Connect the guide lever to the guide base.
(4) Connect the ball cup fitting from the thread rod 2
to the door handle.
(5) Connect the front fork head to the slide axle.
(6) Pre-fit the inner door handle.
(7) Install the guide base.
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(8) Adjust the rear locking bolt:
S Check that the short lever arm from the

guide lever position is more than 90° in the
closed position. If necessary adjust long
connecting rod.
S Check the rear locking bolt over length in

closed position min. 43 mm max. 45 mm. If
necessary adjust the locking bolt thread rod.
For adjustment remove the guide base and
lever.
S Check the locking mechanism for release.

Push with 15 kg on the rear locking bolt in
the closed position. The closing mechanism
has to stay locked up to a force of 15 kg.
S Check the front locking bolt over length in

closed position 40 mm ± 1mm.
S Install the 4 guide base bolts.
S Install the inner door handle.
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7. Remove/Install the Gas Spring Strut for the Passenger Door
A. Remove the Gas Spring Strut for the Passenger Door
S Push and hold the button next to the door

handle.

frame.
S Lift the door open.
(2) Remove the gas strut: Hold the door!
S Remove the locking clips from the gas strut

top and bottom ball-end fittings.
S Pull the gas strut off the ball end fittings on

the fuselage and clear of the airplane.
B. Install the Gas Spring Strut for the Passenger Door

frame.
S Lift the door open. Hold the door!
(2) Install the gas strut:
S Push the gas strut ball end fittings onto the

fuselage gas strut mounts.
S Install the locking clips which lock the ball

end fittings in place.
(3) Close the door.
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8. Test the Canopy and Access Door Warning Lights
(1) Make sure that both the front canopy and the Operating handles flush against the
passenger door are fully closed. canopy/door frame.
(2) Test the operation of the DOOR warning caption Monitor the integrated cockpit display.
on the ICS display:
S Set the ELECT. MASTER switch to ON. The DOOR warning caption must be off.
S Move the passenger door operating handle The DOOR warning caption must come
towards the open position. on when the operating handle has
moved away from the door frame.
S Move the door operating handle to the fully The DOOR warning caption must go off.
closed position.
S Move the canopy operating handle towards The DOOR warning caption must come
the open position. on when the operating handle has
moved away from the door frame.
S Move the canopy operating handle to the The DOOR warning caption must go off.
fully closed position.
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9. Examine the Carbon Hinges on the Passenger Door
(1) Open the passenger door to carry out the

carbon hinge inspection.
% (2) Examine the carbon hinges for cracks and Refer to Figure 7.
delamination on the side faces:
S Hold the passenger door frame with one

hand to the left and one hand to the right of
the hinge.
S Apply torsional test force to the hinge by Apply test force of approx. 8 kg (18 lb)
alternately pulling with one hand and with each hand.
pushing with the other hand.
S If cracks become visible on the side faces of Refer to Paragraph 11.

the hinges when test force is applied, the
hinge is structurally damaged due to
delamination. Replace the carbon hinges.
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% (3) Cracks at the outer face of the hinges where Refer to Figure 8.
they meet the door frame may be visible.
If cracks in this area are visible, perform the

following checks:
S Hold the passenger door frame with one

hand to the left and one hand to the right of
the hinge.
S Apply torsional test force to the hinge by Apply test force of approx. 8 kg (18 lb)
alternately pulling with one hand and with each hand.
pushing with the other hand, check the
cracks on the outer face of the hinge.
S If cracks expand extensively when applying

test force, the hinges are structurally
damaged. Replace the carbon hinge. Refer to Paragraph 11.
If cracks expand extensively when applying test

force, the hinges are structurally damaged.
Contact Diamond Aircraft for repair instructions.
If the cracks do not expand extensively when

applying test force, they are limited to the
painting and do not affect the serviceability of
the door.
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Cracks on the
side faces
% Figure 7: Passenger Door Torsional Hinge Test
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Cracks on the
outer faces
% Figure 8: Passenger Door Outer Face Hinge Test
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10. Inspection of the Door Locking and Safety Hook Mechanisms
(1) Make sure the door lock mechanism works

correctly:
S The pins must engage in the guarding plates

of the door frame correctly.
(2) Make sure the safety hook mechanism works

correctly:
S Lubricate the red button of the safety hook Refer to Section 12-20.
mechanism from outside, where it enters the
door frame.
S Operate the button several times. Repeat

lubrication procedure until button moves
smoothly.
S Make sure the safety hook engages

correctly into the retaining block on the
fuselage when the door is closed but
unlatched.
11. Replace a Passenger Door Carbon Hinge
(1) Remove the passenger door. Refer to Paragraph 5.
(2) Clean the surface around the hinge on fuselage

and passenger door.
(3) Cover the surface around the hinge with Use enough masking tape to prevent
masking tape. bonding paste touching the paint.
(4) Remove the peel ply from the carbon hinge.
(5) Install and center the new carbon hinge on the Use shims to keep the bearing centered.
fuselage side.
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(6) Remove the carbon hinge from the passenger Make sure not to damage to door
door. structure.
(7) Cover the surface around the hole for the Use enough masking tape to prevent
carbon hinge with masking tape. bonding paste touching the paint.
(8) Put the passenger door into position for trial fit. Use shims to make sure there are equal
Close door lock. gaps and contour fit. Mark shims and
positions for later use.
(9) Remove the passenger door.
(10) Prepare bonding surfaces. Refer to Section 51-20.
(11) Coat bonding surface with mixed resin. Refer to Section 51-20.
(12) Fill the hole for the carbon hinge with bonding Refer to Section 51-20.
paste completely.
(13) Put the passenger door into position. Make sure there are equal gaps and
Close door lock. contour fit.
(14) Remove excessive bonding paste.
(15) Pre-cure hinges. Refer to Section 51-20.
(16) Remove the passenger door.
(17) Remove masking tape from fuselage and

passenger door.
(18) Post-cure the carbon hinge. Refer to Section 51-20.
(19) Grind surface smooth.
(20) Paint surface. Refer to Section 51-20.
(21) Install passenger door. Refer to Paragraph 5.
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12. Remove/Install the Passenger Door Handle (if MÄM 42-097 is installed)
A. Remove the Passenger Door Handle
(1) Remove the passenger door. Refer to Paragraph 4.
(2) Fix the passenger door on a flat surface. Protect the door surface finish.
(3) Remove the outer door handle:
S Open the inner door handle in order to gain

access to the spring pin.
S Push the spring pin through the inner door Use a 4 mm punch.
handle.
S Remove the outer door handle.
Remove the rod guide base from the door shell:
S Remove the 4 screws.
S Move the guide base free of the door shell.
Disconnect the thread rod from the rod guide

lever:
S Remove the cotter pin and the bolt.
(6) Remove the inner door handle from the

passenger door shell:
S Remove the 4 screws from the inner door

handle.
(7) Lift the inner door handle and disconnect the

front fork head from the slide axle.
(8) Remove the circlip and move the axle free of the
door shell.
(9) Disconnect the rear fork head from the lever.
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(10) Move the door handle free of the door shell.
(11) Remove the spring pin from the door handle.
B. Install the Passenger Door Handle
(1) Install the inner door handle of the passenger

door:
S Move the door handle into place.
S Connect the rear fork head to the inner door

handle lever.
(2) Connect the front fork head and install the slide
axle and secure the axle with a circlip.
S Connect the rear thread rod to the rod guide

lever.
Install the rod guide base to the door shell:
S Install the 4 screws.
(5) Install the inner handle:
S Install the 4 screws.
(6) Install the outer door handle of the passenger

door:
S Align the outer door handle with the hole of

the inner door handle.
S Push the door handle into the inner door

handle.
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(7) Install the spring pin through the inner door Use a 4 mm punch.
handle.
13. Remove/Install the Door Handle Compression Gas Spring (if MÄM 42-097 is installed)
A. Remove the Door Handle Compression Gas Spring
(1) Remove the canopy or passenger door handle. Refer to Paragraph 12.
(2) If installed, remove the circlip from the gas Protect the door surface finish.
spring tie bolt.
(3) Pull the rear end of the door handle frame

approximately 4 mm apart and pull out the gas
spring tie bolt.
If MÄM 42-981 is installed, pull the tie bolt out Door handle must be in open position.
axially.
Caution: spring loaded!
(4) Unscrew the piston of gas spring from the door

handle.
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B. Install the Door Handle Compression Gas Spring
(1) Screw the piston of the gas spring into the door Use Loctite 243.
handle.
(2) Adjust the length of the compression gas spring. The mechanical stop of the red
Make sure that the polyamide bushing defines aluminum door handle must not be
the mechanical stop of the red aluminum door defined by the internal stop of the
handle. compression gas spring.
(3) Compress the gas spring and insert the tie bolt.
Pull the rear end of the door handle frame

approximately 4 mm apart and push the gas
spring tie bolt in.
If MÄM 42-981 is installed, push the tie bolt in

axially.
(4) If MÄM 42-981 is installed, install the circlip on

the gas spring tie bolt.
(5) Install the canopy or passenger door handle. Refer to Paragraph 12.
14. Test the Passenger Door Handle Compression Gas Spring (if MÄM 42-097 is installed)
(1) Open the passenger door.
(2) Move the door handle into open position.
Slowly move the door handle to closed position

and check, if the door handle snaps into closed
position by itself at least 10 mm (measured at
the outermost point of the lever) before reaching
the end position.
(3) If the distance is less then 10 mm, replace the Refer to Paragraph 13.
compression gas spring.
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15. Canopy Jettison System (if OÄM 42-194 is installed)
The canopy jettison system consists of:
) Special canopy hinge with attached canopy jettison mechanism.
) Canopy jettison mechanism with the LH and RH Bowden cables.
) Canopy jettison lever assembly.
) Canopy- and Roeger type hooks.
The standard remove / install procedure is valid for the standard canopy and the canopy with the
jettison system installed (if OÄM 42-194 is installed).
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Canopy Hinge
LH and RH Jettison
Mechanism
Canopy Jettison Lever
% Figure 9: The Canopy Jettison System consists of the Canopy Hinge, the LH and RH Canopy
Jettison Mechanism and the Canopy Jettison Lever
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Canopy Jettison Lever
Washer
Screw
% Figure 10: Canopy Jettison Lever Assembly
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Plug
Locking Pin
Contraction Ring
Conduit Connector
Spring Element
Jettison Retainer
Spring
Bowden Cable
Terminal
% Figure 11: Canopy Jettison Mechanism I
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Plug
Spring Element
Jettison Retainer
Contraction Ring
Locking Pin
Spring
Conduit Connector
Bowden Cable
% Figure 12: Canopy Jettison Mechanism II
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/-0
0.5
1+
% Figure 13: Configuration of the Canopy and Roeger Type Hooks
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Bowden Cable
Lock Nut Terminal Canopy Jettison Lever
% Figure 14: Adjustment of the Bowden Cable Play
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A. 100 Hours Maintenance Check
% (1) Check if the lead plumbing on the canopy jettison Refer to Figure 10.
lever is not broken.
% (2) Make sure, that the bowden cables protrude Refer to Figures 9 and 12.
7 mm (± 2 mm) from the plug on each side.
(3) Make sure, that torque seal on the bowden cable

at the plug is not broken.
% (4) Check clearance between canopy hooks and Refer to Figure 13.
Roeger type hooks: 1.0 +0.5/-0 mm
(0.04 +0.02/-0 in.).
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B. Release Test
WARNING: THE JETTISON MECHANISM IS SPRING LOADED. PARTS CAN

SNAP AND CAUSE SERIOUS INJURIES.
(1) Position one person on each side of the canopy.

They should hold the canopy in an almost closed
position.
(2) A third person sitting inside the airplane releases Use spring scale.
the canopy jettison system.
S The release force on the lever must not

exceed 160 N.
S If the force exceeds 160 N, contact Diamond

Aircraft Industries.
(3) Remove the canopy.
(4) Report test result to the manufacturer,

Office of Airworthiness
N.A. Otto-Str. 5
Austria
by mail, fax (+43-2622-26780) or
e-mail (airworthiness@diamond-air.at).
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C. Remove the Canopy Jettison System

(1) Perform a release test.
(2) Remove the canopy. Refer to Section 52-10.
(3) Remove the spring element from the canopy.
% (5) Remove the canopy jettison lever assy from the Refer to Figure 10.
instrument panel.
(6) Remove the bowden cable from the canopy-

jettison lever assy.
(7) Remove the canopy jettison mechanism LH and

RH from the canopy hinge.
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D. Install the Canopy Jettison System

(1) Remove the conduit connector from the jettison

retainer.
(2) Connect the jettison retainer to the spring Apply molykote on spring element.
element (LH/RH).
% (3) Assemble the jettison mechanism (LH/RH): Refer to Figure 11.
S Slide the conduit-connector, the spring and

the contraction ring onto the bowden cable.
(4) Insert the locking pin into the spring element Apply molykote on locking pin.
(LH/RH):
% Refer to Figure 12.
S Pull at the end of the bowden cable.
S Make sure, that the bowden cable protrudes

7 mm ± 2 mm (0.28 in ± 0.08 in) from the
plug.
(5) Screw the jettison retainer on the bowden cable Secure bowden cable conduit-
conduit-connector (LH/RH). connector with Loctite 243.
(6) Install the plug on the jettison retainer (LH/RH).
(7) Install the bowden cables (LH/RH) in the canopy

hinge.
(8) Install the jettison mechanism (LH/RH) in the Secure with Loctite 243.
canopy hinge.
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% (9) Install the bowden cables on the canopy jettison Refer to Figure 10.
assy:
S Set the hexagon nuts of the bowden cable to

the most inward position.
S Install the bowden cables in the lower part of

the canopy jettison assy.
S Insert the terminal into the canopy jettison

lever.
S Install the canopy jettison lever in the lower

part of the canopy jettison assy.
(10) Adjust the bowden cable length and tension with

the hexagon nut until following conditions apply:
S There is no pretension on the bowden

cables.
S The cables do not touch the bracket.
S The bowden cables can be pushed down

approximately 2 diameters of the cable with
a small screwdriver.
(11) Make sure, that the bowden cables protrude

7 mm ± 2 mm (0.28 in ± 0.08 in) from the plug.
(12) Fix the positions of the bowden cables with the Secure with Loctite 243.
worm screws.
(13) Tighten the hexagon screws on the bowden Secure with Loctite 243.
cables.
(14) Install the lead plumbing on the canopy jettison Do not use fuse wire!
lever.
(15) Install the canopy jettison lever assy below the

instrument panel.
(16) Adjust the spring element of the canopy jettison

mechanism, so that the mounting holes match
those of the canopy.
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AIRCRAFT
(17) Make sure, that the bowden cables protrude

7 mm ± 2 mm (0.28 in ± 0.08 in) from the plug.
(18) Apply torque seal on the bowden cable at the Use Loctite 243.
plugs.
(19) Install the canopy. Refer to Section 52-10.
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Section 52-30
Front Baggage Compartment Doors
1. General
This Section tells you about the front baggage compartment doors. The DA 42 NG has access doors
to the front baggage compartment on each side of the fuselage.
2. Description
Figure 1 shows the front baggage compartment doors. Figure 2 shows the front baggage compartment
% doors, if MÄM 42-600 is installed. Figures 3 shows the option with the adjustable micro switch (if MÄM
% 42-1129 is installed).
The doors are CFRP moldings with a foam core. Each door has a finishing layer of glass cloth.
Mounting brackets for the door locking latches are bonded to the doors with resin.
Both doors are hinged at the upper edge and lift up. Door locking latches are installed at the bottom
corners of the doors. Three small gas springs are integrated in each of the four hinge assemblies (if
MÄM 42-600 is NOT installed). If MÄM 42-600 is installed, each door is mounted with two gooseneck
hinges supported by a gas spring mounted to the forward gooseneck hinge and the NLG bulkhead.
A door warning caption is displayed on the integrated cockpit system display when a door is not
locked.
3. Operation
A door locking latch on each lower corner of the door operates two locking bolts. A spring loading
mechanism holds the door latch in the locked position. You pull the outer side of the door latch away
from the door recess to unlock the latching mechanism and move the door up into the open position.
The gas springs will hold the door open.
You close the door by pushing the door down against the gas spring strut until it is flush with the door
surround. Hold the door in this position and push the door locking latch lever towards the door. The
door locking latch lever must be flush with the door when the door is locked.
A micro switch for each door operates a door unlocked warning alert in the integrated cockpit system
primary display panel.
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A
Gas Strut
Screw
Washer
Hinge Assembly
Door
Washer
Screw Rivet
A
A
A
A
B LH Shown,
C RH Similar
B
C Door
Door Seal
Screw
Counter Bearing
B
C
Microswitch Screw
Locking Door Latch Door Latch

Door Striker Plate
Figure 1: Front Baggage Compartment Access Doors
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22 Dec 2021 52-30-00 Rev. 5
DA 42 NG AMM Doors
AIRCRAFT
Gas Spring Assy

Gas Spring
Mounting Bracket
Washer Screw
Nut
Cargo Door Assy
Bonded to
Bonded to Cargo Door
Fuselage
Door Seal
LH Shown,
RH Similar
Washer
Washer Screw
Nut
Bolt
Washer Hinge Arm Assy
Bushing
Washer
Nut
Hinge Arm with Linkage Assy
Figure 2: Front Baggage Compartment Access Doors (if MÄM 42-600 is installed)
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%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
% Figure 3: Front Baggage Compartment Doors Micro Switch Installation (if MÄM 42-1129 is
% installed)
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22 Dec 2021 52-30-00 Rev. 5
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AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the front baggage compartment door. If you have
the trouble detailed in the Trouble column, read across to the Possible Cause column. Then do the
repair in the Repair column.
Access door is difficult to Door damaged. Replace the door.

move.
Door hinges damaged. Replace the damaged parts.
Gas springs defective. Replace the hinge assembly.
Door handle is difficult to move. Locking bolts damaged. Replace the damaged bolt.
Door locking mechanism Replace the door locking

defective. mechanism.
% Door warning light does not Micro Switch is broken. Replace Micro Switch.
% extinguish with closed
%
% baggage compartment doors.
% Micro Switch adjustment Adjust Micro Switch.
% incorrect.
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1. General
% These Maintenance Practices tell you how to remove and install the front baggage compartment doors,
% and how to remove, install and adjust a door warning Micro Switch. They also tell you how to test the
baggage compartment door warning light system.
2. Remove/Install a Front Baggage Compartment Door
A. Remove a Front Baggage Compartment Door
(1) Open the front baggage compartment door that

you will remove.
(2) Remove the door from the hinges Support the door.
(if MÄM 42-600 is NOT installed):
S Remove the 4 nuts and washers that attach

each door hinge to the door.
S Move the door clear of the airplane.
(3) Remove the gas spring (if MÄM 42-600 is

installed).
(4) Remove the door from the hinges Support the door.
(if MÄM 42-600 is installed):
S Remove the nuts, bolts and washers that

attach each gooseneck hinge to the
fuselage.
S Move the door clear of the airplane.
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B. Install a Front Baggage Compartment Door
(1) Connect the door to the door hinges

(if MÄM 42-600 is NOT installed):
S Move the door into position at the door

hinges.
S Align the door with the hinge and install the 4

washers and nuts that attach each hinge to
the door.
(2) Connect the door to the door hinges

(if MÄM 42-600 is installed):
S Move the door with the installed gooseneck

hinges in position and align the gooseneck
with the attachment brackets on the fuselage
nose.
S Install the bolt, nut and washer.
(3) Install the gas spring (if MÄM 42-600 is

installed).
(4) Close the door and lock the door.
(5) Do a test for the correct operation of the door

warning caption:
S Make sure that the canopy, passenger door

and both forward baggage compartment
doors are closed.
S Set the ELECT. MASTER switch to ON. The DOOR warning caption must be off.
S Move the operating handle of the baggage The DOOR warning caption must come
compartment door that you replaced towards on when the operating handle has
the open position. moved away from the door frame.
S Move the door operating handle to the fully The DOOR warning caption must go off.
closed position.
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% 3. Remove, Install and Ajust a Front Baggage Compartment Micro Switch (if MÄM 42-1129 is
% installed)
% A. Remove a Front Baggage Compartment Micro Switch
% Detail Steps/ Work Item Key Items/References
% (1) Remove the carpet on the baggage

% compartment floor until the plug of the switch
% can be disconnected.
% (2) Cut the cable tie on the cable plug. Mark the position of the cable.
% (3) Disconnect the plug.
% (4) Remove the 2 self locking nuts, 2 screws, the

% toothed washers and washers that attach the
% switch to the counter bearing back.
% B. Install a Front Baggage Compartment Micro Switch
% (1) Connect the plug to the cable.
% (2) Install the cable tie.
% (3) Lead the cable to the correct position.
% (4) Attach the switch to the counterbearing back,

% push it away from the front baggage
% compartment door along the hole and install the
% self locking nuts, screws, washers and toothed
% washers.
% (5) Do a test for the correct function of the door

% warning light.
% (6) Make sure that the canopy, passenger door and

% baggage compartment doors are closed.
% (7) Set the ELECT. MASTER switch to ON. The door warning caption must be off.
% (8) Open the front baggage compartment door. The door warning caption must come
% on when the operating handle has
% moved away from the door frame.
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% (9) Close the front baggage compartment door. The door warning caption must be off.
% (10) Set ELECT. MASTER switch to OFF.
% (11) If the door warning light does not indicate

% correctly: Refer to Paragraph C and adjust the
% micro switch.
% C. Adjust a Front Baggage Compartment Micro Switch
% Detail Steps/ Work Item Key Items/References
% (1) Open the 2 screws which hold the micro switch

% in position.
% (2) Adjust the micro switch towards the cone in a

% small step.
% (3) Tighten the 2 screws on the micro switch.
% (4) Perform a test of the correct function of the door If the test fails: refer to Paragraph B,
% warning light. steps 5 to 11.
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Section 52-40
Access Panels
1. General
The DA 42 NG has access panels where needed for routine maintenance of the airplane and its
systems. Panels which must be removed more often (for example, the engine cowlings) have
quick-release fasteners. Other access panels have the usual screws. The two access panels for the
TKS system in the horizontal stabilizer (if installed) are installed with a sealant. Refer to Section 71-20
for data about the engine cowlings.
2. Description
Figure 1 shows the location of the access panels on the airplane.
Most panels are CFRP/GFRP moldings. Screws hold the panels in position. There are no special
procedures for removing the access panels. When install access panels you must make sure that the
area inside the access panel has no loose objects (for example, tools or rags).
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Doors DA 42 NG AMM
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Stabilizer
Fairing
VIEW FROM BELOW
Lightning, TKS (Optional) Lightning, TKS (Optional)
Main Landing Gear Flap/Aileron Flap/Aileron Main Landing Gear

Push Rods Push Rods Fuel Cooler
Fuel Cooler
Maintenance Cap 2 RH Maintenance Cap 2 LH
Aileron Flap Flap Aileron
Bellcrank Bellcrank B-Bolt B-Bolt Bellcrank Bellcrank
Pitot Tube Fuel Fuel Flux Valve

Tanks Tanks
Nacelle Cap Rear RH Fuel Filter Nacelle Cap Rear LH

Maintenance Cap 1 RH Cap LH Maintenance Cap 1 LH
Nacelle Cap ECU RH De-Icing Nacelle Cap ECU LH
System Nose Landing Gear
Fuel Filter Cap RH (optional,
in Baggage
Compartment)
Figure 1: Access Panel Locations
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22 Dec 2021 52-40-00 Rev. 5
DA 42 NG AMM Fuselage
AIRCRAFT
CHAPTER 53
FUSELAGE
Doc # 7.02.15 Page 1

Fuselage
DA 42 NG AMM
AIRCRAFT
Page 2
22 Dec 2021 53-TITLE Doc # 7.02.15
Rev. 5
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 53
FUSELAGE
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 53-10
Fuselage Structure
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Composite Debris Protection (OÄM 42-090) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4. Adhesive Foil Debris Protection (OÄM 42-088 & 42-089) . . . . . . . . . . . . . . . . . . 13
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Composite Debris Protection (OÄM 42-090) . . . . . . . . . . . . 201
3. Remove/Install the Trim Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Remove/Install the Trim Weight (if MÄM 42-600 is installed, Serial numbers
42.N100 and subsequent) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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Page 2 Doc # 7.02.15

AIRCRAFT
CHAPTER 53
FUSELAGE
1. General
The DA 42 NG fuselage has a semi-monocoque structure. Two CFRP half-shells make the fuselage
skin. GFRP frames and webs give the fuselage strength and stiffness. The vertical stabilizer is an
integral part of the fuselage.
The fuselage shells have many layers of carbon cloth with some layers of glass cloth. Some areas
have more layers of cloth than other areas. This gives more strength and stiffness where it is needed.
Rigid foam inserts give stiffness where necessary.
The frames and webs also have many layers of glass cloth. Some areas have layers of carbon fiber
cloth or tape to give extra strength. Some components also have rigid inserts of GFRP for attaching
brackets or other components.
In order to protect the fuselage from damages caused by ice accumulation which drops off from the
rotating propellers, debris protection is installed on the fuselage. The debris protection is made from
composite material (OÄM 42-090) or adhesive foil (OÄM 42-088 and OÄM 42-089).
Section 53-10 gives the data for the fuselage structure and the debris protection.
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Rev. 5 53-00-00 22 Dec 2021
Fuselage
DA 42 NG AMM
AIRCRAFT
Aft Baggage
Compartment Frame
Roll-Over Molding RH Shell
Wing LH Shell
Center Section
Ring Frame 3
RH Engine Nacelle Ring Frame 2
Ring Frame 1
Nose Landing Gear
Rib, Upper & Lower
Floor Panel
Nosewheel Compartment LH Engine Nacelle
Figure 1: Fuselage Structure - Main Components
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22 Dec 2021 53-00-00 Rev. 5
AIRCRAFT
Section 53-10
Fuselage Structure
1. General
This Section gives you the data about the fuselage structure. It also includes the vertical stabilizer. See
Chapter 51-00 for data about repair to the structure.
All of the main structural components are CFRP rigid moldings. Many layers of carbon cloth bond
together to make each molding. Some components have more layers of carbon fiber cloth. This gives
more strength and stiffness.
Most components have rigid GFRP inserts. The inserts give strength and stiffness for attaching other
components such as brackets for controls.
Bonding paste (thickened resin) bonds components to other components. Most of the components in
the fuselage are also bond to the fuselage shell.
To trim the airplane’s CG, it is possible to install a trim weight in the lower vertical tail. It can be varied
in 3.0 kg (6.6 lb) steps up to 15 kg (33 lb) by installing the required number of lead plates.
If MÄM 42-600 is installed, Serial number 42.N100 and subsequent:
To trim the airplane’s CG, it is possible to install a trim weight in the lower vertical tail. It can be varied
in 1.0 kg (2.2 lb) steps from 2.0 kg (4.4 lb) up to 12 kg (26.4 lb) by installing the required number of
steel plates (min. 2 to max. 12 plates).
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Fuselage
DA 42 NG AMM
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Nose Gear
Frame-Top
Radar Frame
Floor Panel Nose Gear
Nose Gear Leg Frame
Compartment
Figure 2: Fuselage Structure - Nose Section
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22 Dec 2021 53-10-00 Rev. 5
AIRCRAFT
2. Description
Figures 1 thru 5 show the structure of the fuselage.
A. Fuselage Shells
Two CFRP shells make the outer skin of the fuselage. The shells transmit structural loads. The
shells bond to each other at the top and bottom of the fuselage. Each shell has many layers of
carbon cloth. Some areas have of the shell have more layers to give more strength and stiffness.
Some areas have rigid foam inserts to give more stiffness. The vertical stabilizer is integral with the
fuselage shells.
Thickened resin bonds all other structural components to the fuselage shells. Many small
components bond to the fuselage shells, these include:
) Air inlet and outlet ducts.
) Conduits for electrical wires, antenna cables and fuel pipes.
) Mountings for airplane system components.
B. Nose Section
The nose section bonds to the front of the fuselage. The nose section has a left shell and it has a
right shell. The shells are made from CFRP with rigid foam inserts. Each shell has a hinged door
to give access to the nose baggage compartment. Refer to Section 52-30 for more data about the
front baggage compartment doors.
The nose gear frame top and the nose gear frame close the front of the cockpit and make the rear
of the nose section. The nose gear leg compartment attaches to the nose gear frame at the rear
and the radar frame at the front. Left and right floor panels strengthen the nose section and make
the floor for the front baggage compartment. Access holes in the floor panels give access to the
nose landing gear leg mountings. The nose cone is bonded to the nose section shell.
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Rev. 5 53-10-00 22 Dec 2021
Fuselage
DA 42 NG AMM
AIRCRAFT
Main Landing Floor Panel

Gear Rib
Rear
Front Box-spar
Box-Spar
Middle Root Rib RH
Rear Inner
Root Rib RH
Control Bellcrank
Mounting Bracket
Rear Inner
Root Rib LH
Flap Rib
Rear Inner
Rib
Front Inner
root Ribs
Rear Outer
Middle Root Rib LH Root Rib
Middle Outer
Engine Root Rib
Firewall
Engine Nacelle
Figure 3: Fuselage Structure - Wing Center Section
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22 Dec 2021 53-10-00 Rev. 5
AIRCRAFT
C. Wing Center Section
The wing center section attaches to the fuselage shells and is an integral part of the fuselage.
The wing center section has the mountings for the wings, the engine nacelles and the main landing
gear. It has a front box spar and it has a rear box spar. The box spars have the mountings for the
outer wings. The spar extensions of the outer wings slide into the box spars and are secured with
special bolts. The box spars are CFRP rigid moldings. The control bellcrank mounting-bracket is
bonded to the rear face of the rear main bulkhead, in the center.
The engine nacelles are located at the outer ends of the wing center section. The engine nacelles
bond to the box spars and provide mountings for the engine mounting frame. The forward face of
the engine nacelle makes the engine firewall.
Front, middle and rear inner-root-ribs bond to the inner ends of the front and rear box spars. The
ribs are rigid CFRP moldings which make the inner face of the wing center section.
Middle and rear closing ribs bond to the box spars at the outer end of the center section, to the rear
of the outer end of the engine nacelles. These ribs close the end of the wing center section.
The rear inner ribs and flap ribs bond to the aft face of the rear box spar. The flap rib has the
mountings for the inner flap relay lever and the rear inner gives rigidity to the rear of the wing center
section.
A rigid CFRP bottom shell bonds to the lower surface of the center section and makes the bottom
surface of the wing center section and fuselage. Rigid CFRP top shells bond to the top outer
surface of the center section and makes the top surface of the wing center section.
D. Floor Panel
Note: Do not use surface protection except the certified!
The floor panel is a rigid GFRP molding. It bonds to the inner bottom skin of the fuselage shell and
the instrument panel frame. The center part of the floor panel makes the center console.
The rear part of the floor makes the front support for the pilots' seats. It also holds the front of the
control stick support brackets. The rudder pedal assembly for each pilot attaches to the floor panel.
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Rev. 5 53-10-00 22 Dec 2021
Fuselage
DA 42 NG AMM
AIRCRAFT
Aft Baggage Compartment Frame
Roll-Over Molding
Ring Frame 3
Ring Frame 2
Ring Frame 1
Figure 4: Rear Fuselage Structure
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22 Dec 2021 53-10-00 Rev. 5
AIRCRAFT
E. Roll Over Molding
The roll-over molding is a rigid GFRP molding. Carbon tape gives strength and stiffness to the
molding. The roll over molding bonds to the inner face of the fuselage shell and around the canopy,
window and passenger door cut-outs.
F. Aft Baggage Compartment Frame
The aft baggage compartment frame is a rigid GFRP molding. It closes the rear of the cockpit and
makes a support for the passenger seat (rear seat pan). The frame bonds to the inner fuselage
shells and the center section lower shell.
The lower part of the frame has holes for the rudder cables and trim control. It also has a control
rod guide for the elevator control rod.
G. Ring Frame 1
The ring frame 1 is a rigid GFRP molding. It bonds to the fuselage shells just aft of the baggage
compartment frame. It has holes for the rudder control cables and trim control. It also has a control
rod guide for the elevator control rod.
H. Ring Frame 2
The ring frame 2 is a rigid GFRP molding. It bonds to the fuselage shells aft of ring frame 1. It has
holes for the rudder control cables and trim control. It also has a control rod guide for the elevator
control.
I. Ring Frame 3
The ring frame 3 is a rigid GFRP molding. It bonds to the fuselage shells just forward of the vertical
stabilizer. It has holes for the rudder control cables and trim control.
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Rev. 5 53-10-00 22 Dec 2021
Fuselage
DA 42 NG AMM
AIRCRAFT
Vertical Stabilizer
Front Web Reinforcing Rib
Vertical Stabilizer
Rear Web
Vertical Stabilizer
Front Lower Rib
Vertical Stabilizer
Rear Lower Rib
Ring Frame 3
Figure 5: Fuselage Structure - Vertical Stabilizer
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22 Dec 2021 53-10-00 Rev. 5
AIRCRAFT
J. Vertical Stabilizer Front Lower Rib
The vertical stabilizer front lower rib is a rigid GFRP molding. It bonds to the fuselage shell at the
bottom of the vertical stabilizer. It also bonds to the vertical stabilizer front web. It has a hole for the
flexible control cable for the elevator trim tab.
K. Vertical Stabilizer Rear Lower Rib
The vertical stabilizer rear lower rib is a rigid GFRP molding. It bonds to the fuselage shell at the
bottom of the vertical stabilizer. It also bonds to the vertical stabilizer front and rear webs. It has a
large slot for the elevator control pushrod.
L. Vertical Stabilizer Front Web
The vertical stabilizer front web is a rigid GFRP molding. It bonds to the fuselage shell. It also
bonds to the vertical stabilizer lower ribs and to the top of the rear web.
The top of the front web is a rigid channel section. GFRP inserts give strength to the area where
the horizontal stabilizer mounts attach.
M. Vertical Stabilizer Rear Web
The vertical stabilizer rear web is a rigid GFRP molding. It bonds to the fuselage shell and it bonds
to the vertical stabilizer front web. The top of the rear web has the top mounting for the rudder. It
also has a reinforcing rib bonded to the rear face.
The vertical stabilizer rear web closes the rear of the vertical stabilizer.
N. Trim Weight
The trim weight can be varied in 3.0 kg (6.6 lb) steps up to 15 kg (33 lb) by installing the required
number of lead plates. For each number of lead plates, the attachment bolts with adequate length
must be used. The lead plates are fixed by seven bolts to the attachment plate. The trim weight
assembly replaces the access hole cover in the lower vertical tail and is fixed by eleven screws.
O. Trim Weight (if MÄM 42-600 is installed, Serial numbers 42.N100 and subsequent)
The trim weight can be varied in 1.0 kg (2.2 lb) steps from 2 kg (4.4 lb) up to 12 kg (26.4 lb) by
installing the required number of steel plates (minimum 2 to max. 12 plates). For each number of
steel plates, attachment bolts with adequate length must be used.
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Rev. 5 53-10-00 22 Dec 2021
Fuselage
DA 42 NG AMM
AIRCRAFT
Figure 6: Trim Weight
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22 Dec 2021 53-10-00 Rev. 5
AIRCRAFT
Self Locking Nut

Washer
Self
Locking
Nut
Washer
Bolt
Steel Plates (max. 10 pieces)
Bolt
Steel Plates (total max. 12 pieces)
Figure 7: Trim Weight (if MÄM 42-600 is installed, Serial numbers 42.N100 and subsequent)
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Fuselage
DA 42 NG AMM
AIRCRAFT
3. Composite Debris Protection (OÄM 42-090)
This Section contains all necessary information concerning the composite debris protection (certified
with OÄM 42-090). Refer to Paragraph 4 for information concerning the foil based debris protection
(certified with OÄM 42-088 and 42-089).
The composite debris protections are installed on both sides of the forward fuselage with a silicone
based adhesive. Refer to Figure 8.
Flat View RH 290 (11,4 in)

Flat View LH 80 (3,1 in)
RH 160 (6,3 in)

LH 140 (5,5 in)
Figure 8: Composite Debris Protection (OÄM 42-090)
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AIRCRAFT
4. Adhesive Foil Debris Protection (OÄM 42-088 & 42-089)
A. Single Layer Debris Protection (OÄM 42-089)
Figure 9 shows the single layer debris protection (material: 3M) certified with OÄM 42-089 for
installation on the DA 42 NG.

RH 160 (6,3 in)

LH 140 (5,5 in)
Figure 9: Single Layer Debris Protection (OÄM 42-089)
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Rev. 5 53-10-00 22 Dec 2021
Fuselage
DA 42 NG AMM
AIRCRAFT
B. Triple Layer Debris Protection (OÄM 42-088)
Figure 10 shows the triple layer debris protection (material: PM) certified with OÄM 42-088 for
installation on the DA 42 NG.
40 (1,6 in)
20 (0,8 in)
40 (1,6 in)
20 (0,8 in)

RH 160 (6,3 in)

LH 140 (5,5 in)
Figure 10: Triple Layer Debris Protection (OÄM 42-088)
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22 Dec 2021 53-10-00 Rev. 5
AIRCRAFT
1. General
There are no special Maintenance Practices for the DA 42 NG fuselage. You must keep the airplane
clean and you should visually examine the airplane fuselage for damage when you clean it. Refer to
Section 12-30 for data about airplane cleaning.
If you find any damage you must refer to Chapter 51-10 for data about damage classification. Only
authorized persons can classify and repair damage to the DA 42 NG airplane.
If the composite debris protection (OÄM 42-090) is installed, refer to Paragraph 2 for more information.
If the adhesive foil debris protection (OÄM 42-088 & OÄM 42-089) is installed, refer to Paragraph 3
for more information.
2. Remove/Install the Composite Debris Protection (OÄM 42-090)
A. Remove the Composite Debris Protection (OÄM 42-090)
(1) Carefully cut around the debris protection by use

of a sharp knife.
(2) Remove the separated silicone seal.
(3) Cut between the fuselage and the composite

debris protection using a long sharp knife.
(4) Remove the debris protection.
(5) Visually inspect the fuselage skin.
(6) Remove the silicone left on the fuselage by use Make sure that the agent does not harm
of a palette-knife together with silicone removal the paint finish.
agent.
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Rev. 5 53-10-00 22 Dec 2021
Fuselage
DA 42 NG AMM
AIRCRAFT
B. Install the Composite Debris Protection (OÄM 42-090)
(1) Clean fuselage surface and the rear side of the

composite debris protection.
(2) Mark exact position of both composite debris Refer to Figure 8.

protections on fuselage.
(3) Install the composite debris protection using

Terostat MS 9380 white adhesive.
(4) Seal cleave around the composite debris

protection with Terostat MS 9380 white.
3. Remove/Install the Trim Weight
A. Remove the Trim Weight

(1) Remove the rudder. Refer to Section 55-40.
(2) Remove the trim weight assembly:
S Loosen the outer eleven screws which Use an Allen wrench size 3. Begin with
attach the trim weight assembly to the lower the lower screws and hold the trim
vertical tail. weight assembly in place.
(3) Pull the trim weight assembly carefully out of the

lower vertical tail.
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AIRCRAFT
B. Install the Trim Weight
(1) Check the trim weight attachment structure

(lower vertical tail) for:
S Cracks.
S Other damages.
S Loose or missing anchor nuts.
(2) Put the seven bolts with adequate length from Use 8 mm box wrenches.
the attachment plate side in the vertical lead
Use new self locking nuts.
weight(s), put the washers on the bolts and
tighten the trim weight assembly.
(3) Carefully place the trim weight assembly in the

lower vertical tail.
(4) Tighten all eleven outer screws. Use an Allen wrench size 3.
(5) Install the rudder. Refer Section 55-40.
(6) Verify completeness of the tools.
(7) Verify correctness of Weighing Report. Refer to Section 08-10.
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Rev. 5 53-10-00 22 Dec 2021
Fuselage
DA 42 NG AMM
AIRCRAFT
4. Remove/Install the Trim Weight (if MÄM 42-600 is installed, Serial numbers 42.N100 and
subsequent)
A. Remove the Trim Weight

(1) Remove the rudder. Refer to Section 55-40.
(2) Remove the trim weight assembly:
S Loosen the two screws which attach the trim Hold the trim weights in place.
weights to the lower vertical tail.
(3) Pull the trim weights carefully out of the lower

vertical tail.
B. Install the Trim Weight
(1) Check the trim weights structure (lower vertical

tail) for:
S Cracks.
S Other damages.
(2) Carefully place the trim weights in the lower

vertical tail.
(3) Put the two bolts with adequate length in the

steel weight(s), put the washers on the bolts Use new self locking nuts.
and tighten the trim weight assembly.
(4) Install the rudder. Refer Section 55-40.
(5) Verify completeness of the tools.
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22 Dec 2021 53-10-00 Rev. 5
DA 42 NG AMM Stabilizers
AIRCRAFT
CHAPTER 55
STABILIZERS
Doc # 7.02.15 Page 1

Stabilizers DA 42 NG AMM
AIRCRAFT
Page 2
22 Dec 2021 55-TITLE Doc # 7.02.15
Rev. 4
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 55
STABILIZERS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 55-10
Horizontal Stabilizer
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Horizontal Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 55-20
Elevator
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Elevator Trim-Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Section 55-30
Lower Fin
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Doc # 7.02.15 Page 1

AIRCRAFT
Section 55-40
Rudder and Trim Tab
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Rudder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Rudder Trim-Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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AIRCRAFT
CHAPTER 55
STABILIZERS
1. General
The DA 42 NG has the usual stabilizers. The vertical stabilizer is part of the fuselage. The aft part of
the left and right fuselage shells make the left and right shells of the vertical stabilizer. See Section
53-10 for data on the fuselage structure.
The horizontal stabilizer has top and bottom shells. Each shell has GFRP skins. The horizontal
stabilizer has a front spar and a rear spar. Both spars have mounting brackets. Three pairs of ribs give
strength to the center area. Two trailing edge webs hold the hinges for the elevator.
The elevator has top and bottom shells. Each shell has GFRP skins with a rigid foam core. The bottom
shell also makes the leading edge spar. The hinges attach to the bottom shell. A large horn with the
mass balance weight attaches to the bottom shell at the center. The trailing edge carries a trim tab.
The lower fin is a GFRP molding. Bolts attach the lower fin to the bottom of the fuselage.
The rudder has left and right shells. Each shell has GFRP skins with a rigid foam core. The shells bond
together at a flange. The hinges attach to the top face of the rudder and a flat face near the bottom of
the leading edge. The horn near the top makes the rudder mass balance.
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Rev. 4 55-00-00 22 Dec 2021
AIRCRAFT
Horizontal Stabilizer Tip, RH
Trim Tab
Elevator
Tip, LH
Rudder Trim Tab
Rudder
Tail Skid
Lower Fin
Figure 1: Stabilizers
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22 Dec 2021 55-00-00 Rev. 4
AIRCRAFT
Section 55-10
1. General
The DA 42 NG has the usual horizontal stabilizer. The horizontal stabilizer attaches to the top of the
vertical stabilizer. The elevator attaches to the trailing edge of the horizontal stabilizer. See Section
55-20 for data about the elevator structure.
2. Description
Figure 1 shows the horizontal stabilizer structure.
The horizontal stabilizer has top and bottom shells. Each shell has GFRP skins. The top shell has no
cut-outs. The bottom shell has a large cut-out at the rear for the elevator horn and mass balance. It
also has two smaller holes forward and aft of the front spar.
The horizontal stabilizer has two spars. The spars have GFRP skins with rigid GFRP inserts at the
main mounting points. They also have top and bottom caps. The ends of the front spar turn back to
join the aft spar at mid span. The rear spar goes almost to the tip of the horizontal stabilizer. The spars
bond to the top and bottom shells with resin.
Each spar has four holes for a mounting bracket. You can get access to the attachment bolts from
below. The mounting brackets go down through the cut-outs in the bottom shell. Four more holes in
the bottom part of each mounting bracket attach to the vertical stabilizer front web.
Three pairs of ribs give strength to the center area on each side of the access holes. All are rigid
GFRP moldings. They bond to the other components with resin. The rear 'box' ribs make a box round
the large cut-out in the bottom skin. A short rear rib at mid-span gives strength to the area between
the rear spar and the trailing edge web.
The rear box rib has sides with bends and a top face which joins the sides. It closes the sides of the
large cut-out in the bottom shell. The aft part has three holes on each side for the anchor bracket for
the trim-tab mechanism.
Two trailing edge webs close the trailing edges of the top and bottom shells. The outboard end of each
web is a 'J' shape which goes round the outboard balance weight of the elevator. It extends aft at the
outer side to close the elevator cut-out. The webs also holds the hinges for the elevator. The webs
bond to the top and bottom shells and the rear and rear 'box' ribs with resin.
A rigid GFRP fairing goes around the joint between the horizontal stabilizer and the vertical stabilizer.
Four screws attach the fairing to the vertical stabilizer.
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Rev. 4 55-10-00 22 Dec 2021
AIRCRAFT
Horizontal
Stabilizer Tip, RH
Rear Rib
Center Ribs
Rear 'Box' Ribs
Trailing Edge Web
Rear Spar
Front Spar
Rear Rib
Front Ribs
Front Mounting Bracket

12
Rear Mounting Bracket

Horizontal Stabilizer Tip, LH
Figure 1: Horizontal Stabilizer Structure
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22 Dec 2021 55-10-00 Rev. 4
AIRCRAFT
1. General
These Maintenance Practices tell you how to remove and install the horizontal stabilizer.
2. Remove/Install the Horizontal Stabilizer
A. Remove the Horizontal Stabilizer
Note: Two persons are needed to remove/install the horizontal stabilizer.
(1) Remove the horizontal stabilizer fairing. Hold the fairing.
S Remove the 4 screws that attach the faring

to the structure.
(2) Release the 2 fork-end fittings from the trim-tab Under the elevator.
cranked actuating levers:
Remove the cotter pins from the nuts.

attach the fork-ends to the cranked
actuating levers.
(3) Release the trim-tab mechanism from its Refer to Section 27-38.
mounting bracket.
(4) Release the lightning protection strip and wire

bonding cable from the trim mounting bracket:
S Remove the nut, washer, spacer and bolt

that attaches the lightning protection strip
and wire bonding cable to the trim mounting
bracket.
(5) Move the trim-tab mechanism forward through

the hole in the vertical stabilizer web, clear of
the mounting bracket.
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Rev. 4 55-10-00 22 Dec 2021
AIRCRAFT
2
1
Elevator Horn
Large
Washer
Bush
Spacer
Rear Spar
Elevator Push Rod
Rear Mounting Plate

12
Vertical Stabilizer Front Web
Figure 2: Horizontal Stabilizer Installation
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22 Dec 2021 55-10-00 Rev. 4
AIRCRAFT
(6) Disconnect the elevator push-rod from the

elevator horn:
S Loosen the 2 bolts holding the elevator Refer to Section 55-20, Figure 2.
mass-balance lever.
S Remove the nut, bolt and washer which Refer to Figure 2.

connects the elevator vertical push rod to
the elevator horn.
S Remove and retain the large washer, bush Note the location of the large washer,
and spacer from the push rod to elevator bush and spacer.
horn assembly.
(7) Remove the 8 lower bolts which attach the Hold the horizontal stabilizer.
horizontal stabilizer and lightning protection strip
to the front and rear mounting brackets.
(8) Disconnect the VOR antenna.
(9) Lift the horizontal stabilizer clear of the airplane.
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AIRCRAFT
B. Install the Horizontal Stabilizer
(1) Examine the horizontal stabilizer attachments.

Look specially for:
S Corrosion or wear of the bolts.
S Distortion of the mounting brackets.
S Cracks in the mounting brackets.
S Damage to the mounting holes.
(2) Put the horizontal stabilizer in position on the Hold the horizontal stabilizer.
vertical stabilizer.
(3) Connect the VOR antenna.
(4) Install the 8 lower bolts, washers and nuts which Use new self-locking nuts.
attach the horizontal stabilizer and lightning Torque: 45 Nm (33.2 lbf.ft.)
protection strip to the front and rear mounting
brackets.
(5) Connect the elevator control push rod to the

elevator horn:
S Install the large washer, bush and spacer As noted in Paragraph 2A, item (6).
into the push rod to elevator horn assembly.
S Install the bolt, washer and nut that attaches Torque: 1.7 Nm (1.2 lbf.ft.). Use a new
the elevator control push-rod to the elevator self-locking nut.
horn.
S Tighten the 2 bolts holding the elevator That you loosened in Paragraph 2A,
mass-balance lever. item (6).
(6) Move the trim-tab mechanism aft through the

hole in the vertical stabilizer web, through the
mounting bracket for the trim mechanism.
(7) Attach the trim-tab mechanism to its mounting Use new self-locking nuts.
bracket:
S Install 2 bolts, washers and nuts.
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AIRCRAFT
(8) Install the lightning protection strip and wire

bonding cable to the trim mounting bracket:
S Move the lightning protection strip into

position at the elevator trim mount.
S Move the wire bonding cable into position at

the elevator trim mount.
S Install the bolt, spacer, washer and nut that

attaches the lightning protection strip and
wire bonding cable to the trim mounting
bracket.
(9) Connect the 2 fork-end fittings to the trim-tab Under the elevator.
cranked actuating levers:

attach the fork-end fittings to the trim-tab
actuating levers.
S Secure the nuts to the bolts with cotter pins.
(10) Do a test for correct, full and free movement of Refer to Section 27-30.
the elevator control. If necessary, adjust the
elevator control.
(11) Do a test for correct, full and free movement of Refer to Section 27-38.
the trim control. If necessary, adjust the trim
control.

a duplicate inspection of the elevator control
system.

a duplicate inspection of the elevator trim
control system.
(14) Install the horizontal stabilizer fairing:
S Install the 4 screws that attach the fairing to

the structure.
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AIRCRAFT
Section 55-20
Elevator
1. General
The DA 42 NG has the usual elevator. The elevator attaches to the rear web of the horizontal
stabilizer. See Section 27-30 for data about the elevator controls.
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Rev. 4 55-20-00 22 Dec 2021
AIRCRAFT
Figure 1: Elevator Structure
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22 Dec 2021 55-20-00 Rev. 4
AIRCRAFT
2. Description
Figure 1 shows the elevator structure. Figure 2 shows the installation of the elevator on the horizontal
stabilizer. Figure 3 shows the trim tab installation.
The elevator has top and bottom shells. Each shell has GFRP skins with a rigid foam core. The leading
edge of each shell has a curve. The shells bond together where the curves overlap. The shells also
bond together at the ends and at the trailing edge.
The elevator has a horn rib in the middle. It is a strong box with an open front. The elevator horn goes
into the horn rib. Two bolts attach the horn to the elevator.
The horn has a hole with a bush for the elevator push rod. The front of the horn has elevator mass
balance weight. More mass balance weight is attached at the front of the elevator tips.
Five bearings hold the elevator. The elevator horn has a plain bearing. A bolt and spacer attach the
elevator horn to the trailing edge webs of the horizontal stabilizer.
A small bearing rib at mid-span on each side holds an elevator hinge assembly. The hinge assembly
has an eye-end with a plain shank. The eye-end has a spherical bearing. The shank engages in a
bush in the trailing edge web.
The outer end of the elevator on each side has an end bearing. A reinforcing block holds a bonded
bush. The bush aligns with a bonded bush in the horizontal stabilizer trailing edge web. A pivot pin
goes through both bushes to make the outer bearing. A roll pin locks the pivot pin in the bonded bush.
A GFRP trim tab attaches to the trailing edge of the elevator. The trim tab has six GFRP hinges. The
front half of each hinge bonds to the trailing edge of the elevator. The rear half of each hinge bonds
to the leading edge of the trim tab. Two hinge rods go through the hinges. Lock wires hold the hinge
rods in place.
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AIRCRAFT
Mass Balance Lever
Removable Tip
Elevator
Horn Rib
Elevator Horn
Trailing Edge Web
Bonded Bush
Elevator Pivot Pin

Bonded
Bush
Cotter Pin
Rear Rib Trailing Edge Web
Figure 2: Horizontal Stabilizer - Elevator Installation
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AIRCRAFT
1. General
These Maintenance Practices tell you how to remove and install the elevator and trim tab. Refer to
Sections 27-30 and 27-31 for data on the elevator and trim tab control setting.
2. Remove/Install the Elevator
A. Remove the Elevator
(1) Remove the horizontal stabilizer fairing. Refer to Figure 2.
S Remove the 4 screws that attach the fairing

to the structure.
(2) Remove the horizontal stabilizer tips: Hold the tips.
S Remove the 8 screws that attach the tip to

the stabilizer.
(3) Release the 2 fork-end fittings from the trim-tab Under the elevator.
cranked actuating levers.
(4) Remove 2 bolts, nuts and washers which attach Refer to Figure 2.
the elevator horn rib to the elevator.
(5) Remove the pivot pins from the end bearings: Hold the elevator.
S Remove the roll pin.
S Pull the pivot pin out of the end bearing.
(6) Pull the elevator aft to release the elevator horn

and hinge assemblies.
(7) Put the elevator in a stand or on a padded

surface.
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Attaching Bolt
Trim Tab
Cranked Actuating Lever RH
Lightning Protection Strip Trim Tab Horn
Fork-end Fitting
Cranked Actuating Lever LH
Trim
Damper
Fork-end Fitting Hinge Trim Tab

Rubber Gaiter Rod
Elevator
Bonding Cable
Bowden Cable
Lightning
Protection
Trim Tab Hinge
Hinge Rod
Lock Wire
Trim Tab
Elevator
Trim Tab Hinge

(6x)
Hinge Rod
Figure 3: Trim-Tab Installation
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B. Install the Elevator
(1) Put the elevator in position aft of the horizontal Refer to Figure 2.
stabilizer:
S Align the elevator with the horn.
S Move the elevator forward over the horn.
S Align the shanks of the hinge assemblies at

mid-span with the bushes in the trailing
edge web of the horizontal stabilizer.
S Push the elevator forward to engage the

shanks in the bushes.
S Align the end bearings with the bushes in

the trailing edge spar of the horizontal
stabilizer.
(2) Install the pivot pins in the end bearings and

lock the pivot pins in position with a roll pin.
(3) Install the bolts, washers and nuts which attach Torque: 6.4 Nm (4.7 lbf.ft.). Use new
the elevator to the elevator horn. self-locking nuts.
(4) Install the 2 fork-end fittings for the trim-tab Under the elevator.
cranked actuating levers.
(5) Install the horizontal stabilizer tips:
S Install the 8 screws that attach the tip to the

(6) Install the horizontal stabilizer fairing:
S Install 4 screws that attach the fairing to the

structure.
(7) Do a test for correct range of movement of the Refer to Section 27-30.
elevator control.
elevator trim control.
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AIRCRAFT

control.
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3. Remove/Install the Elevator Trim-Tab
A. Remove the Elevator Trim-Tab
(1) Remove the nut, washer and bolt which Refer to Figure 3.
attaches the cranked actuating levers to the trim
tab.
CAUTION: DO NOT USE FORCE TO REMOVE THE LOCK WIRE FROM THE
TRIM TAB HINGE. YOU CAN DAMAGE THE GFRP HINGE.
(2) Remove the lock wire at the outer hinge on

each side of the trim tab.
(3) Move the hinge rods out of the hinges. Hold the trim tab.
(4) Remove the trim tab from the elevator.
B. Install the Elevator Trim-Tab
(1) Put the trim tab in position on the elevator. Refer to Figure 3.
(2) Align the hinges.
(3) Install the hinge rods in each side.
CAUTION: DO NOT USE FORCE TO INSTALL THE LOCK WIRE IN THE TRIM
TAB HINGE. YOU CAN DAMAGE THE GFRP HINGE.
(4) Lock the hinge rods in position with wire. Use new lock wire.
(5) Align the cranked actuating levers with the trim

tab.
(6) Install the bolt, washer and nut which attaches

the cranked actuating levers to the trim tab.
elevator trim control.

control system.
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Section 55-30
Lower Fin
1. General
The DA 42 NG has a lower fin. The lower fin is a GFRP molding that is bonded to the bottom of the
rear fuselage. A tail-skid is attached to the bottom of the lower fin. Refer to Section 32-70 for more data
about the tail-skid.
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AIRCRAFT
Section 55-40
Rudder and Trim Tab
1. General
The DA 42 NG has the usual rudder. The rudder attaches to the rear web of the vertical stabilizer.
Refer to Section 27-20 for data about the rudder controls.
The rudder has a mechanical trim-tab. A rotary knob at the top of the cockpit center console controls
the rudder trim-tab. Refer to Section 27-21 for data about the rudder trim-tab controls.
2. Description
A. Rudder
Figure 1 shows the rudder structure.
The rudder has left and right shells. Each shell has GFRP skins with a rigid foam core. The leading
edge of each shell has a curve and a flange. The shells bond together at the flanges. The shells
also bond together at the top, bottom and at the trailing edge. The left shell has a molded fairing
for the ruder trim control rods.
The rudder has a flat face at the bottom of the leading edge. The flat face has two bonded bolts.
The bolts attach the rudder to the rudder lower mounting bracket. Refer to Section 27-20 for data
about the rudder lower mounting bracket.
The rudder has a mass balance weight bonded into the leading edge near the top and in its rudder
horn. You cannot adjust the mass balance.
Two bearings hold the rudder. A pivot pin bonds into the leading edge near the top. It engages with
a bearing attached to the rear web of the vertical stabilizer. The rudder lower mounting bracket has
the bottom bearing.
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AIRCRAFT
Top Pivot Pin

Insert
Mass Balance
Left Shell
Right Shell
Bottom Mounting Bolt
Figure 1: Rudder Assembly
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AIRCRAFT
B. Rudder Trim-Tab
Figure 2 shows the rudder trim-tab.
The trim-tab has left and right shells. Each shell has GFRP skins. A rigid foam insert strengthens
the trim-tab at the leading edge. The leading edge of each shell has a curve and a flange. The
leading edge flange has a vertical tube for the trim-tab hinge-wire. The shells bond together at the
flanges. The shells also bond together at the top, bottom and at the trailing edge.
A GFRP control horn is bonded to the left side of the trim-tab. Two GFRP shells bonded together
make the control horn.
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AIRCRAFT
Right Shell
Left Shell
Figure 2: Rudder Trim-Tab
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22 Dec 2021 55-40-00 Rev. 4
AIRCRAFT
1. General
These Maintenance Practices tell you how to remove and install the rudder and the rudder trim-tab.
Refer to Section 27-20 for data on the rudder control setting. And refer to Section 27-21 for the rudder
trim-tab setting.
2. Remove/Install the Rudder Assembly
A. Remove the Rudder Assembly
(1) Disconnect the 2 control rods for the rudder Refer to Figure 3. Refer to Figure 4, if
trim-tab: MÄM 42-600 is installed.
S Remove the 2 nuts, washers and bolts that At the rudder bottom bracket.
attach the control rods to the trim operating
lever.
S Move the rods clear of the operating lever.
(2) Remove 2 nuts and washers which attach the

rudder to the rudder lower mounting bracket. Hold the rudder.
(3) Pull the bottom of the rudder aft to disengage

the bottom bolts.
(4) Lower the rudder to disengage the top pivot and

move the rudder and trim-tab assembly clear of
the airplane.
(5) Put the rudder in a stand or on a padded

surface.
B. Install the Rudder Assembly
(1) Move the rudder assembly into position at the

vertical stabilizer.
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AIRCRAFT
(2) Install the rudder assembly:
S Move the rudder to engage the top pivot pin

in the upper pivot bearing.
S Install the 2 washers and nuts that attach Torque: 6.4 Nm (4.7 lbf.ft.). Use new
the rudder to the rudder mounting bracket. self-locking nuts.
(3) Connect the trim-tab control rods:
S Align the control rod eye-ends with the trim

control levers.

attach the eye-ends to the control levers.
(4) If MÄM 42-600 is installed and the rudder

sealing tape and the sliding tape are worn:
S Remove the rudder sealing tape and the

sliding tape from the fin and the rudder
surface.
S Use solvent to clean the surfaces.
S Install the self adhesive sliding tape to the

rudder surface.
S Install the self adhesive sealing tape to the

rudder fin surface. The not adhesive half of
the sealing tape must protrude from the fin
towards the rudder and cover the gap.
(5) Do a test for the correct range of movement of Refer to Section 27-20.
the rudder control.
(6) Do a test for the correct range of movement of Refer to Section 27-21.
the rudder trim control.

a duplicate inspection of the rudder control
system.
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Vertical Stabilizer
Rear Web
Top Pivot Pin
Nut Washer
Bottom
Mounting Bolts
Rudder Bottom Bracket
Rudder Stop Bolt
Figure 3: Rudder Assembly Installation
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Vertical Stabilizer
Rear Web
Top Pivot
Pin
Rudder Assy
Bottom
Washer Mounting Bolts
Nut
Rudder Stop Bolt
Rudder Pedestal
Figure 4: Rudder Assembly Installation (if MÄM 42-600 is installed)
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AIRCRAFT
Trim Tab
Trim Control Horn
Rudder Pedestal
Eye-End
Coupling
Connecting Rod
Friction Damper
Mounting Bracket
Friction Damper
Figure 5: Rudder Trim-Tab Installation
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3. Remove/Install the Rudder Trim-Tab
A. Remove the Rudder Trim-Tab
(1) Disconnect the 2 control rods for the rudder Refer to Figure 5.
trim-tab:
S Remove the 2 nuts, washers and bolts that At the trim-tab control horn.
attach the trim control rods to the trim
control horn.
S Move the rods clear of the operating lever.
(2) Remove the trim-tab:
S Remove the locking wire that secures the

hinge pin.
S Remove the hinge pin from the trim-tab. Hold the trim-tab!
S Move the trim-tab clear of the airplane.
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B. Install the Trim-Tab
(1) Install the trim-tab:
S Move the trim-tab into position at the rudder.
S Align the hinges in the trim tab with the

hinges in the rudder.
S Install the hinge pin.
S Secure the hinge pin with lock-wire. Use new lock-wire.
(2) Connect the control rods for the trim-tab:
S Align the eye-ends of the control rods with

the trim tab control horn.
S Install the bolt, spacer, washers and nut that

attaches the control rods to the control horn.
(3) Do a test for the correct range of movement of

the rudder trim-tab control system.

a duplicate inspection of the rudder trim control
system.
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DA 42 NG AMM Windows
AIRCRAFT
CHAPTER 56
WINDOWS
Doc # 7.02.15 Page 1

Windows DA 42 NG AMM
AIRCRAFT
Page 2
22 Dec 2021 56-TITLE Doc # 7.02.15
Rev. 5
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 56
WINDOWS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 56-10
Flight Compartment Windows
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Replace a Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Window Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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Page 2 Doc # 7.02.15

AIRCRAFT
CHAPTER 56
WINDOWS
1. General
The DA 42 NG has three windows. All of the windows are molded acrylic glass (plexiglass). The
one-piece canopy window covers the pilots’ cockpit. It is also the windscreen. The passenger door has
a window. The right side of the fuselage has a window for the passenger compartment.
A high-performance elastic adhesive bonds each window to the structure.
Section 56-10 gives the data for all of the windows. Refer to Section 52-10 for data about the canopy
and door structure.
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AIRCRAFT
Section 56-10
Flight Compartment Windows
1. General
This Section tells you about the windows in the canopy, passenger door and fuselage. Refer to
Section 52-10 for data about the canopy and door structure.
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Painted Areas
Direct-Vision Panel
Canopy Window
Direct-Vision Panel
Fuselage Window
Passenger Door Frame
Painted Edge
Painted Edge
Canopy Frame
Passenger Door Window
Figure 1: Windows
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AIRCRAFT
Figure 1 shows the windows.
The DA 42 NG has three windows. Each window is polycast molded acrylic glass (plexiglass). This
material gives good optical characteristics. It is also strong. It can be accurately formed into
3-dimensional shapes. A high-performance elastic adhesive bonds each window to the structure.
A flexible white sealant fills the small gap between the edge of the window and the structure.
The one-piece canopy window covers the pilots’ cockpit. It is also the windscreen. It has a small
direct-vision panel in each side. The direct vision-panels have hinges. You can open the direct-vision
panels in flight.
The passenger door has a window for the left side of the passenger compartment. The right side of
the fuselage also has a window for the passenger compartment.
Each window has a band of white paint over the area where it bonds to the structure. The canopy
window also has a screened area above the pilots’ heads. This is a sun-shade. New windows are
painted by the manufacturer.
As an option you can install tinted windows in the DA 42 NG. Refer to the Illustrated Parts Catalog for
data about tinted windows.
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22 Dec 2021 56-10-00 Rev. 5
AIRCRAFT
1. General
This Section tells you how to replace or repair damaged windows. See Section 12-30 for data on
cleaning windows.
2. Replace a Window
You must remove the window by cutting out the damaged window.
A. Equipment
Rocker saw with non-rotating saw blade. 1 Commercial.
Adhesive. A/R Terostat MS 9380.
White sealant. A/R Terostat MS 9380.
B. Replace a Window
Note: Do not use cleaning agents containing alcohol on windows and canopy bubbles.
(1) Remove the canopy or door. Put the canopy or If the canopy or door window must be
door on a firm working surface. replaced. Refer to Section 52-10.
(2) Put protective covers on the inside of the If the right fuselage window must be
cockpit. replaced.
(3) Cut the damaged window from the frame. Use the rocker saw with non-rotating
saw blade.
(4) Grind the frame in order to remove the

remaining window material and sealant.
(5) Put the new window in frame position. Align the

2 holes in the window (center front and back)
with the holes in the frame.
(6) Carefully remove the protective coating from the

new window/canopy bubble on the future
bonding surface.
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(7) Prepare the surfaces:
S Window/canopy bubble. Use sand paper (grid size 320) until the
surface is rough and not shiny.
S Canopy frame/ fuselage. Use sand paper (grid size 80).
S Remove dust from the bonding surfaces and

make sure to get no grease or silicone on
the bonding surfaces.
(8) Apply thin red adhesive tape on the frame and Refer to Figure 2.
the window/canopy bubble.
(9) Apply the dam tape to the canopy Refer to Figure 2. Make sure to achieve
frame/fuselage. a wide bonding surface.
Note: The following bonding of the window/canopy bubble and the alignment must be
finished within 10 minutes.
(10) Apply the sealant and follow the suggested Refer to Figure 2.
shape and positioning around the entire canopy Make sure to apply a constant amount
frame/fuselage. of sealant.
Note: It is very important that the Plexiglas is positioned within ten minutes after the
sealant has been applied.
(11) Position the window/canopy bubble in place on

the canopy frame/fuselage by use of the 2 pins.
(12) Push the window/canopy bubble into position. Refer to Figure 3. Align the
After first positioning, do not move the window window/canopy bubble with the frame
again, to prevent sealant smearing. surface.
(13) Use adhesive tape to hold the window/canopy

bubble in place.
(14) Allow the sealant to cure. Minimum 24 hrs.
(15) Remove the 2 pins.
(16) Remove the adhesive tape which held the

window/canopy bubble in place on the frame.
(17) Remove the excess sealant along the joint Use plastic spattle.
(1 - 2 mm [0.04 - 0.08 in] deep).
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(18) Apply masking tape on both sides of the joint. Refer to Figure 3.
(19) Use sealant to fill the joint and the pinholes and Use plastic spattle.
smoothen the surface.
(20) Spray the joint with a water/cleaning solvent

solution and smooth the surface by hand.
(21) Remove all adhesive and masking tapes.
(22) Allow the sealant to cure. Minimum 24 hrs.
(23) Install the canopy or door. Only if you have replaced the canopy or
door window.
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AIRCRAFT
Visible Edge
(End of Paint)
Tesafilm Red
~ 4mm (0.16 in) Canopy Bubble
28mm (1.1 in)

Tesafilm Red
~ 10mm (0.39 in) Max 5mm (0.2 in)
Masking Tape
~ 8mm (0.31 in) Damtape

6mm high
(0.24 in)
Canopy Frame
Sealant
= =
Figure 2: Position and Form of the Applied Adhesive
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AIRCRAFT
Painting of the Canopy

3mm (0.12 in) 25mm (0.98 in)
± 1mm (0.04 in) A
Masking Tape Masking Tape Canopy Bubble

A
~ 4mm (0.16 in)
Tesafilm Red
Damtape
Canopy Frame
Joint
Figure 3: Filling After Placing the Glazing
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AIRCRAFT
3. Window Repairs
A. Damage Limits
Maximum crack length: 150 mm (6 in).
Do not repair cracks which are more than 150 mm (6 in) from the edge of the window.
B. Equipment
Small high-speed rotary grinder. 1 Commercial.
Filler: Acryfix 92 or Tensol cement No. 70. A/R Commercial.
Masking tape. A/R Commercial.
Plastic adhesive tape. A/R Commercial.
Cold ultra-violet light source (only for Acryfix 92). A/R Commercial.
Note: Fillers become smaller when they cure. Apply enough filler to be above the level
of the window surface. Cut the filler back when it has cured.
If you repair a vertical crack, keep the filler in place with plastic adhesive tape.
Apply a second coat of filler after the first coat has cured.
C. Temporary Repairs to Windows
Stop-drill the ends of short cracks. Use a 2.5 mm (3/32 in) drill. Refer to Figure 4.
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Figure 4: Window Repairs
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AIRCRAFT
D. Permanent Repairs to Windows

(1) Remove the canopy or door. Put the canopy or Only if you will repair the canopy or
door on a firm working surface with the crack door window. Refer to Section 52-10.
horizontal.
(2) Put protective covers over the inside of the Only if you will repair the right fuselage
cockpit. window.
(3) Mask the area around the crack on both inner

and outer surfaces.
(4) Cut a groove along the crack in the outer surface Refer to Figure 4, step 1.
of the window.
(5) Countersink temporary stop-drill holes.
(6) Seal the stop-drill holes on the inner surface. Use plastic adhesive tape.
(7) Apply filler to the groove and the stop-drill holes. Refer to Figure 4, step 2. Use
Acryfix 92 or Tensol cement no. 70.
(8) Let the filler cure. Refer to the manufacturer’s data.
(9) If possible, turn the window so that the inner

surface is up. Remove any plastic adhesive tape.
(10) Cut a groove along the crack in the inner surface Refer to Figure 4, step 3.
of the window.
Note: This groove is less deep than the outer surface groove. It must cut into the outer
layer of filler. This prevents holes in the filler.
(11) Countersink the filler in the stop-drill holes on the

inner surface to 1 mm (0.04 in).
(12) Apply filler to the groove and the stop-drill holes. Refer to Figure 4, step 4.
(13) Let the filler cure. Refer to the manufacturer’s data.
(14) Remove the masking materials.
(15) Grind the filler to the profile of the surface. Grind both sides. Refer to Figure 4,
step 5.
(16) Polish the repair area with fine abrasive paper.
(17) Verify sufficient remaining thickness of the Measure thickness, for example with an
window in the repair area. ultrasonic thickness gauge.
Minimum thickness: 4.25 mm
(0.167 in).
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DA 42 NG AMM Wings
AIRCRAFT
CHAPTER 57
WINGS
Doc # 7.02.15 Page 1

Wings DA 42 NG AMM
AIRCRAFT
Page 2
22 Dec 2021 57-TITLE Doc # 7.02.15
Rev. 5
DA 42 NG AMM Wings
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 57
WINGS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 57-10
Wing Structure
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Wings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the A or B-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4. Remove/Install Control Surface Hinge Brackets . . . . . . . . . . . . . . . . . . . . . . . . . 215
Section 57-50
Flaps
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Section 57-60
Ailerons
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Wings DA 42 NG AMM
AIRCRAFT
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install an Aileron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Page 2
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DA 42 NG AMM Wings
AIRCRAFT
CHAPTER 57
WINGS
1. General
The DA 42 NG is a low wing monoplane with cantilever wings. A wing center section with stub wings
and the engine nacelles attaches to the fuselage. Refer to Section 53-10 for more data about the
fuselage center section.
The outer wings attach to the wing center section stub wings. Each wing has a flap attached to the
inboard trailing edge of the outer wing and to the trailing edge of the stub wing. An aileron attaches
to the outboard trailing edge of each outer wing.
The wings have a semi-monocoque structure. Each wing has top and bottom shells. The shells have
CFRP outer skins, a rigid foam core and GFRP inner skins. Each wing has two I-section spars. Uni-
directional carbon fiber cloth makes the spar caps. Each wing also has GFRP ribs and webs.
The flaps and ailerons have a mixture of CFRP and GFRP cloth in the shells. The shells have rigid
foam cores.
Refer to Chapter 51 for general composite repair data. Refer to Chapter 27 for data about the control
systems which operate the flaps and ailerons.
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Section 57-10
Wing Structure
1. General
This Section tells you about the structure of the outer wing. Refer to Section 53-10 for data about the
structure of the wing center section. Refer to Section 57-50 for data about the structure of the flaps.
Refer to Section 57-60 for data about the structure of the ailerons.
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Top Shell
Middle
Root Rib Rear
Root Rib
Bush
Flap Control Rib
Rear Web
Spar
Stub
Aileron Control Rib
Front
Root Rib Removable
Rear Spar Wing Tip
Front Spar
Inner Fuel
5x Screws
Chamber Ribs
Mid Fuel
Chamber Ribs
Bottom Shell
Outer Fuel
Left Wing Shown, Chamber Ribs
Right Wing Opposite
End Rib
7x Screws
Figure 1: Wing Structure
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2. Description
Figure 1 shows the wing structure. The wing has top and bottom shells. It has front and rear spars and
a root rib made in three parts. Five ribs hold the fuel tanks between the spars. Flap and aileron control
ribs hold the bellcranks for the control systems.
A rear web closes the trailing edge of the wing. An end rib closes the outboard end of the wing.
A removable GFRP tip attaches to the wing shells and outer rib with screws.
Bonding paste (thickened resin) bonds the wing components to each other. The following section gives
more data about the main parts:
A. Wing Shells
Each wing has top and bottom shells. Each shell has a CFRP skin with a rigid foam core. The fibers
in the layers of cloth which cover the whole wing run at ± 45° to the lateral axis of the wing. The
outer layer of the wing is carbon fiber. The inner layer of the wing is glass fiber.
Some areas have more layers of cloth to give more strength. For example, the area around each
access hole has extra layers of carbon fiber cloth.
The bottom shell of each wing has 8 access holes. These give access to the flap and aileron
bellcranks and fuel tanks. The top shell has a hole for the fuel cap of the outer fuel chamber.
B. Spars
Each wing has two I-section spars. The front spar on one side is the same as the rear spar on the
opposite side.
Many layers of uni-directional carbon fiber make the spar caps. The number of layers in the spar
caps decreases from root to tip.
Each spar has a shear web. The shear web has GFRP skins and a rigid foam core. Glass cloth
fillets attach the spar caps to the shear web.
The inboard end of each spar (the 'stub') goes past the root rib. The spar stub is a box-section with
many layers of glass cloth wrapped round the spar caps. Two large bushes bond into the spar stub.
The wing main bolts engage these bushes and attach the wing to the fuselage center section. The
bushes and bolts transmit the wing bending loads into the center section. Figure 2 shows the main
bolt installation.
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C. Root Rib
Each outer wing has a three-piece root rib. Each piece is a GFRP molding with many layers of
glass fiber cloth. The front root rib bonds to the top and bottom shells and the front face of the front
spar. It has a housing for the A-bolt. The A-bolt transmits lift loads into the center section.
The middle part of the root rib bonds to the top and bottom shells, the aft face of the front spar and
the front face of the rear spar. It has a large oval access panel for removing the fuel tanks.
The rear root rib bonds to the top and bottom shells, the aft face of the rear spar and the rear web.
It has a housing for the B-bolt. The B-bolt transmits lift loads into the center section. It also has
guide rollers for the flap and aileron push rods.
D. Fuel Tank Ribs
Six ribs hold the fuel tanks in each wing. Each rib is a GFRP molding with a large oval hole. The
hole has a flat inner flange to hold the tank. The ribs bond to the top and bottom shells, the aft face
of the front spar and the front face of the rear spar.
E. Flap and Aileron Control Ribs
Each wing has two flap and one aileron control ribs. The ribs are GFRP moldings. Each rib has a
bend with a solid insert. The insert gives extra strength where the control bellcrank attaches. The
ribs bond to the top and bottom shells, the aft face of the rear spar and the rear web.
F. Rear Web
Each wing has a rear web. The web closes the trailing edge of the wing. The web bonds to the top
and bottom shells. It also bonds to the rear faces of the rear root rib, the flap control ribs and the
aileron control rib. The rear web has extra layers where the flap and aileron hinges attach. Rivets
hold anchor-nut plates to the forward face of the rear web where the hinges attach.
G. Wing End Rib
Each wing has an end rib. The end rib is a GFRP molding. The end rib has eight anchor nuts which
attach the wing tip. It also has a threaded strong-point for a tie-down ring.
H. Wing Tip
The wing tip is a GFRP molding with top and bottom shells. The wing tip holds the external lights.
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1. General
These Maintenance Practices tell you how to remove and install the outer wings. They also tell you
how to remove and install the wing tips and other small components.
2. Remove/Install the Wings
A. Equipment
Padded wing trestles. 4 Commercial.
Main bolt removal tool. 1 -
Wing stand (not essential). 1 per wing Commercial.
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Rear Box-Spar Bushes
Rear Spar
Locking Tube
Locking Bolt
Front Box-Spar
Bushes
Rear
Main Bolt
Short Spar Bush
End-Piece
Long
End-Piece
Front
Main Bolt
Front Spar
Spar Bush
Figure 2: Wing Main Bolt Installation
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B. Remove the Wings
Use this procedure to remove the left wing or the right wing. Where a part of the procedure applies
to only one wing it will tell you so.
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.
(4) Put trestles under both wing tips. Under the end rib.
(5) Disconnect the flap push-rod: At the wing root. Through the engine
nacelle access panels.
S Remove the nut, washer and bolt.
(6) Disconnect the aileron pushrod: At the wing root. Through the engine
nacelle access panels.
(7) Disconnect the cable for the fuel probes and the At the fuel tank.
fuel sensor.
(8) Disconnect these items at the wing root: Left wing only.
S The Pitot hose. The hose is 8 mm (5/16 in) diameter

(green color).
S The static hose. The hose is 8 mm (5/16 in) diameter

(purple color).
(9) Disconnect the wing electrical connector. Engine nacelle panels.
(10) Disconnect the wing bonding connections. Engine nacelle panels.
(11) Disconnect the fuel lines.
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WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE DISEASE.
(12) Disconnect the fuel hose from the fuel tank. Put a container to catch a small quantity
of fuel. Remove spilt fuel.
(13) Remove the locking tube from the inboard and

outboard main bolts:
S Move the tube over the long end piece.
S Remove the short end piece.
S Remove the tube and the long end piece.
WARNING: USE 3 PERSONS TO LIFT THE WING. IF YOU DO NOT, YOU CAN
CAUSE INJURY.
CAUTION: DO NOT LIFT ON THE FLAP. YOU CAN DAMAGE THE FLAP.
Note: For the rest of this procedure, one person must lift the wing tip. One person
must lift the leading edge at the root rib. One person must lift the trailing edge
at the root rib.
(14) Remove the main bolts:

If necessary, move the wing tip a small
S Take the weight off the wing.
amount up and down to help release the
S For each bolt: main bolts.
S Install the main bolt removal tool. Make a note of the location of each bolt.
S Extract the bolt.
(15) Lift the wing away from the center section. Make sure that the electrical cables do
not catch on the center section conduit.
(16) Put the wing on trestles or a wing stand.
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Note: If you use trestles, put one trestle under the spar stubs. Put the second trestle
under the wing end rib.
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C. Pre-Installation Procedure
Do this check before you install the wings.
(1) Examine the inner faces of the front and rear Refer to the manufacturer if you find
boxspars. Look specially for: damage in any of these areas.
S Damage to the main bolt bushes. Clean the bushes.
S Damage to the structure round the bushes.
S Looseness between the bushes and the

structure.
S Damage to the top and bottom shells of the

center section (where the spar stubs can
touch the shells during wing removal).
S Delamination between the boxspars and the

shells.
(2) Examine the front, middle and rear end ribs in Refer to the manufacturer if you find
the wing center section. Look specially for: damage in any of these areas.
S Damage to the A and B-bolt bushes. Clean the bushes.
S Looseness between the A and B-bolt

bushes and the end ribs.
S Delamination between the end ribs, the

boxspars and the shells.
(3) Examine the wing spar stubs. Look specially for: Refer to the manufacturer if you find
damage in any of these areas.
S Damage to the main bolt bushes. Clean the bushes.
S Damage to the spar stub around the

bushes.
S Looseness between the bushes and the

spar stub.
S Delamination between the spars and the

shells.
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(4) Examine the wing root ribs. Look specially for: Refer to the manufacturer if you find
damage in any of these areas.
S Damage to the A and B-bolts and bushes. Clean the bolts and bushes.
S Damage to the front and rear root ribs

around the bushes.
S Looseness between the bushes and the root

ribs.
S Delamination between the root ribs, the

spars and the shells.
(5) Examine the main bolt assemblies. Look Clean the main bolt assembly.
specially for:
S Corrosion of the end-pieces or tube. Remove corrosion. Repair the surface

finish. Refer to Section 51-20.
S Corrosion of the main bolts. No corrosion permitted.
S Scratches on the bearing surfaces. Maximum depth 0.1 mm (0.004 in).
S Deformation. No deformation permitted.
S Damage to the threads for the removal tool. Replace the bolt if you cannot attach the
removal tool correctly.
(6) Measure the radial play of each main bolt in the Maximum radial play 0.2 mm (0.008 in).
related main bulkhead bushes.
(7) Measure the radial play of each main bolt in the Maximum radial play 0.2 mm (0.008 in).
related spar stub bush.
(8) Lubricate these items: Refer to Section 12-20.
S Main bolts.
S Front and rear main bulkhead bushes.
S Spar bushes.
S A and B-bolt bushes in the end ribs.
S A and B-bolts in the wing root ribs.
(9) Examine the flap. Look specially for damage to

the inner end rib.
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D. Install the Wings
Use this procedure to install the left wing or the right wing. Where a part of the procedure applies
to only one wing it will tell you so.
(1) Do the pre-installation check. Refer to Paragraph C.
WARNING: USE 3 PERSONS TO LIFT THE WING. IF YOU DO NOT, YOU CAN
CAUSE INJURY.
CAUTION: DO NOT LIFT ON THE FLAP. YOU CAN DAMAGE THE FLAP.
CAUTION: DO NOT LET THE SPAR STUBS TOUCH THE CENTER SECTION
SHELLS. YOU CAN DAMAGE THE SHELLS.
Note: Until you install the main bolts, one person must lift the wing tip. One person
must lift the leading edge at the root rib. One person must lift the trailing edge
at the root rib.
(2) Lift the wing into position:
S Install inboard fuel tank access panel.
S Move the spar stubs part way into the front Hold the wing in position.
and rear box spars.
S Put the electrical cable, Pitot static and fuel Hold the wing in position. Pitot static
lines through the conduit in the leading edge tube left wing only.
of the center section.
S Align the flap inner rib with the inner flap. Hold the wing in position.
S Move the wing fully into the center section to

engage the A and B-bolts and the outer flap
to inner flap transfer lug.
(3) Install the main bolts: If necessary, move the wing tip a small
amount up and down to help install the
S Hold the weight of the wing.
main bolts.
S Install each bolt.
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(4) Install the locking tubes on the inboard and Refer to Figure 2.
outboard main bolts:
S Install the long end piece in one main bolt.
S Move the tube over the long end piece.
S Install the short end piece in the other main

bolt.
S Move the tube over the short end piece.
S Install the bolt, washer and self-locking nut

through the tube and the long end piece.
(5) Connect these items: Left wing only.
S The Pitot hose. The hose is 8 mm (5/16 in) diameter

(green color).
S The static hose. The hose is 8 mm (5/16 in) diameter

(purple color).
(6) Connect the electrical connector. Engine nacelle access panels.
(7) Connect the bonding connections. Engine nacelle access panels.
(8) Connect the fuel hose. At the fuel tank.
(9) Connect the fuel probe and fuel sensor cables. At the fuel tank.
(10) Connect the flap pushrod: Engine nacelle access panels.
S Install the bolt, washer and self-locking nut. Torque: 6.4 Nm (4.7 lbf.ft.).
(11) Connect the aileron pushrod: Engine nacelle access panels.
S Install the bolt, washer and self-locking nut. Torque: 6.4 Nm (4.7 lbf.ft.).
(12) If you must also install the other wing, do

steps 1 to 11 again for the other wing.
(13) Connect the battery. Refer to Section 24-31.
(14) Do a test for correct operation and range of Refer to Section 27-50.
movement of the flap system. If necessary,
adjust the flap system.
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(15) Do an inspection of the flap controls which you

have connected or adjusted.

Authority, do a second inspection of the
controls.
(16) Do a test for correct operation and range of Refer to Section 27-10.
movement of the aileron system. If necessary,
adjust the aileron system.
(17) Do an inspection of the aileron controls which

you have connected or adjusted.

Authority, do a second inspection of the
controls.
(18) Do a functional check of these lights: Refer to Section 33-40.
S Position lights.
S Strobe lights (ACLs).
(19) Do a Pitot and static system leak test. Left wing only.
(20) Refuel the airplane to the unusable fuel level. Refer to Section 12-10.
(21) Do a fuel quantity indication calibration check. Refer to Section 28-40.
(22) Do a check flight. Refer to the DA 42 NG Airplane Flight

Manual.
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3. Remove/Install the A or B-Bolts
A. Remove the A or B-Bolts
(1) Remove the wing. Refer to Paragraph 2.
(2) Remove the A or B-bolt: Refer to Figure 3.
S Hold the flats on the flange of the bolt with Access for the A-bolt through the hole in
a wrench. the front root rib.
S Remove the self-locking nut from the Access for the B-bolt through the access
A or B-bolt. panel in the bottom shell.
S Remove the A or B-bolt.
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Rear
Root Rib
Bonded
Bush
Front
Root Rib
Access B-Bolt
Panel
Access RIGHT SHOWN,

Hole LEFT OPPOSITE
Bonded
Bush
A-Bolt
Figure 3: A and B-Bolt Installation
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B. Install the A or B-Bolt
(1) Examine the A or B-bolt. Look specially for:
S Corrosion. No corrosion permitted.
S Scratches on the bearing surfaces. Maximum depth 0.1 mm (0.004 in).
S Deformation. No deformation permitted.
S Damage to the threads. No damage permitted.
(2) Examine the A or B-bolt bush. Look specially

for:
S Looseness between the A or B-bolt bush

and the root rib.
S Damage to the root rib where the bush

attaches.
S Damage to the bush.
(3) Install the A or B-bolt: Refer to Figure 3.
S Install the bolt in the bush. Access for the A-bolt through the hole in
the front root rib.
S Hold the flats on the flange of the bolt with a Access for the B-bolt through the access
wrench. panel in the bottom shell.
S Install the washer and self-locking nut. Torque: 32 Nm (23.6 lbf.ft.).
(4) Install the wing. Refer to Paragraph 2.
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Flap Hinge And

Aileron Inner Hinge
Anchor-Nut
Plate
Aileron
Outer Hinge
Rear Web
Anchor-Nut
Plate
Flap Control
Horn Hinge
Flap Bellcrank
Access Panel
Aileron Control
Horn Hinge
Aileron Bellcrank
Access Panel
LEFT SHOWN
RIGHT OPPOSITE
Figure 4: Control Surface Hinge Bracket Installation
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4. Remove/Install Control Surface Hinge Brackets
A. Remove a Control Surface Hinge Bracket
(1) Remove the control surface. Refer to Sections 57-50 and 57-60.
(2) For brackets at the control horn hinge: The flap brackets have 3 bolts.
S Remove the control bell crank access panel The aileron brackets have 2 bolts.
under the wing.
S Remove the attaching nuts and large From inside of the wing.
washers.
S Remove the bolts and small washers.
S Remove the bracket.
(3) For brackets not at the control horn hinge: All brackets have 2 bolts.
S Remove the bolts and small washers.
S Remove the bracket.
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B. Install a Control Surface Hinge Bracket
(1) For brackets at the control horn hinge: The flap brackets have 3 bolts.
S Put the bracket in position on the rear web. The aileron brackets have 2 bolts.
S Install the bolts with small washers.
S Install the large washers and self-locking From inside of the wing.
nuts. Torque: 3.6 Nm (2.7 lbf.ft.).
S Install the control bellcrank access panel

under the wing.
(2) For brackets not at the control horn hinge: All brackets have 2 bolts.
S Put the bracket in position on the rear web.
S Install the bolts and small washers. Torque: 3.6 Nm (2.7 lbf.ft.).
(3) Install the control surface. Refer to Sections 57-50 and 57-60.
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Section 57-50
Flaps
1. General
This Section tells you about the flap of the DA 42 NG. The DA 42 NG has an inner and an outer flap
on each wing. The outer flap attaches to the outer wing and the inner flap attaches to the airplane wing
center section. The flap selector in the cockpit controls both inner and outer flaps.
Refer to Section 27-50 for data about the flap control system.
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Inner End Rib
Flap Outer, LH
Hinge
Hinge
Flap Horn
Hinge
Hinge
Hinge
Figure 1: Outer Flap Assembly
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2. Description
Figures 1 and 2 show the outer and inner flaps. Both flaps have a similar construction.
A. Outer Flap
The outer flap has a top shell and a bottom shell.
The bottom shell has inner and outer skins which bond to a foam core. The outer layer of the skins
are GFRP. The inner layers are CFRP. The leading edge of the shell bends up to form a web. It
then curves forward to form a shroud which seals the gap between flap and wing when the flap is
down.
The outboard end of the bottom shell also bends up to close the end of the flap. The leading edge,
the ends, and the area where the horn attaches have more carbon fiber cloth to give more strength
and stiffness.
The top shell has inner and outer GFRP skins which bond to a foam core. The outer layer of the
skins are GFRP. The inner layers are CFRP. The top shell bonds to the bottom shell and the inner
end rib.
The flap has an inner end rib. The inner end rib is a CFRP molding. The rib has an recess which
engages with an extension on the inner flap. The end rib bonds to the top and bottom shells.
A flap horn drives the outer flap. 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.
Hinges attach the outer flap to the trailing edge of the outer wing. 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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Flap Inner, LH
Hinge
Flap Horn
Hinge
Hinge
Figure 2: Inner Flap Assembly
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B. Inner Flap
The inner flap has a top shell and a bottom shell.
The bottom shell has inner and outer skins which bond to a foam core. The outer layer of the skins
are GFRP. The inner layers are CFRP. The leading edge of the shell bends up to form a web.
The inboard end of the bottom shell also bends up to close the end of the flap. The leading edge,
the ends, and the area where the horn attaches have more carbon fiber cloth to give more strength
and stiffness.
The top shell has inner and outer GFRP skins which bond to a foam core. The outer layer of the
skins are GFRP. The inner layers are CFRP. The top shell bonds to the bottom shell and the inner
end rib.
The flap has an outer end rib. The outer end rib is a CFRP molding. The rib has an extension which
engages with a recess on the outer flap. The end rib bonds to the top and bottom shells.
A flap horn drives the inner flap. 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.
Hinges attach the inner flap to the trailing edge of the airplane center section. Each inner flap has
four 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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1. General
These Maintenance Practices tell you how to remove and install the flaps. Refer to Section 27-50 for
the flap setting procedure.
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A Flap Outer, LH
LH installation shown
RH installation opposite
A
A
Access Hole
Hinge Pin
Roll Pin Flap Structure
Flap Horn
A
Hinge Pin
Brackets attached
to Wing Roll Pin
Bracket attached
to Wing Flap Hinge
Figure 3: Outer Flap Installation
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A
Hinge Pin A
Split Pin
A
Bushing B
Nut
A
A
Blanking Plug
Hinge A C
Screw
B Screw
Washer
Nut
Hinge Pin
Nut Screw
Nut
Split Pin Bolt Washer
Washer
Screw
Cap Nut
Nut
Screw
Screw
Hinge Cover C
Maintenance Cover
Washer
Screw
Figure 4: Outer Flap Installation (if MÄM 42-600 is installed)
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2. Remove/Install a Flap
A. Remove an Outer Flap
EQUIPMENT.
(1) Lower the flaps:
S Set the flap selector to LDG.
S When the flaps stop moving.
(2) Open the circuit breaker for the flap control. Instrument panel. Right side.
(3) Remove the flap hinge cover (if MÄM 42-600 is

installed):
S Remove the bolts and washers which attach

the flap hinge cover to the flap horn.
S Remove the flap hinge cover including the

bushings.
(4) Disconnect the flap push rod from the flap horn: Refer to Figure 3. Hold the flap.
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.
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(5) Remove the 6 hinge pins from the flap hinges Support the flap assembly!
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.
(6) Carefully move the flap aft, and clear of the

airplane.
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AIRCRAFT
Flap Inner, LH
B
Hinge Pin
A
A
Roll Pin
A
Bracket attached
Flap Hinge
to Wing B
Hinge Pin
Roll Pin
Bracket attached
to Wing Flap Horn
Figure 5: Inner Flap Installation
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Bonding Wire
Hinge Pin Split Pin A B

A
Bushing
Nut
A
Bonding Wire
Hinge B
Screw Screw
Nut
LH installation shown Bushing
Nut
Washer
Split Pin Nut
Hinge Pin
Screw Washer
Screw
Screw
Washer
Screw
Hinge Cover
Washer
Screw Maintenance Cover
Figure 6: Inner Flap Installation (if MÄM 42-600 is installed)
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B. Remove an Inner Flap
EQUIPMENT.
(1) Lower the flaps:
S Set the flap selector to LDG.
S When the flaps stop moving.
(2) Open the circuit breaker for the flap control. Instrument panel. Right side.
(3) Remove the flap hinge cover (if MÄM 42-600 is Refer to Figure 6.
installed):

the flap hinge cover to the flap horn.
S Remove the flap hinge cover including the

bushings.
(4) Disconnect the flap push rod from the flap horn: Refer to Figure 5. Hold the flap.


from the horn.
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(5) Remove the 4 hinge pins from the flap hinges Support the flap assembly!
and the flap horn:
S Remove the roll pins which locate the flap

hinge pins.

the hinges.
(6) Carefully move the flap aft, and clear of the

airplane.
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C. Install an Outer Flap
(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 Make sure that there is a gap of
horn: 0.5 - 2.5 mm (0.002 - 0.010 in) between
the faces of the hinge at the horn and a
S Push the hinge pins into position from the
gap of 1 - 3 mm (0.004 - 0.012 in)
inboard side.
between the faces at the other hinges.
S Align the holes in the hinges with the holes
in the hinge pins and install the roll pins.
(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) Install the flap hinge cover (if MÄM 42-600 is

installed):
S Position the flap hinge cover to the flap

horn.
S Install the bushings.
S Install the washer and bolts. Apply Loctite Screw Locking 243 (blue)
or equivalent.
(7) If necessary for your Airworthiness Authority, do

a second inspection of the flap controls.
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AIRCRAFT
D. Install an Inner Flap
damaged.
(2) Put the flap into position on the airplane.
(3) Install the 4 hinge pins in the hinges and flap Make sure that there is a gap of
gap of 1 - 3 mm (0.004 - 0.012 in)
inboard side.
(4) Install the bolt which attaches the flap push rod
to the flap horn:

rod.
(5) Do a test for correct adjustment of the flaps. Refer to Section 27-50.
(6) Install the flap hinge cover (if MÄM 42-600 is

installed):
S Position the flap hinge cover to the flap

horn.
or equivalent.

a second inspection of the flap controls.
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Section 57-60
Ailerons
1. General
This Section tells you about the aileron. Refer to Section 27-10 for data about the aileron control
system.
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Wings DA 42 NG AMM
AIRCRAFT
Trim Tab
Aileron
Hinge
Aileron Horn
LH aileron shown
RH aileron opposite
Mass Balance
Hinge
Figure 1: Aileron Assembly
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2. Description
Figure 1 shows the aileron assembly.
The aileron has a bottom shell and a top shell. The bottom shell has inner and outer CFRP skins. The
outer and inner layers of the skins are GFRP. The skins bond to a rigid plastic foam core. The leading
edge of the shell bends up to form a web. It then curves forward to form a shroud which seals the gap
between aileron and wing when the aileron moves down.
The ends of the bottom shell also bend up to close the ends of the aileron. The leading edge, the ends
and the area where the horn attaches have more carbon fiber cloth to give more strength and stiffness.
The top shell has inner and outer CFRP skins. The outer and inner layers of the skins are GFRP. The
skins bond to a rigid plastic foam core.
The aileron horn is an aluminum alloy component. Three bolts attach the horn to the bottom surface
of the aileron. A small hole in the leading edge of the aileron gives access to the front attaching nuts
and washers. The horn also makes one of the aileron hinges.
Each aileron has three hinges (as well as the aileron horn). Two bolts attach each hinge to the leading
edge of the aileron. 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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1. General
These Maintenance Practices tell you how to remove and install the ailerons. Refer to Section 27-10
for the aileron control setting procedure.
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Wings DA 42 NG AMM
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A Aileron
Aileron Horn
Hinge Pin
Roll Pin
Hinge Pin
A
Brackets attached Roll Pin

to Wing
Bracket attached
to Wing Aileron Hinge
Figure 2: Aileron Installation
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Hinge Pin A
Split Pin B
Bushing A
Nut
Hinge
Blanking Plug A
Screw Screw
Washer
Nut
Hinge Pin
Bushing
RH installation opposite Screw Nut
Nut
Split Pin
Bolt
Washer
Screw
B Cap
Screw
Hinge Cover
Maintenance Cover
Washer
Screw
Figure 3: Aileron Installation (if MÄM 42-600 is installed)
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2. Remove/Install an Aileron
A. Remove an Aileron
(1) Remove the aileron hinge cover (if MÄM 42-600

is installed):

the aileron hinge cover to the aileron horn.
S Remove the aileron hinge cover including

the bushes.
(2) Disconnect the aileron push rod from the aileron Hold the aileron.
horn:


from the horn.
(3) Remove the 4 hinge pins from the aileron Support the aileron assembly!
hinges and the aileron horn:
S Remove the roll pins which locate the

aileron hinge pins.

the hinges.
(4) Carefully move the aileron aft, and clear of the

airplane.
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AIRCRAFT
B. Install an Aileron
damaged.
(2) Put the aileron into position on the airplane.
(3) Install the 4 hinge pins in the hinges and aileron Make sure that there is a gap of
gap of 1 - 3 mm (0.004 - 0.012 in)
inboard side.
(4) Install the bolt which attaches the aileron push

rod to the aileron horn:

rod.
(5) Do a test for correct adjustment of the aileron. Refer to Section 27-60.
(6) Install the aileron hinge cover (if MÄM 42-600 is

installed):
S Position the aileron hinge cover to the

aileron horn.
or equivalent.

a second inspection of the aileron controls.
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CHAPTER 61
PROPELLER
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Propeller DA 42 NG AMM
AIRCRAFT
Page 2
22 Dec 2021 61-TITLE Doc # 7.02.15
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TABLE OF CONTENTS
CHAPTER 61
PROPELLER
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 61-10
Propeller Assembly
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the MTV-6-R-C-F Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Propeller Blade Tracking Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4. Check/Adjust the V-Belt Tension of the Additional Alternator (if OÄM 42-204 is
installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
5. Remove/Install the Additional Alternator V-Belt (if OÄM 42-204 is installed) . . . 210
6. Remove/Install the Additional Alternator Pulley (if OÄM 42-204 is installed) . . . 216
Section 61-20
Propeller Control
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Propeller Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Propeller Un-Feathering Accumulator . . . . . . . . . . . . . . . . . 205
4. Propeller Un-Feathering Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Page 2
22 Dec 2021 61-CONTENTS Doc # 7.02.15
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AIRCRAFT
CHAPTER 61
PROPELLER
1. General
This Chapter tells you about the propeller installed on the DA 42 NG. Refer to Section 61-10 for data
about the propeller and refer to Section 61-20 for data about the propeller control.
For more data on the propeller refer to the propeller manufacturer’s manuals.
Service Bulletin.
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Propeller
Spinner
Figure 1: Propeller Assembly
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AIRCRAFT
Section 61-10
Propeller Assembly
1. General
The DA 42 NG has MTV-6-R-C-F/CF187-129 variable pitch and feathering propellers. Each propeller
has three blades. The blades are made from wood and are covered with GFRP. The blades have an
acrylic lacquer painted finish. The outboard leading-edges of the blades are protected from erosion
by a stainless-steel sheath. The stainless-steel sheath is bonded into position. The inboard section of
the leading-edge is protected by a self-adhesive rubber strip (PU tape).
This Section tells you how to remove and install the propellers and how to do a test for blade tracking.
Section 61-20 tells you about the propeller governor.
Refer to the propeller manufacturer’s manuals for more data on the propeller.
If OÄM 42-204 is carried out, a gearbox fan with an additional alternator pulley is installed on the
gearbox flange of the LH engine.
2. Description
Figure 1 shows the propeller. The propeller hub has six studs on the rear face. The propeller attaches
to the engine gearbox flange with six nuts and washers.
If OÄM 42-204 is carried out, an additional alternator gearbox fan with an additional alternator pulley
is installed on the gearbox flange of the LH engine using a prop flange pulley support. The six propeller
attachment nuts mount the gearbox fan assy and the propeller to the gearbox flange (Figure 2).
A spinner bulkhead (spinner backplate) attaches to the rear of the hub with six bolts. The bolts are
locked with wire. A front support plate attaches to the front of the hub with six screws. The screws are
locked with wire. A spinner which is made from composite material attaches to the aft bulkhead with
screws.
When the engine is running centrifugal twisting moments make the propeller blades move towards fine
pitch. The propeller of the DA 42 NG has counterweights attached to the propeller blades. The
counterweights overcome the centrifugal twisting moment of the blades and cause the blades to move
to coarse pitch.
The engine has a electronic engine control system EECS including an electronic engine control unit
(EECU). The EECU controls the propeller pitch hydraulically. Gearbox oil flows via the constant speed
governor to control the oil pressure in the propeller pitch change mechanism. The oil pressure is
increased for lower pitch angles and reduced for higher pitch angles. The oil flows from the governor
to the propeller hub through the hollow propeller shaft.
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Metal Erosion Sheath
Wood/Composite
Blade
PU Tape Spinner Bulkhead

Engine Flange
Balance Weights
Attaching Nut
and Washer
Hub
Blade Ferrule
Low
Pitch Stop
Front
Support Plate
Spinner Attaching
Spinner Dome Screws
Figure 1: Propeller Assembly
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AIRCRAFT
Figure 2: Propeller Assembly (if OÄM 42-204 is carried out)
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AIRCRAFT
3. Operation
When the propeller is turning, aerodynamic twisting moments normally cause the blades to turn
towards fine pitch. The propeller installed on the DA 42 NG has counterweights attached to each
propeller blade to overcome the aerodynamic twisting moments. The counterweights act in the
opposite sense to the aerodynamic twisting moments and move the blades towards coarse pitch. In
addition to that a spring within the propeller hub also supports the counterweight and forces the
propeller blades to feathered position.
High pressure oil is used to control the propeller pitch. Oil from the engine gearbox is pumped to the
governor. The governor directs the oil to the propeller as necessary to control the propeller pitch.
Hydraulic pressure in the cylinder acts on a piston and the piston moves the propeller blades towards
low pitch.
The propeller pitch control system is integrated into the engine EECS system. The pitch is controlled
automatically by the EECU. Depending on the power setting the propeller pitch is adjusted so that the
required RPM will be obtained as shown in Figure 3.
An pitch stop (start lock) limits the blade movement towards coarse pitch (propeller RPM below
1300 RPM). When the propeller RPM is higher than 1300 RPM the centrifugal latches (pitch stop) are
disengaged and allow the propeller blades to move past the start lock position.
If the oil pressure fails during normal flight (propeller RPM greater than 1300 RPM), the centrifugal
latches are disengaged and the counterweights and a spring in the propeller hub will force the
propeller to the feathered position.
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Figure 3: Propeller RPM Adjusted by the Engine ECU System
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Trouble-Shooting
1. General
The table below lists the defects you could have for the propeller. If you have the trouble detailed in
the Trouble column read across to the Possible Cause column. Then do the repair in the Repair
column.
Engine vibration. Propeller out of balance. Examine the propeller. If you

find damage refer to the
manufacturer’s Owners
Manual.
Spinner out of balance. Replace the spinner.
Propeller mounting loose. Tighten the mounting nuts to

the correct torque. Refer to the
manufacturer’s Owners
Manual. Use new nuts.
Spinner attaching screws Tighten the attaching screws.

loose. Refer to the manufacturer’s
Owners Manual.
Blade tracking not correct. Refer to the manufacturer’s

Owners Manual.
Cracks in the blades. Over-speed. Refer to the manufacturer’s

Owners Manual.
Holes/nicks/dents in the blade. Stone damage. Repair/replace the propeller.

Refer to the manufacturer’s
Owners Manual.
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1. General
These Maintenance Practices tell you how to remove and install the propeller. They also tell you how
to do a propeller blade tracking test and how to remove and install the additional alternator pulley assy
(if OÄM 42-204 is installed).
2. Remove/Install the MTV-6-R-C-F Propeller
A. Remove the Propeller
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE PROPELLER. IF THE ENGINE IS TURNED, THE
PROPELLER CAN CAUSE INJURY OR DEATH.
S Set the related ENGINE MASTER switch to

OFF.
(3) Remove the engine cowlings. Refer to Section 71-10 or 71-11.
Note: Mark the propeller, spinner, front support plate and spinner bulkhead, with an
index mark. This will help you install these items in the correct position.
(4) Remove the spinner: Refer to Figure 4.
S Mark the spinner and spinner bulkhead with

index marks to aid installation.
S Release the screws holding the spinner to

the spinner bulkhead and move the spinner
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AIRCRAFT

(5) Remove the nuts and washers which attach the Hold the propeller!
propeller to the propeller shaft flange.
(6) Pull the propeller forward and clear of the

propeller shaft flange.
(7) Use caps to cover open lines.
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Engine
Flange
Hub
Oil Seal
OIL SEAL LOCATION IN THE HUB Spinner Bulkhead
Oil Seal
Balance Weights Engine Flange
Nut
Washer
Attaching Bolts
Hub
Spinner Attaching
Screws
Spinner Dome
Figure 4: Propeller Installation
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AIRCRAFT
Figure 5: Propeller Installation (if OÄM 42-204 is installed)
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B. Install the Propeller

OFF.
(2) Make sure that the propeller shaft flange and

the propeller flange are clean and dry.
(3) Make sure that the shipping plug is removed

and check the inside of the propeller hub area
for contamination.
(4) Make sure that a new O-ring oil seal is in place Refer to Figure 4.
in the propeller hub. Lightly oil the seal.
Use clean gearbox oil.
(5) Move the propeller into position on the propeller Take care not to damage the propeller
shaft flange. O-ring seal.
Note: Make sure that the propeller is pushed into the correct position by hand. Do not
use the nuts to pull the propeller into position.
(6) Install the 6 washers and nuts.
(7) When the propeller is in the correct position, Torque 85 - 90 Nm (63 - 66 lbf.ft.).
fully tighten the nuts in opposing pairs.
(8) Check gearbox oil level and refill if necessary. Refer to Section 12-10.
(9) Do a test for correct blade track. Refer to Paragraph 3.
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AIRCRAFT

(10) Install the spinner: Align the index mark.
S Loosely install the screws and plastic

washers which attach the spinner to the
spinner bulkhead.
S Tighten all the attaching screws. Torque 4 - 5 Nm (35 - 44 lbf.in.).
(11) Install the engine cowlings. Refer to Section 71-10 or 71-11.

operation of the propeller.
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3. Propeller Blade Tracking Test
A. Equipment
Tracking stand. 1 Commercial.
B. Procedure
Refer to mt-Propeller Operation and Installation manual, latest revision.
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4. Check/Adjust the V-Belt Tension of the Additional Alternator (if OÄM 42-204 is installed)
WORK ON THE ADDITIONAL ALTERNATOR ASSEMBLY. IF THE
DEATH.
(3) Remove the LH engine cowlings. Refer to Section 71-10 or 71-11.
(4) Check the v-belt tension by conducting one of the

following test methods:
S Pull the v-belt half way between the pulleys

down with 25 N (5.6 lbf) and measure the
deflection.
S Measure the natural frequency of the v-belt Recommended tension gauge:

half way between the pulleys according the CONTI® VSM-1.
instructions of the tension gauge
manufacturer. Repeat this measurement
4 times turning the propeller blade each
time 90°.
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(5) If the deflection is 4 mm to 5 mm

(0.16 in to 0.20 in) respectively the natural
frequency is 123 Hz +12/-0:
S Refer to item 6 of this checklist.
If the deflection is not in between 4 mm and

5 mm (0.16 in and 0.20 in) respectively the
natural frequency is not 123 Hz +12/-0:
S Remove the safety wires on the alternator

bracket bolts.
S Release the two alternator bracket bolts.
S Install Diamond tool. Use Diamond tool

No. 044-6116-00-00-SW
S Adjust the v-belt tension.
S Tighten the accessible bracket bolt.
S Check the v-belt tension. Refer to item 4 of this checklist.
S If the deflection is 4 mm to 5 mm
(0.16 in to 0.20 in) respectively the natural
frequency is 123 Hz +12/-0:
S Remove Diamond tool.
S Tighten the remaining bracket bolt.
S Install the safety wires.

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5. Remove/Install the Additional Alternator V-Belt (if OÄM 42-204 is installed)
A. Remove the Additional Alternator V-Belt
DEATH.
(4) Remove the safety wires on the alternator

bracket bolts.
(5) Release the three alternator bracket bolts.
(6) Lift the v-belt from the additional alternator pulley.
(7) Remove the six bolts which attach the LH Refer to Figure 5.
propeller pulley assembly to the propeller flange
pulley support and move the assembly towards
the propeller.
(8) Release the six propeller attachment nuts. Support the propeller.
(9) Remove the propeller, v-belt and the propeller

pulley assembly.
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B. Install the Additional Alternator V-Belt
DEATH.
(2) Verify that the airplane main battery is Refer to Section 24-31.
disconnected.
(3) Make sure that the LH propeller shaft, the Refer to Section 71-10 or 71-11.
propeller flange and the propeller flange pulley
support are clean and dry.
(4) Assemble the LH propeller flange pulley and the Use new self locking nuts.
fan wheel with six bolts, washers and self locking
nuts.
(5) Remove the caps which cover the propeller and

the gearbox hub.
(6) Make sure that a new O-ring oil seal is in place in Refer to Figure 5.
the propeller hub. Lightly oil the seal. Use clean gearbox oil.
(7) Move the v-belt, the propeller pulley assembly Take care not to damage the propeller
and the propeller into position on the propeller O-ring seal.
flange.
Note: Make sure that the propeller is pushed into the correct position by hand. Do not
use the nuts to pull the propeller into position.
(8) Put the propeller flange pulley support into

position and install the six nuts.
(9) If the propeller is in the correct position fully Refer to mt-Propeller Operation and
tighten the nuts in opposing pairs. Installation Manual, latest revision.
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(10) Install the six bolts which attach the propeller

pulley assembly to the propeller flange pulley
support.
(11) Lift the v-belt into position on the additional

alternator and the propeller flange pulley
assembly.
(12) Adjust the additional alternator v-belt tension. Refer to Paragraph 4.
(13) Check the gearbox oil level and refill if necessary. Refer to Section 12-10.

(17) Check for oil leaks.
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2nd Alternator
Voltage Regulator
Bolt
Washer
P-Clamp
Voltage
Bushing Regulator
Nut Support
Washer Fuse Mounting
Bushing Washer
Fuse
Washer
Nut
Washer
Washer
Screw
Bolt
Bolt
Alternator
Washer Spray Shield
Lockwire Bolt
Bolt
Alternator Mounting Bracket Washer
Bushing
Washer
Nut
2nd Alternator
Washer
Fan
Pulley
Lock Washer Washer
Nut/Extension
Mounting Lockwire
Bolt
Nut Bolt
Washer Nut
Washer
V-Belt
Engine Mounting Arm RH
Figure 6: Additional Alternator and Regulator Installation

(if OÄM 42-204/e or earlier is installed)
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2nd Alternator
Voltage Regulator
Bolt
Washer
P-Clamp
Voltage
Bushing Regulator
Nut
Support
Bushing Washer
Fuse
Washer
Nut
Washer
Washer
Screw
Bolt
Bolt
Washer Alternator
Bushing Spray Shield
Lockwire Bolt
Bolt
Washer
Alternator Mounting Bracket
Washer
Nut
Washer
2nd Alternator
Washer
Fan Washer
Pulley Nut Bolt
Lock Washer Lockwire Nut/Extension
Bushing
Mounting
Bolt Nut
Nut
Washer
V-Belt

(if OÄM 42-204/g or later and MÄM 42-600 are installed)
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2nd Alternator
Voltage Regulator
Bolt
Washer
P-Clamp
Voltage
Bushing Regulator
Nut Support
Bushing Washer
Fuse
Washer
Nut
Washer
Washer
Screw
Bolt
Bolt
Alternator
Washer Spray Shield
Lockwire Bolt
Bolt
Alternator Mounting Bracket Washer
Bushing
Washer
Nut
2nd Alternator
Washer
Fan
Pulley Nut
Lock Washer Washer
Nut/Extension
Mounting Lockwire
Bolt
Nut Bushing Bolt
Washer Nut
V-Belt

(if OÄM 42-204/o or later is installed and MÄM 42-600 is NOT installed)
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6. Remove/Install the Additional Alternator Pulley (if OÄM 42-204 is installed)
A. Remove the Additional Alternator Pulley
DEATH.
(4) Remove the safety wires on the additional

alternator bracket bolts.
(5) Release the three alternator bracket bolts. Refer to Figure 6 - 8.
(6) Lift the v-belt from the additional alternator

pulley.
(7) Release the steel nut on the additional Use hook wrench on provided pulley
alternator pulley. holes.
(8) Remove the additional alternator pulley and the Refer to Figure 6 - 8.
locking washer. Discard the locking washer.
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B. Install the Additional Alternator Pulley
DEATH.
(1) Make sure that the engine are safe:
(2) Verify that the airplane main battery is Refer to Section 24-31.
disconnected.
(3) Install the additional alternator pulley. Use new locking washer.
(4) Position the v-belt on the propeller pulley
assembly and the additional alternator pulley.
(5) Adjust the v-belt tension. Refer to Paragraph 4.
(6) Check the two safety wires on the additional

alternator bracket bolts.

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Section 61-20
Propeller Control
1. General
The DA 42 NG has two MTV-6-R-C-F/CF187-129 or two MTV-6-R-C-F/CF190-69 (if MÄM 42-600 is

installed) variable pitch and feathering propellers. The engines have mounted constant speed
governors P-877-16. The constant speed governor is controlled by the engine EECS system. The
constant speed governor controls the engine speed by changing the propeller blade angle (pitch).
For further information about the constant governor unit refer to mt-Propeller Operation and Installation
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AIRCRAFT
Figure 1: Propeller RPM Adjusted by the EECU System
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The DA 42 NG has two MTV-6-R-C-F/CF187-129 or two MTV-6-R-C-F/CF190-69 (if MÄM 42-600 is

installed) variable pitch and feathering propellers. A counterweight is fitted to each propeller blade.
When the propeller is rotating the counterweight overcomes the centrifugal twisting moment and
causes the blades to move towards coarse pitch. The propeller uses oil pressure to decrease the blade
angle (pitch).
The constant speed governor is an mounted part of the engine control system. The engine control
system measures many engine parameters. The propeller blade angle is adjusted automatically. The
pilot has only one lever for each engine to control the engine performance. Figure 1 shows the
propeller RPM as set by the engine EECU system for a given load.
As with other constant speed propeller control systems, the EECU senses engine performance and
sets the governor to regulate oil pressure to the propeller to change blade angle as necessary.
Depending on the power setting the propeller pitch is adjusted so that the required RPM will be
obtained as shown in Figure 1.
Figure 2 shows the propeller control system schematic diagram.
The oil pressure at the governor is 22 bar (320 PSI). If the engine speed is too high, the constant
speed governor operates the governor so that the oil flows out from the propeller. The counterweights
on each blade moves the blades to a coarse pitch and increases the blade angle. This reduces the
RPM.
If the engine speed is too low, the governor increases oil flow into the propeller. The piston moves to
reduce the blade angle. This increases engine RPM.
For further information of the governor's working principles refer to the mt-Propeller Operation and
Installation Manual, latest revision.
During normal operation a preset coarse-pitch-stop prevents the propeller blades from moving past
a preset blade angle. A centrifugal latching mechanism disengages the coarse-pitch-stop when the
propeller is rotating at speeds greater than 1300 RPM. If the engine fails in flight, or if the propeller oil
supply fails in flight, the blade counterweights will increase the blade pitch angle. If the engine is
rotating faster than 1300 RPM the centrifugal latching mechanism will be disengaged and the propeller
blades can move to the feather position. The propeller pitch angle in feather position is 81° ± 1°
(80° ± 1° if MÄM 42-600 is incorporated).
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Figure 2: Propeller Control System Schematic Diagram
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A nitrogen-oil type accumulator is installed in the propeller control system. If OÄM 42-224 is performed,
the unfeathering accumulator is NOT installed. Oil at system pressure can flow into the accumulator
through an electrically operated shut-off valve. When the ENGINE MASTER switch is set to OFF the
accumulator shut-off valve is closed. Oil is stored in the accumulator at normal system pressure.
To un-feather the propeller you must set the ENGINE MASTER switch to ON. This will open the
electric valve at the accumulator and allow oil to flow under pressure from the accumulator to the
propeller. The oil flowing to the propeller will cause the blades to move into low pitch position. The
propeller pitch angle in low pitch position is 12° ± 0.2° (13° ± 0.2° if MÄM 42-600 is incorporated). As
soon as the propeller starts turning and the gearbox oil operates, the accumulator will be refilled.
The specified propeller settings are given as follows:
) Low pitch: 12° ± 0.2° (13° ± 0.2° for MTV-6-R-C-F/CF 190-69)
) Start lock position: 15° ± 1.5°
) Feathered position: 81° ± 1° (80° ± 1° for MTV-6-R-C-F/CF 190-69)
Technical data governor:
) Specific installation: DA 42
) Specific engine: Austro Engine E4
) Max. revolution: 2680 RPM ± 10 RPM
) Min. revolution: 2030 RPM ± 10 RPM
) Rotation: LH
) Control head position: 355°
) Specific installation: DA 42 NG (with MÄM 42-600 is installed)
) Specific engine: Austro Engine E4-C
) Max. revolution: 2680 RPM ± 10 RPM
) Min. revolution: 2030 RPM ± 20 RPM
) Rotation: LH
) Control head position: 355°
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22 Dec 2021 61-20-00 Rev. 5
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Trouble-Shooting
1. General
The table below lists the defects you could have for the propeller control. If you have the trouble
Repair column.
Propeller RPM fluctuating. Engine gearbox oil level low. Replenish gearbox oil level.
Refer to Chapter 72.
Engine gearbox oil Replace engine gearbox oil.

contaminated. Refer to Chapter 72.
Electrical connection between Do a continuity check of the

related engine EECU system wiring between the EECU
and governor. system and the governor.
Replace/repair faulty wiring.
Refer to Chapter 92 for the
wiring diagrams.
Governor defective. Replace the governor.
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1. General
This Section tells you how to remove/install the governor and how to test/adjust the governor. It also
tells you how to replace/adjust the propeller control cable.
2. Remove/Install the Propeller Governor
A. Remove the Propeller Governor

OFF.
(4) Disconnect the cable connector GOV from the Refer to the AE Maintenance Manual,
governor. latest revision, Chapter 71-50-05.
(5) Remove the oil hose from the governor.
If OÄM 42-224 is performed, the oil hose is not

installed.
(6) Put a blanking cover on the oil hose.
(7) Release the four nuts which attach the governor Use a container to catch the small
to the drive-pad and remove the governor from amount of oil from the governor.
the gearbox.
(8) Remove and discard the gasket.
(9) Put a blanking cover on the governor drive-pad

and put a cover over the governor mounting
face.
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B. Install the Propeller Governor
Note: It is prohibited to adjust propeller RPMs.
(1) Compare governor Equipment Log-Sheet with

the settings given in Section 61-20, page 5.
(2) Put the governor and gasket in position on the Use a new gasket. Verify installation
gearbox drive pad. direction.
(3) Install the four washers and nuts which attach Torque: 28 Nm (20.7 lbf.ft).
the governor to the drive pad. Use new self locking nuts.
(4) Connect the propeller control cable connector Refer to the AE Maintenance Manual,
GOV to the governor. latest revision, Chapter 71-50-05.
(5) Install the oil hose from the unfeathering

accumulator to the governor.
If OÄM 42-224 is performed, install the safety

cap to the governor.
(6) Install the engine cowling. Refer to Section 71-10 or 71-11.
(8) Do an engine ground run.
(9) Check the gearbox oil level. Refer to Section 12-10.
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22 Dec 2021 61-20-00 Rev. 5
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Accumulator Spray Shield Bolt

Washer
Oil Pressure Hose
Accumulator
Fitting
Fitting
Mounting Clamp
Bolt
Washer
Charging Valve
Rubber Strip
Figure 4: Propeller Un-Feathering Accumulator Installation
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Rev. 5 61-20-00 22 Dec 2021
AIRCRAFT
Accumulator Spray Shield Bolt

Washer
Oil Pressure Hose Accumulator

Fitting
Fitting
Bolt
Bolt
Washer
Air Intake Washer Nut
Washer
P-Clamp Charging Valve
Washer Mounting Clamp Engine Mounting Frame
Nut
Figure 5: Propeller Un-Feathering Accumulator Installation (if MÄM 42-600 is installed)
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22 Dec 2021 61-20-00 Rev. 5
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3. Remove/Install the Propeller Un-Feathering Accumulator
A. Remove the Propeller Un-Feathering Accumulator

OFF.
S Set the power lever to IDLE.
ACCUMULATOR BEFORE YOU REMOVE IT. NITROGEN AT HIGH
PRESSURE CAN PENETRATE THE SKIN. THIS CAN CAUSE
DISEASE.
(4) Drain the propeller un-feathering accumulator:
S Set the ELECT. MASTER ON.
S Set the ENGINE MASTER ON.
S Set ENGINE and ELECT. MASTER OFF.
(5) Release the nitrogen pressure from the

accumulator:
S Release the pressure from the charging

valve at the end of the accumulator.
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(6) Disconnect the electrical cables from the At the in-line connector at the shut-off
shut-off valve. valve. Cut the tie wraps.
(7) Remove the accumulator:
S Remove the 2 bolts on engine mount that Support the accumulator!

hold the accumulator.
S Remove both mounting clamps.
S Lift the accumulator clear of the mounting

bracket.
(8) Remove the accu spray shield. Remove the bolt

and washer.
(9) Disconnect the oil hose from the accumulator. Use a suitable container to collect spilt
oil. Cap open oil lines.
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B. Install the Un-Feathering Accumulator
(1) Install the oil hose to the governor.
(2) Install the accumulator:
S Install the spray shield.
S Move the accumulator into position in the Make sure that the accumulator is
mounting bracket. orientated correctly.
S Install both mounting clamps.
S Install the 2 bolts that attach the

accumulator to the mounting bracket.
(3) Connect the electrical cables to the governor. Fix it with tie wraps.
(4) Charge the accumulator with nitrogen:
S Connect a suitable nitrogen supply to the Follow the manufacturer’s instructions

charging valve and charge the accumulator for the nitrogen supply.
to the correct pressure. 10.4 bar (150 PSI).
(7) Do a test for oil leaks:
S Start the engine and allow to reach normal Refer to the Airplane Flight Manual.
operating temperature.
S Stop the engine. Refer to the Airplane Flight Manual.
S Remove the engine cowlings. Refer to Section 71-10 or 71-11.
S Look for oil leaks. Specially in the area of

the propeller un-feathering accumulator.
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(9) Do a test for the correct operation of the Refer to the Airplane Flight Manual.
un-feathering accumulator.
(10) Install the engine cowling. Refer to Section 71-10 or 71-11.
4. Propeller Un-Feathering Test

WARNING: DO NOT LET PERSONS INTO THE SAFETY RANGE OF THE
AIRPLANE. PROPELLERS CAN CAUSE INJURY OR DEATH.
(1) Position the airplane on level ground. Make sure

that:
S There are no loose stones on the ground

near the propeller.
S The safety zone around the airplane is clear.
S The airplane heads into the wind.
(2) Put chocks in front of each main wheel.
(3) Set the parking brake to ON.
(4) Make sure that the ENGINE FUEL SELECTOR

is set to ON for both engines.
(5) Make sure that the passenger door is closed

and locked. Close and lock the canopy.
(6) Set both engine power levers to 0%. Make sure that the power levers are free
to move.
(7) Set the ELECT. MASTER key switch to ON.
(8) Set the alternate air control to OFF.
(9) Make sure the area of the propellers is clear.
(10) Set the related ENGINE MASTER switch to ON.
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(11) Make sure that the engine instruments read The RPM, LOAD and FUEL FLOW
correctly. indications must be zero (0). Dashes (-)
indicate a malfunction.
(12) Turn the START key switch to the LH or RH Do not start the engine as long as the
position as required. white GLOW status light is illuminated.
(13) When the selected engine starts:
S Release the START key switch.
(14) Leave the power lever at 0%. Make sure that there are no warning
lights on.
(15) Monitor the oil pressure. The oil pressure must rise to 1 bar
minimum, within 3 seconds of starting
the engine. If it does not, then you must
shut-down the engine.
(16) Let the engine idle at 900 RPM for 4 minutes. Monitor the engine instruments for
unusual indications.
(17) Set the power lever to give a speed frequency

of 1500 RPM.
(18) Shut off the engine by setting the related The engine must stop. The propeller
ENGINE MASTER switch to OFF. must feather (´ feathered position: 81°).
(19) Reset the ENGINE MASTER switch to ON. Do not start the engine.
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(20) Observe the change in propeller pitch angle. The propeller must un-feather within
12 to 15 sec (´ low pitch: 12°).
Check the functional efficiency of the

accumulator if the propeller does not un-
feather.
If the unfeathering accumulator is not installed

(if OÄM 42-224 is performend):
Restart the engine:
S STARTER of affected engine: engage,

5 seconds maximum.
S Note: Unfeathering of the propeller is done

in the start sequence by building up system
oil pressure when cranking the starter.
S Circuit breakers: check/reset if necessary.
If the engine does not start: wait 30 seconds

and proceed with first item of starting sequence.
(21) Set the ENGINE MASTER switch to OFF. The propeller must remain in the un-
feathered position. There is just a small
change in pitch angle of 3° (´ start lock
position: 15°).
Check the functional efficiency of the

accumulator if the propeller does not
remain in the un-feathered position.
(22) Set both engine power levers to 0%.
(23) Redo steps 9 thru 22 for the other engine.
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DA 42 NG AMM Power Plant
AIRCRAFT
CHAPTER 71
POWER PLANT
Doc # 7.02.15 Page 1

Power Plant DA 42 NG AMM
AIRCRAFT
Page 2
22 Dec 2021 71-TITLE Doc # 7.02.15
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AIRCRAFT
TABLE OF CONTENTS
CHAPTER 71
POWER PLANT
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description an Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Engine Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3. Engine Test - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Section 71-10
Engine Cowlings
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Engine Cowlings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Cleaning and Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Section 71-11
Engine Cowlings (if MÄM 42-600 is installed)
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Doc # 7.02.15 Page 1

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Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Engine Cowlings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Cleaning and Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Section 71-20
Engine Mounting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install an Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 71-50
Electrical Cables in the Engine Compartment
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 71-60
Air Intakes
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Page 2
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1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install an Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install an Alternate Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Remove/Install an Alternate Air Control Inner-Cable (if MÄM 42-933 is NOT
installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5. Remove/Install an Alternate Air Control Cockpit Lever Cable (if MÄM 42-933 is
installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
6. Adjust an Alternate Air Valve Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Section 71-61
Air Intakes (if MÄM 42-600 is installed)
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Section 71-70
Engine Drains
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Breather Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 71-71
Engine Drains (if MÄM 42-600 is installed)
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Breather Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Page 4
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CHAPTER 71
POWER PLANT
1. General
This Chapter contains information about the AE E4-B and the AE E4-C (if MÄM 42-600 is installed)
engines installation in the DA 42 NG. It describes the removal/installation of the power plant.
For data on the engine test after installation refer to the Operation Manual for the AE E4-B or AE E4-C
(if MÄM 42-600 is installed) engine. Refer to the DA 42 NG Airplane Flight Manual for engine start/stop
procedures. For particular information on the applicable firmware refer to DAI Service Bulletin
MSB-42NG-002.
Refer to these Chapters for data about other engine systems:
) Chapter 72. Refer to the AE Operation Manual, latest revision for data on the engine.
) Chapter 73. Engine fuel and control. Refer to the AE Operation Manual, latest revision 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 nacelle. Refer to the AE Operation
Manual, latest revision for data on the engine oil system.
) Chapter 80. Starter system control and installation. Refer to the AE Operation Manual, latest
revision for data on the starter.
) Chapter 81. Turbo charger.
Service Bulletin.
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Top RH Cowling
Top LH Cowling
New Generation Engine
Bottom Cowling
Engine Cooling
Air Intake
Figure 1: Power Plant
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Top RH Cowling
Top LH Cowling
Engine
Bottom Cowling
Engine Cooling
Air Intake
Figure 2: Power Plant (if MÄM 42-600 is installed)
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2. Description an Operation
The DA 42 NG has a AE E4-B liquid-cooled, in-line four-stroke four cylinder engine with a double
overhead camshaft (DOHC) with four valves per cylinder. The valves are actuated by the cam follower
The direct fuel injection is realized by means of a common rail technique and the engine is charged
by a turbo charger in combination with an inter-cooler.
The propeller is activated by a directly integrated gearbox with an integral torsional vibration damper.
All engine components are controlled by an EECU system.
The power plant has these components installed:
A. Cowlings
The power plant has a left side cowling, a right side cowling and bottom engine cowling. All the
cowlings attach to each other and the engine nacelle with Camloc quick release fasteners.
The bottom cowling has air intakes for the engine cooling, the cabin heat exchanger and the engine
air intake.
B. Engine Mounts
The engine mount attaches to the firewall at five locations. Tubular steel makes the mounting
frame. The engine attaches to the engine mount with four shock-mounts. Gel-filled rubber elements
make the engine shock-mounts.
C. Electrical Harness
Electrical cables go through the firewall to connect to the engine. They give electrical supply to the
engine sensors. Electrical cables from the main battery and from the generator supply electrical
power to the airplane electrical system.
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3. Engine Specification
Note: The engine drives the propeller through a speed-reducing gear. All RPMs are
shown as propeller RPMs.
AE E4-B and E4-C (if MÄM 42-600 is installed) Engine Specification
Engine manufacturer. Austro Engine GmbH.
Engine model. E4-B, E4-C (if MÄM 42-600 is installed).
Engine operating limits:
S Maximum take-off power. 123.5 kW (165.6 DIN-hp) at 2300 RPM.
S Maximum continuous power. 114.0 kW (152.9 DIN-hp) at 2100 RPM.
S Maximum overspeed (max. 20 sec). 2500 RPM.
Oil pressure (indicated values are corrected for Refer to Airplane Flight Manual.
pressure altitude):
Oil temperature: Refer to Airplane Flight Manual.
Oil consumption:
0.1 liter/hr. (0.11 US qt/hr.).
S Maximum.
Oil quantity: Refer to Airplane Flight Manual.
Coolant temperature: Refer to Airplane Flight Manual.
Fuel consumption: Refer to Airplane Flight Manual.
Gearbox oil capacity: 2.1 liter (2.22 US qts).
Engine weight, bare: 185 kg (407.9 lb).
Fuel grade: Refer to Airplane Flight Manual.
Oil specification: Refer to Airplane Flight Manual.
Coolant: Refer to Airplane Flight Manual.
Gearbox oil: Refer to Airplane Flight Manual.
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Trouble-Shooting
1. General
The table below lists the defects you could have with the power plant. It does not give trouble shooting
data for the engine or the engine systems. Refer to the AE Operation Manual, latest revision for engine
and engine system trouble-shooting.
WARNING: YOU MUST BE CAREFUL WHEN YOU DO POWER PLANT TROUBLE

SHOOTING. OPERATION OF A DAMAGED ENGINE CAN CAUSE MORE
DAMAGE TO THE ENGINE. THIS CAN CAUSE INJURY TO
PERSONNEL.
Engine vibration. Damaged shock mounts. Replace the shock mounts.
Propeller unbalance. Balance the propeller.
Engine operates with only Refer to the engine

3 fuel injectors. manufacturer.
Engine does not produce full Engine air inlet blocked. Examine the air inlet.
power.
Air filter blocked. Examine/Replace the air filter
Sensor signal out of limits. Read AE engine data with

laptop computer via CAN
interface. Refer to the
AE Maintenance Manual, latest
revision, Chapter 72-00.
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1. General
These Maintenance Practices tell you how to remove/install the engine.
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER. IF

THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
TURN THE PROPELLER. DISCONNECT THE BATTERY.
WARNING: DO NOT GO BELOW THE ENGINE WHEN YOU LIFT THE ENGINE WITH
THE HOIST. THE HOIST CAN FAIL. THIS CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: DO NOT GET ENGINE OIL, GEAR OIL OR COOLANT ON YOU. THESE
LIQUIDS CAN CAUSE SKIN DISEASE.
NOT ALLOW FIRE OR SPARKS NEAR FUEL. FUEL BURNS AND
BURNING FUEL CAN CAUSE INJURY TO PEOPLE AND DAMAGE TO
EQUIPMENT.
CAUTION: YOU MUST ATTACH CAPS TO HOLES/PIPES WHEN YOU REMOVE

THE ENGINE. IF YOU DO NOT DO THIS, CONTAMINATION CAN
ENTER THE HOLES/PIPES. THIS CAN CAUSE BLOCKAGE TO THE
AIRPLANE SYSTEMS.
CAUTION: AFTER WORK ON THE FUEL DISTRIBUTION SYSTEM, BEFORE

STARTING THE ENGINE BLEED THE FUEL SYSTEM AT THE INLET OF
THE HIGH PRESSURE PUMP.
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2. Remove/Install the Engine
A. Equipment
Hoist. 1 Commercial.
Engine sling. 1 Commercial.
Engine stand. 1 Commercial.
Tail trestle. 1 Commercial.
Hoisting points. 4 Delivered with engine.
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Coolant
Temperature Coolant Tank
Sensor
Alternator
Oil Temperature Sensor

Oil Filter Housing
Oil Case
Coolant Radiator
Crankshaft 2 Sensor
Oil Pressure Sensor
Figure 3: Left Side of Engine
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Coolant
Temperature
Sensor
Coolant Tank
Alternator
Oil Temperature
Sensor Oil Filter
Housing
Fuel Cooler
Coolant Radiator Oil Case
Crankshaft 2 Sensor
Oil Pressure Sensor
Figure 4: Left Side of Engine (if MÄM 42-600 is installed)
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B. Remove the Engine without Cable Harness

(1) Read the engine EECU data out and send them via Refer to Section 72-00.
email to Austro Engine GmbH. Refer to the
(2) Set the related engine FUEL SELECTOR to OFF.
(6) Remove the propeller. Refer to Section 61-10.

(7) Drain the coolant system. Refer to Section 75-00.
(8) Remove the hose from the alternate air valve to the
turbo charger.
(9) Remove the air intake duct from the intercooler.
(10) Remove the coolant tank. Refer to Section 75-00.
(11) Disconnect the coolant hoses from the coolant Refer to Section 75-00.
radiator:
S Remove the 8 worm-drive-clamps. 4 on each hose.
S Remove the hoses.
S Remove the cooling pipe.
(12) Disconnect the coolant hoses from the heating Refer to Section 75-00.
radiator.
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(13) Disconnect the oil hose from the accumulator. Use a suitable container to catch the
oil in the tubes.
(14) Remove the propeller accumulator.
(15) Disconnect the breather line.
(16) Disconnect the TKS line from the engine (if installed).
(17) Disconnect the electrical cables on the alternator.
S Release all clips and ties holding the cables to the

engine.
(18) Disconnect the electrical cables from the starter motor. Do not remove clips and ties on the
engine mount.
S Disconnect the two control cables at the solenoid.
S Disconnect the main supply cable at the solenoid.
S Release all clips and ties holding the cables to the

engine.
(19) Disconnect all electrical connections (glow plugs, Refer to the AE Maintenance
injectors, etc.). Manual, latest revision.
(20) Remove the hose that connects the turbo charger Refer to Section 73-00.
outlet to the inter-cooler:
S Remove the 4 worm-drive-clamps.
S Remove the hose.
(21) Remove the exhaust. Refer to Section 78-00.
(22) Release clips, ties and clamps holding the engine

wire harness to the engine mount.
Move the harness clear of the engine.
(23) Disconnect the fuel supply hose and remove the fuel At the high-pressure fuel pump.
line mounting bracket.
(24) Disconnect the fuel return hose. Behind the rail pressure regulator.
(25) Remove the bonding cable at the engine near each

engine shock-mount and safety cables.
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(26) Support the airplane at the tail. Use the tail trestle. Refer to
Section 07-10.
(27) Remove the TKS bracket:
S Remove the three bolts located at the upper right

side of the gearbox and engine housing.
(28) Install hoisting points.
(29) Attach the sling to the engine. There are lifting points at:
Attach the sling to the hoist. S Front right cylinder head.
S Rear left of the cylinder head

near coolant pump.
S Rear right at the alternator

bracket.
Refer to AE Installation Manual,

latest revision.
(30) Take the weight of the engine with the hoist.
(31) Remove the nuts, bolts and washers that attach the
engine support brackets to the engine mount.
(32) Remove the safety rope from the engine.
(33) Lift the engine a small distance, turn it slightly to the Make sure that the engine does not
right side and move it at the same time forward and hit the engine mount.
clear of the engine mount.
(34) Remove the support bracket from the engine.
(35) Attach the shipping stand to the engine. Refer to AE Installation Manual,
latest revision.
(36) Put caps on the open end pipes and connections.
(37) Prepare engine for shipping. Note TTSO hours and reason for
removal.
(38) Clean firewall and engine mount.
(39) Examine the engine mount for cracks and corrosion.
(40) Check lifetime of the elastomer hoses and replace as

necessary.
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(41) If the engine was removed because of oil system Refer to Section 79-00.
contamination:
S Remove and discard oil radiator and oil hoses.
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Direction
of Flight
Fuel High Fuel Line

Air Filter Box Turbocharger Pressure Pump Pressure Sensor
Propeller
Flange
Radiator
Cabin Heat Exchanger
Exhaust
Figure 5: Right Side of Engine
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Direction
of Flight
Fuel High Fuel Line

Propeller
Flange

Radiator
Exhaust
Figure 6: Right Side of Engine (if MÄM 42-600 is installed)
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Safety Rope
Engine Mount
Bonding Wire
Washer
Bolt
Nut
Washer
Washer Nut Washer
Bolt Washer
Bolt
Engine
Engine Mounting Mount
Frame Bonding
Wire Nut
Washer
Bolt
Washer
Bolt
Washer
Mounting Arm
Washer Mounting Arm Spacer

Bolt
Washer
Bolt Bolt
Washers Bolt Washer

Bolt Washers Washer
Washer Bolt
Nut Spacer Bonding
Washer Wire
Bonding Wire
Nut
Engine Mount Bolt
Engine Mount
Safety Rope Safety
Rope
Washer
Washer Washer
Bolt Bolt
Figure 7: Engine Shock-Mounts
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Safety Rope Bushing

Washer
Bolt
Engine Mount
Bonding Wire
Nut Washer
Washer Bolt
Bolt
Washer Nut Engine
Mount
Bonding
Wire
Engine Mounting
Frame
Washer
Bolt
Mounting Arm
Washer Bonding Wire
Bolt Washer
Spacer
Bolt
Bolt Bolt Washer

Mounting Arm Washer Washer Bolt
Nut Washer
Nut Safety
Bonding Wire Rope
Engine Mount
Engine Mount
Safety Rope
Bolt
Washer
Washer Washer
Bolt Bolt
Figure 8: Engine Shock-Mounts (if MÄM 42-594 is installed)
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Engine Mount
Safety Rope
Spacer
Washer
Nut
Bolt
Washer
Engine Mounting
Frame
Nut
Washer
Engine Mount
Washer
Washer Mounting Arm
Bolt
Bolt Bolt Spacer
Washer
Nut Washer
Mounting Arm Washer
Nut Washer Bolt
Washer
Safety Rope Safety
Bolt Rope
Engine Mount
Engine Mount Bolt
Washer
Washer Washer
Bolt Bolt
Figure 9: Engine Shock-Mounts (if MÄM 42-600 is installed)
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C. Install the Engine
(1) Attach the sling to the engine. There are lifting points at:
Attach the sling to the hoist. S Front right cylinder head.
S Front left of the reduction gear

housing.
S Rear left of the cylinder head

near coolant pump.
S Rear right at the alternator

bracket.
(2) Remove the shipping stand from the engine.
(3) Install the engine shock-mounts at the engine mount. Front:

Torque: 16 Nm (11.8 lbf.ft.),
if MÄM 42-600 is installed:
20 Nm (14.75 lbf.ft.).
Use Loctite 243.
Rear:
Torque: 28 Nm (20.64 lbf.ft.).
(4) Install engine support bracket at the engine with Use Loctite 243.
safety rope.
(5) Carefully move the engine back into position in the

engine mount.
(6) Install the bolts, nuts, and washers that attach the Refer to Chapter 20 for torque
engine shock-mounts to the engine mounting arms. values.
Front bolt: Lubricate with

CA 1000-PRC De Soto,
Torque: 85 Nm (62.7 lbf.ft.).
Rear bolt: Use Loctite 243,

Torque: 32 Nm (23.6 lbf.ft.),
if MÄM 42-594 or MÄM 42-600 is
installed: RH: 54 Nm (39.83 lbf.ft.),
LH: 44 Nm (32.45 lbf.ft.).
(7) Install the bonding cable at the engine near each

shock-mount.
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(8) Install the safety cables at the engine near each Refer to Figure 7, 8 or 9.
shock-mount, except the rear LH shock-mount.
(9) Install the water tube with clamp at the engine mount.
(10) Connect the electrical cables to the starter motor:
S Connect the two control cables at the solenoid.
S Connect the main supply cable at the solenoid.
S Attach all clips and ties holding the cables to the

engine.
(11) Move the engine wire harness into position on the

engine. Connect the engine wire harness and
bonding cables to these electrical sensors:
S Fuel rail pressure regulator. At the rear end of the fuel rail.
S Propeller governor. At the right side of the reduction

gear.
S Waste gate valve solenoid. At the lower crankshaft cover.
S Fuel injectors. At each fuel injector.
S Glow plugs. At the lower crankshaft cover.
(12) Install clips and ties clamps holding the engine wire
harness to the engine.
(13) Connect the fuel supply hose. At the high pressure pump.
(14) Connect the fuel return hose. At the high pressure pump.
(15) Install the coolant tank. Refer to Section 75-00.
(16) Install the coolant hoses to the coolant radiator: Refer to Section 75-00.
S Install the 2 hoses, at the radiator.
S Install the 8 worm-drive-clamps that hold the 4 on each hose.

hoses.
(17) Install the hose which connects the alternate air to

the turbo charger.
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(18) Install the hose which connects the intercooler to the

turbo charger.
(19) Connect the breather tube. At the oil pre-separator.
(20) Install exhaust pipe flange. Torque: 25 - 34 Nm

(18.44 - 25.08 lbf.ft.).
(21) Install the propeller accumulator. Connect the hose

to the governor.
(22) Install the air intake duct at the intercooler.
(23) Install the TKS bracket:
S Install the three bolts located at the upper right

side of the gearbox and engine housing.
(24) Install the propeller. Refer to Section 61-00.
(25) Fill and bleed the cooling system. Refer to Section 75-00.
(26) Fill the engine with oil. Refer to Section 12-10.
(27) Fill the reduction gear with oil. Refer to Section 12-10.
(30) Remove the tail trestle. Refer to Section 07-10.
CAUTION: AFTER WORK ON THE FUEL DISTRIBUTION SYSTEM, BEFORE

STARTING THE ENGINE BLEED THE FUEL SYSTEM AT THE INLET
OF THE HIGH PRESSURE PUMP.
(31) Do an engine test. Refer to Paragraph 3.
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ft)
0
(3
m
10
3
m
(1
0
ft)
3
m
(1
0
ft)
ft)
0
(1
m
3
Figure 10: Engine Testing Safety Zone
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3. Engine Test - General
For engine starting and warm-up, ECU test, propeller control test, ECU swap test and performance
check refer to AE Operation Manual, latest revision and Airplane Flight Manual.
Note: The engine drives the propeller through a speed-reducing gear. All RPMs are
shown as propeller RPMs.
CAUTION: ONLY AUTHORIZED PERSONNEL MAY READ ENGINE DATA WITH

THE 'ECU OPERATOR' SOFTWARE.
A. Equipment
Airplane chocks. 2 Commercial.
Fuel sample kit. 1 Commercial.
Laptop computer. 1 Commercial.
"Wizard 300" software, latest approved revision. n/a n/a.
CAN interface. 1 n/a.
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B. Preparation
WARNING: DO NOT LET PERSONS INTO THE SAFETY RANGE OF THE

AIRPLANE. PROPELLERS CAN CAUSE INJURY OR DEATH.
(1) Look in the engine records for reports of

problems.
(2) Make sure that all switches are OFF.
(3) Position the airplane on level ground. Make sure

that:
S There are no loose stones on the ground

near the propeller.
S The safety zone around the airplane is clear. Refer to Figure 10.
S The airplane heads into the wind.
(4) Check engine oil level, gearbox oil level, and

coolant level. For the engine that you will test.
(5) Do a test of a sample of fuel for contamination. Refer to Section 12-10.
(6) Put chocks in front of each main wheel.
(7) Make sure that there is enough fuel for the

engine test:
S Read the fuel quantity indicator.
S Refuel the airplane if necessary.
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Section 71-10
Engine Cowlings
1. General
The DA 42 NG has three carbon fiber reinforced plastic (CFRP) panels which make the engine
cowlings. A top-left cowling, a top-tight cowling and a bottom cowling. CFRP is very strong and is easy
to maintain. The cowlings give a good aerodynamic shape to the engine nacelles. They are very easy
to remove and give good access to the engine.
Refer to Section 51-20 for repair data for the cowlings. Refer to Section 51-60 for data on the
quick-release fasteners.
2. Description
Figure 1 shows the cowlings.
Camloc quick-release fasteners attach the cowlings to each other and to the engine nacelle. All the
cowlings are very light and one person can hold them easily.
The bottom cowling has an air intake on the right side of the cowling and a large air intake on the
bottom of the cowling at the front. The side-intake supplies air for the cabin heat exchanger. The intake
at the front of the bottom cowling supplies air for the coolant radiator.
The top cowling consists of a right and a left half. The left cowling half has one air intake for the
intercooler and the engine. The right cowling half has one outlet next to the turbo-charger.
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Camloc Receptacle
TYPICAL FASTENER
ASSEMBLY
Ring
Grommet
Rivet Camloc Stud
Top RH Cowling Top LH Cowling
Cooling Air
Intake
Camloc Stud
Cooling Air to Oil Cooler

Cooling Air Intake
Rubber Seal
Camloc Receptacle
Engine Cooling
Air Intake Bottom Cowling
Figure 1: Engine Cowlings 1
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Top LH Cowling
Access Panel
Fillister Head Screw
Figure 2: Engine Cowlings 2
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Trouble-Shooting
1. General
The table below lists the defects you could have with the engine cowlings. If you have the trouble
Repair column.
Outer surface of the cowling Engine overheating. Examine the engine for hot gas
discolored. Paint blistered. Hot gas leak. leaks. Examine the exhaust for
Black soot on the inner Engine fire. cracks and leaking gaskets.
surface. Replaced damage items.
Repaint the cowlings.
Oil/fuel/coolant on the inner Oil, fuel or coolant leak. Examine the engine. Look
surface of the cowling. specially for oil, fuel and
coolant leaks. Correct
problems which you have
found. Clean the cowling.
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1. General
This Section contains the Maintenance Practices for the cowlings. It tells you how to remove/install the
cowlings. It also tells you how to clean and paint the cowlings.
2. Remove/Install the Engine Cowlings
Use these procedures for the left engine or the right engine.
A. Remove the Engine Left and Right Top Cowlings
WORK NEAR TO THE PROPELLER.
- SET THE ELECT. MASTER SWITCH TO "OFF".
- SET THE ENGINE MASTER SWITCH TO "OFF".
- SET THE POWER LEVER TO "0%".
- DISCONNECT THE AIRPLANE MAIN BATTERY.
WORK ON THE COWLINGS. IF THE ENGINE IS TURNED, THE

OFF.
(3) Release the fasteners that attach the top-left and Refer to Figure 1.
top-right cowlings to each other, the bottom
cowling and the engine nacelle.
(4) Pull the top of the top-right cowling up and away Take care not to scratch the cowling on
from the top-left cowling, the bottom cowling and the propeller!
clear of the engine nacelle.
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(5) Pull the bottom edge of top-left cowling away Take care not to scratch the cowling on
from the bottom cowling and clear of the engine the propeller!
nacelle.
B. Remove the Bottom Cowling
(1) Release the quick-release fasteners which hold Hold the bottom cowling!
the bottom cowling.
(2) Remove the bottom cowling:
S Lower the rear of the cowling. Take care not to scratch the cowling on
the propeller and spinner cone.
S Move the cowling down and forward.
S Move the cowling clear of the airplane.
C. Install the Bottom Cowling
(1) Examine the bottom cowling. Make sure that:
S The cowling is clean.
S The cowling is not damaged. Repair any damage.
S The quick-release fasteners are not Replace missing/damaged fasteners.

missing/damaged.
S Drain holes must be clear.
(2) Lift the cowling into position:
S Move the cowling upwards.
S Lift the cowling fully into position. Take care of the air inlets. Engage the
respective shrouds.
S Tighten the quick-release fasteners that

attach the cowling to the engine nacelle.
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D. Install the Engine Left and Right Top Cowlings
(1) Examine the top-left and top-right cowlings.

Make sure that:
S The cowlings are clean.
S The cowlings are not damaged. Repair any damage.

missing/damaged.
(2) Install the top-left cowling:
S Move the top-left cowling into position on the Make sure that the fasteners engage
engine nacelle. correctly in the engine nacelle and
bottom cowling.
S Move the top-right cowling into position on Make sure that the fasteners engage
the engine nacelle. correctly in the top-left cowling, the
engine nacelle and bottom cowling.
(3) Tighten all the quick-release fasteners that

attach the top-left and top-right cowlings to the
bottom engine cowling and the engine nacelle.
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3. Cleaning and Painting
A. Clean the Cowlings
(1) Wash the outer surface with a mixture of water Obey the detergent manufacturer’s
and a mild detergent. instructions.
(2) Wash the inner surface with a mixture of water Obey the detergent manufacturer’s
CAUTION: DO NOT USE POLISH CONTAINING SILICONE. SILICONE MAKES

CFRP REPAIR DIFFICULT.
(3) Polish the outer surface with wax polish. Obey the polish manufacturer’s
instructions. Do not use silicone polish.
B. Paint the Insides of the Cowlings
This Paragraph gives the data for painting the inside of the engine cowlings with fire protection
paint. Refer to Section 51-20 for repairs and painting the outside of the cowlings.
Note: If OÄM 40-205 has been carried out (cowling made from self extinguishing
resin), do not apply fire protection paint on the inside of the cowling. Use
only self extinguishing resin for repair (refer to Section 51-30).
(1) Clean the inside of the cowling.
(2) Make the area rough for painting. Use 150-320 grade wet and dry paper.
WARNING: DO NOT GET ACETONE ON YOUR SKIN. ACETONE CAN CAUSE

SKIN DISEASE.
WARNING: DO NOT BREATHE ACETONE FUMES. ACETONE FUMES CAN

CAUSE ILLNESS.
CAUTION: REMOVE ACETONE AS SOON AS POSSIBLE FROM GFRP.

ACETONE CAN CAUSE THE RESIN TO SOFTEN AND FAIL.
(3) Clean the area for painting. Use acetone.
(4) Paint the inside of the cowling with fire Obey the paint manufacturer’s
protection paint. instructions.
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Section 71-11
Engine Cowlings (if MÄM 42-600 is installed)
1. General
The DA 42 NG with MÄM 42-600 installed has three carbon fiber reinforced plastic (CFRP) panels
which make the engine cowlings. A top-left cowling, a top-tight cowling and a bottom cowling. CFRP
is very strong and is easy to maintain. The cowlings give a good aerodynamic shape to the engine
nacelles. They are very easy to remove and give good access to the engine.
Refer to Section 51-20 for repair data for the cowlings. Refer to Section 51-60 for data on the
quick-release fasteners.
2. Description
Figure 1 shows the cowlings.
Camloc quick-release fasteners attach the cowlings to each other and to the engine nacelle. All the
cowlings are very light and one person can hold them easily.
The bottom cowling has three air intakes at the front of the cowling. The intake at the front bottom of
the lower cooling supplies air to the coolant radiator, the fuel cooler, the cabin heat exchanger and the
gearbox oil cooling. A gearbox cooling hose directs air from the air intake to the gearbox oil cooling
fins.
The top cowling consists of a right and a left half. The left cowling half has one air intake for the
intercooler and engine air intake. The right cowling half has one outlet aft of the turbo-charger.
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Figure 1: Engine Cowlings 1 (if MÄM 42-600 installed)
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Top LH Cowling
Access Panel
Fillister Head Screw
Figure 2: Engine Cowlings 2 (if MÄM 42-600 installed)
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Trouble-Shooting
1. General
The table below lists the defects you could have with the engine cowlings. If you have the trouble
Repair column.
Outer surface of the cowling Engine overheating. Examine the engine for hot gas
discolored. Paint blistered. Hot gas leak. leaks. Examine the exhaust for
Black soot on the inner Engine fire. cracks and leaking gaskets.
surface. Replaced damage items.
Repaint the cowlings.
Oil/fuel/coolant on the inner Oil, fuel or coolant leak. Examine the engine. Look
surface of the cowling. specially for oil, fuel and
coolant leaks. Correct
problems which you have
found. Clean the cowling.
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1. General
This Section contains the Maintenance Practices for the cowlings. It tells you how to remove/install the
cowlings. It also tells you how to clean and paint the cowlings.
2. Remove/Install the Engine Cowlings
Use these procedures for the left engine or the right engine.
A. Remove the Engine Left and Right Top Cowlings
WORK NEAR TO THE PROPELLER.
- SET THE ENGINE MASTER SWITCH TO "OFF".- SET THE ELECT.
MASTER SWITCH TO "OFF".
- SET THE POWER LEVER TO "0%".
- DISCONNECT THE AIRPLANE MAIN BATTERY.
WORK ON THE COWLINGS. IF THE ENGINE IS TURNED, THE

OFF.
(3) Release the fasteners that attach the top-left and Refer to Figure 1.
top-right cowlings to each other, the bottom
cowling and the engine nacelle.
(4) Pull the top of the top-right cowling up and away Take care not to scratch the cowling on
from the top-left and bottom cowling and clear of the propeller!
the engine.
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(5) Pull the bottom edge of top-left cowling away Take care not to scratch the cowling on
from the bottom cowling and clear of the engine. the propeller!
B. Remove the Bottom Cowling
(1) Release the worm drive clamp on the gearbox

cooling duct.
(2) Release the air hose from the gearbox cooling

duct.
(3) Release the quick-release fasteners which hold Hold the bottom cowling!
the bottom cowling to them engine nacelle.
(4) Remove the bottom cowling:
S Lower first the left side of the cowling. Take care not to scratch the cowling on
the propeller and spinner cone.
S Move the cowling down.
S Move the cowling clear of the engine.
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C. Install the Bottom Cowling
(1) Examine the bottom cowling. Make sure that:
S The cowling is clean.
S The cowling is not damaged. Repair any damage.

missing/damaged.
S Drain holes must be clear.
S Move first the cowling upwards.
S Lift the right side of the cowling fully into Take care of the air inlets. Engage the
position. respective shrouds.
S Tighten the quick-release fasteners that

attach the cowling to the engine nacelle.
Note: Make sure that the hose clamp lock at the cooling duct connection is positioned
at the top to avoid chafing on the bottom cowling.
S Install the air hose and the worm drive clamp

on the gearbox cooling duct.
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Figure 3: Air Shroud and Clamp Installation (if MÄM 42-600 and MÄM 42-660 are installed)
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D. Install the Engine Left and Right Top Cowlings
(1) Examine the top-left and top-right cowlings.

Make sure that:
S The cowlings are clean.
S The cowlings are not damaged. Repair any damage.

missing/damaged.
(2) Install the top-left cowling:
S Move the top-left cowling into position on the Make sure that the fasteners engage
engine nacelle. correctly in the engine nacelle and
bottom cowling.
S Move the top-right cowling into position on Make sure that the fasteners engage
the engine nacelle. correctly in the top-left cowling, the
engine nacelle and bottom cowling.
(3) Tighten all the quick-release fasteners that

attach the top-left and top-right cowlings to the
bottom engine cowling and the engine nacelle.
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3. Cleaning and Painting
A. Clean the Cowlings
(1) Wash the outer surface with a mixture of water Obey the detergent manufacturer’s
(2) Wash the inner surface with a mixture of water Obey the detergent manufacturer’s
CAUTION: DO NOT USE POLISH CONTAINING SILICONE. SILICONE MAKES

CFRP REPAIR DIFFICULT.
(3) Polish the outer surface with wax polish. Obey the polish manufacturer’s
instructions. Do not use silicone polish.
B. Paint the Insides of the Cowlings
This Paragraph gives the data for painting the inside of the engine cowlings with fire protection
paint. Refer to Section 51-20 for repairs and painting the outside of the cowlings.
(1) Clean the inside of the cowling.
(2) Make the area rough for painting. Use 150-320 grade wet and dry paper.
WARNING: DO NOT GET ACETONE ON YOUR SKIN. ACETONE CAN CAUSE

SKIN DISEASE.
WARNING: DO NOT BREATHE ACETONE FUMES. ACETONE FUMES CAN

CAUSE ILLNESS.
CAUTION: REMOVE ACETONE AS SOON AS POSSIBLE FROM GFRP.

ACETONE CAN CAUSE THE RESIN TO SOFTEN AND FAIL.
(3) Clean the area for painting. Use acetone.
(4) Paint the inside of the cowling with fire Obey the paint manufacturer’s
protection paint. instructions.
(5) Paint the inside of the cowling with clear top Obey the paint manufacturer’s
coat. instructions.
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Section 71-20
Engine Mounting
1. General
Tubular steel makes the engine mount. The engine mount has welded joints. Powder coating protects
the frame from corrosion. Welded brackets hold components such as the coolant radiator and the
inter-cooler. Rubber lined P-clamps and cable ties hold electrical cables and other items of equipment
to the engine mount.
The engine mounting-frame has five small mounting pads at the rear of the frame. Bolts through the
pads attach the engine mount to the engine nacelle.
The engine attaches to the engine mount at four mounting pads. Large gel-filled rubber shock-mounts
go between the engine and the engine mount pads. These shock-mounts isolate the airframe from
engine vibrations.
Additionally there are safety ropes (steel wire ropes) at each engine mounting pad.
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Anchor Nut
Washer
Bolt
Firewall
Firewall Mounting Pad

Alternate Air
Valve Mounting
A Radiator Mounting
Rear Engine
Mounting, RH
Cabin Heater A
Radiator Mounting
A
Exhaust
Mounting Accumulator
Mounting
Firewall
A Rear Engine
Mounting, LH
Front Engine
Mounting, RH
A
Radiator Mounting
Radiator Mounting
Front Engine
Mounting, LH
Figure 1: Engine Mount Assembly
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Anchor Nut
Washer
Bolt
Firewall
Firewall Mounting Pad

Alternate Air
Valve Mounting
A Radiator Mounting
Rear Engine
Mounting, RH
A
A
Cabin Heater
Radiator Mounting
A Accumulator
Mounting
Firewall
Rear Engine
Exhaust Mounting, LH
Mounting
Front Engine
Mounting, RH A
Fuel Cooler Mounting
Radiator Mounting
Front Engine
Mounting, LH
Figure 2: Engine Mount Assembly (if MÄM 42-600 is installed)
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Trouble-Shooting
1. General
The table below lists the defects you could have with the engine mounting. If you have the trouble
Repair column.
Engine vibration. Cracked engine mount. Examine the engine mount.

Look specially for cracks at the
welded joints.
Defective shock mounts. Refer to the engine

manufacturer.
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1. General
The Maintenance Practices for the engine mount are limited to removal/installation. If the engine mount
is damaged it must be repaired by an authorized repair facility.
2. Remove/Install an Engine Mount
A. Equipment
Hoist. 1 Commercial.
Engine sling. 3 Commercial.
Engine stand. 1 Commercial.
Tail trestle. 1 Commercial.
Hoisting points. 4 Delivered with engine.
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B. Remove an Engine Mount

(1) Remove the engine. Refer to Section 71-00.
(2) Release all clamps, clips and ties holding the

electrical harness and hoses to the engine mount.
(3) Remove the un-feathering accumulator. Refer to Section 61-20.
(4) Remove the cabin heating heat-exchanger and Refer to Section 21-40.
shroud.
(5) Remove the engine coolant radiator. Refer to Section 75-00.
(6) Remove the inter-cooler. Refer to Section 81-00.
(7) Remove the turbo charger inter-cooler. Refer to Section 81-00.
(8) Remove the inter-cooler mounting bracket. Refer to Section 81-00.
(9) Remove the air filter housing and alternate air Refer to Section 71-60.
valve.
(10) Remove the 5 bolts and washers which attach the

engine mount to the firewall at the engine nacelle.
(11) Move the engine mount clear of the engine

nacelle.
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C. Install an Engine Mount

(1) Move the engine mount into position on the
firewall.
(2) Install the 5 bolts which attach the engine mount

to the engine nacelle firewall:
S Fasten the bolts through the firewall. Use new bolts. Torque: 40 Nm
(29.5 lbf.ft.).
(3) Install the engine coolant radiator.
(4) Install the inter-cooler mounting bracket. Refer to Section 81-00.
(5) Install the turbo charger inter-cooler.
(6) Install the inter-cooler.
(7) Install the engine air filter housing and alternate

air valve.
(8) Install the cabin heating heat-exchanger and

shroud.
(9) Install the propeller un-feathering accumulator.
(10) Install all the clamps, clips and ties that hold the The clamps, clips and ties that you
electrical harness and hose to the engine mount. removed in Paragraph 2 B, step 2.
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Section 71-50
Electrical Cables in the Engine Compartment
1. General
Each engine compartment has a main electrical wiring harness. The harness is supplied as part of the
engine installation. The harness has all of the low-power cables for the engine control system. It is
integral with the engine control system. Refer to Section 76-00 for data about the main electrical wiring
harness.
There are a small number of separate cables for the alternator and starter. See Chapter 24 for data
about the battery and alternator wiring. See Chapter 80 for more data about the starter cables. See
Chapter 92 wiring diagrams for data about the cables in each system.
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Section 71-60
Air Intakes
1. General
An air filter housing, air filter and alternate air valve assembly make the engine air intake system for
the DA 42 NG airplane. The air filter box is connected to the intercooler air intake by a flexible hose.
The same sort of hose feeds the air from the alternate air valve to the turbo-charger. A lever below the
instrument panel, right-side, operates both alternate air valves.
Figure 1 shows the engine air filter and alternate air valve.
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Air Outlet to
Turbo-Charger
Alternate Air Valve
Worm-Drive Worm-Drive Air Filter Box Assy
Clamp Clamp
Air Outlet
Turbo-Charger
from Air Intake
Worm-Drive
Clamp
Swivel Fitting
Nut
Locking Washer
Inner Control Anti-Vibration Mount
Cable
Outer Sheath
with Adjuster
Engine Mounting
Alternate Air Valve Frame
Worm-Drive Clamp
Air Filter
Air Filter Box Body
Quick Release Fasteners
Bolt
Washer
Air Intake
Nut
Figure 1: Air Filter and Alternate Air Assembly
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Figure 2: Air Valve Assembly
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2. Description
The air intake has 4 main parts:
) Alternate air valve assembly.
) Air filter housing.
) Air filter.
) Alternate air valve operating cables.
A. Alternate Air Assembly
Refer to Figure 1. The alternate air valve is attached to the right hand face of the air filter box. The
air filter attaches to the front of the alternate air valve. The alternate air valve also has an inlet direct
from the engine compartment. Rotary motion of the outer ring opens different holes to the engine
compartment. Thus the valve can select either fresh filtered air or warm unfiltered air which passes
through a fine foreign object damage (FOD) screen. Refer to Figure 2.
B. Air Filter Housing
The air filter housing is made of sheet aluminum. It has a flexible hose which connects the housing
to the air intake duct. Bolts attach the air filter housing to brackets on the engine mount.
C. Air Filter
Refer to Figure 1. The air filter is a K&N RU-1620 high-flow air filter. The air filter located on the air
filter housing, on the right of the engine compartment, just forward of the firewall. It is held to the
forward face of the alternate air valve by a worm-drive clamp.
D. Alternate Air Valve Operating Cables
A control lever on the right side of the center console, below the instrument panel operates the
alternate air valves.
Bowden cable connects the control lever to a relay lever. The relay lever is mounted in the relay
bracket which is located on the cockpit control bulkhead, below the pilot’s seat. Two more Bowden
cables connect the relay lever to the left and right engine alternate air valve operating levers.
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3. Operation
When the pilot pulls the alternate air valve control lever towards the rear of the airplane these events
occur:
) The lever pulls the inner cable of the forward Bowden cable.
) The inner cable of the forward Bowden cable turns the relay lever clockwise.
) The relay lever pulls the inner cables of the left and right alternate valves.
) Both engine alternate air valves move to the alternate (unfiltered) position.
) Both engine alternate air valves move to the alternate (unfiltered) position.
When the pilot moves the alternate air valve control lever forward both alternate air valves move back
to the normal (OFF) position.
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Trouble-Shooting
1. General
The table below lists the defects you could have with the air intake system. If you have the trouble
An engine does not develop Air filter blocked/defective on Replace air filter. For the
full power. related engine. related engine.
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1. General
These Maintenance Practices tell you how to remove and install the air filter and the alternate air valve
assembly. They also tell you how to adjust, remove and install the alternate air control cables.
2. Remove/Install an Air Filter
A. Remove an Air Filter

INJURY TO PERSONS.

OFF.
(3) Remove the engine top cowlings. Refer to Section 71-10.
(4) Disconnect the alternate air valve Bowden

cables.
(5) Open the 3 camloc bolts of the alternate air

valve.
(6) Pull out the alternate air valve with the attached
filter element.
(7) Open the worm-drive clamp which holds the filter

element. Pull off the filter from the air valve.
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B. Install an Air Filter
% (1) Inspect the air filter for loose rubber residues

% from manufacturing. If loose rubber residues are
% found, remove them carefully prior to installation
% of the filter.
% (2) Place the filter on the air valve. Close the worm
drive clamp which holds the filter element.
Do not use the worm drive clamp provided with

K&N filter package. Use 9 mm (3/8 in) wide
worm drive clamp instead.
% (3) Place the alternate air valve with the attached

filter element.
% (4) Close the 3 camloc bolts of the alternate air

valve.
% (5) Connect the alternate air valve Bowden cables.
% (6) Check if position of the alternate air valve is in

accordance to the selector handle position.
% (7) Install the engine top cowlings. Refer to Section 71-10.
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3. Remove/Install an Alternate Air Valve
A. Remove an Alternate Air Valve

INJURY TO PERSONS.
(5) Remove the bolts, nuts and washers that hold

the alternate air valve to the air filter housing.
(6) Disconnect the alternate air control cable.
(7) Disconnect the hose that connects the alternate

air valve to the turbo-charger inlet:
S Open the worm-drive-clamp. At the alternate air valve.
S Pull the hose off the valve.
(8) Move the alternate air valve clear of the airplane.
(9) If the FOD screen of the alternate air valve is

contaminated:
S Clean FOD screen.
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B. Install an Alternate Air Valve
(1) Install the air filter. Refer to Paragraph 2.
(2) Install the alternate air valve on the air filter Apply fire resistant sealant (Dow
housing. Corning 736 or equivalent) between air
filter housing and alternate air valve.
(3) Move the alternate air valve close to the engine

and connect the alternate air control cable to the
valve.
(4) Adjust the alternate air control cable. Refer to Paragraph 6.
(5) Connect the hose that connects the alternate air

valve to the turbo-charger inlet:
S Connect the hose to the valve. At the alternate air valve.
S Tighten the worm-drive clamp.
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4. Remove/Install an Alternate Air Control Inner-Cable (if MÄM 42-933 is NOT installed)
A. Remove an Alternate Air Control Forward Inner-Cable

INJURY TO PERSONS.
(5) Disconnect the control cable from the relay lever Refer to Figure 1.
at the relay bracket:
S Loosen the screw on the cable swivel fitting

at the relay lever.
S Pull the inner control cable clear of the Retain the swivel fitting.
swivel fitting.
(6) Disconnect the control cable from the alternate Refer to Figure 2.
air control operating lever in the cockpit:

at the operating lever.
S Remove the swivel fitting from the cable. Retain the swivel fitting.
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Nipple
Operating Lever
Bush
Cold Air
Spacer
Angle
Bracket
Relay Bracket
To RH Alternate
Air Valve Bowden
Cable, RH
Bowden Cable from

Operating Lever
Bowden
Cable, LH
To LH Alternate
Swivel Air Valve
Swivel Fitting
Fitting
Relay
Lever
Figure 3: Alternate Air Valve Operating Cables
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(7) Remove the inner control cable form the sheath:
S Attach a length of suitable cord to the end of The cord must be longer than the inner
the inner cable. cable!
S Pull the inner cable from the outer sheath

and pull the length of cord into the outer
sheath and clear of the airplane.
S Disconnect the inner cable from the length Leave the length of cord in the outer
of cord. sheath!
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B. Install an Alternate Air Control Forward Inner-Cable
(1) Make sure that the alternate air control cable

outer sheath is in good condition and is not
kinked.
(2) Make sure that the new alternate air valve

forward control cable inner is clean and dry.
(3) Install the new alternate air valve forward control

cable inner:
S Attach the end of the length of cord that is in At the cockpit end.
the control cable outer sheath to the new
control cable inner.
S Pull the new cable into the outer sheath with From the relay lever end.
the length of cord.
S When the new inner cable is fully through the

outer sheath:
S Disconnect the length of cord from the

inner cable.
(4) Connect the alternate air forward inner cable to Refer to Figure 2.
the operating lever in the cockpit:
S Install the swivel fitting into the operating

lever.
S Pass the inner cable through the swivel

fitting and tighten the swivel fitting.
(5) Connect the alternate air inner cable to the relay Refer to Figure 2.
lever:
S Install the swivel fitting into the relay lever.

fitting and tighten the swivel fitting screw.
(6) Adjust the alternate air cable that you installed. Refer to Paragraph 6.
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C. Remove an Alternate Air Control Forward Left/Right-Cable

INJURY TO PERSONS.
(5) Disconnect the control cable from the relay lever Refer to Figure 1.
at the relay bracket:

at the relay lever.
swivel fitting.
(6) Disconnect the control cable from the related Refer to Figure 1.
alternate air valve:

at the alternate air valve.
swivel fitting
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(7) Remove the inner control cable form the sheath:

S Disconnect the inner cable from the length of Leave the length of cord in the outer
cord. sheath!
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D. Install an Alternate Air Control Forward Left/Right-Cable

kinked.
(2) Make sure that the new alternate air valve

control cable inner is clean and dry.
(3) Install the new alternate air valve left/right control

cable inner:
S Attach the end of the length of cord that is in At the related engine end.
S Pull the new cable into the outer sheath with From the relay lever end.
the length of cord.
S When the new inner cable is fully through the

outer sheath:

inner cable.
(4) Connect the alternate air inner cable to the

related engine alternate air valve operating lever:
S Install the swivel fitting into the alternate air

valve operating lever.

(5) Connect the alternate air inner cable to the relay Refer to Figure 2.
lever:
S Install the swivel fitting into the relay lever.

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5. Remove/Install an Alternate Air Control Cockpit Lever Cable (if MÄM 42-933 is installed)
A. Remove an Alternate Air Control Cockpit Lever Cable

INJURY TO PERSONS.
(4) If necessary: remove the pilot’s seat. Refer to Section 25-10.
(5) Disconnect the control cable from the related Refer to Figure 4.

at the alternate air valve.
swivel fitting.
(6) Disconnect the control cable from the alternate Refer to Figure 4.
air control operating lever in the cockpit, by
removing the worm screw.
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(7) Remove the inner control cable from the sheath:

S Disconnect the inner cable from the length of Leave the length of cord in the outer
cord. sheath!
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Bush Operating Lever
Swivel
Alternate Fitting
Spacer
Air Valve, RH
Cold Air
Bowden
Cable, RH
Angle
Bracket
Swivel
Fitting Bowden
Cable, LH
Alternate
Air Valve, LH
Swivel Fitting
Figure 4: Alternate Air Valve Operating Cables (if MÄM 42-933 is installed)
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B. Install an Alternate Air Control Cockpit Lever Cable

kinked.
(2) Make sure that the new alternate air control

cable inner is clean and dry.
(3) Install the new alternate air control cable inner:
S Attach the end of the length of cord that is in

S Pull the new cable into the outer sheath with

the length of cord.
S When the new cable is fully through the outer

sheath:

cable.
(4) Connect the alternate air cable to the operating Refer to Figure 4.
lever in the cockpit.
(5) Connect the alternate air inner cable to the Refer to Figure 4.
S Install the swivel fitting into the alternate air

valve.
S Pass the cable through the swivel fitting and

tighten the swivel fitting screw.
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6. Adjust an Alternate Air Valve Control Cable
A. Adjust the Alternate Air Valve Forward Control Cable

INJURY TO PERSONS.
(2) If necessary, disconnect the airplane main Refer to Section 24-31.

battery.
(3) If necessary, remove the engine top cowlings. Refer to Section 71-10.
(4) Move the alternate air lever in the cockpit from Fully aft.
OFF to ON:
S Make sure the lever moves freely with no

restrictions.
(5) Set the alternate air lever in the cockpit to OFF Fully forward.
and hold it in position:
S Make sure that both left and right engine With the alternate air valve fully closed
alternate air valves are fully closed. there must be at least 3 mm (0.125 in)
clearance (bounce) between the
alternate air lever and the stop.
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(6) Set the alternate air lever in the cockpit to ON

S Make sure that both left and right engine

alternate air control valves are in the fully
open position.
(7) If necessary, adjust the alternate air control At the alternate air lever.
cable to get the correct settings at step 5.
(8) Do steps 5 to 7 again as necessary.
(9) Connect the airplane battery. Refer to Section 24-31.
(10) Install the engine top cowlings. Refer to Section 71-10.
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B. Adjust a Left/Right Engine Alternate Air Valve Control Cable

INJURY TO PERSONS.
(2) If necessary, disconnect the airplane main Refer to Section 24-31.

battery.
(3) If necessary, remove the engine top cowlings. Refer to Section 71-10.
(5) Move the alternate air lever in the cockpit from Fully aft.
OFF to ON:
S Make sure the lever moves freely with no

restrictions.
(6) Set the alternate air lever in the cockpit to OFF Fully forward.
S Make sure that the related engine alternate With the alternate air valve fully closed
air valve is fully closed. there must be at least 3 mm (0.125 in)
clearance (bounce) between the
alternate air lever and the stop.
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(7) Set the alternate air lever in the cockpit to ON

S Make sure that the related engine alternate

air control valve is in the fully open position.
(8) If necessary, adjust the related engine alternate At the relay lever.
air control cable to get the correct settings at
step 6.
(9) Do steps 5 to 8 again as necessary.
(12) If necessary, connect the airplane main battery. Refer to Section 24-31.
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Section 71-61
Air Intakes (if MÄM 42-600 is installed)
1. General
An air filter housing, air filter and alternate air valve assembly make the engine air intake system of the
DA 42 NG (if MÄM 42-600 is installed) airplane. The air filter box is connected to the intercooler air
intake duct via bolts. A flexible hose feeds the air from the alternate air valve to the turbo-charger.
A lever below the instrument panel (right-side) operates both (LH and RH) alternate air valves
simultaneously.
Figure 1 shows the engine air filter and alternate air valve.
2. Description
The air intake has 4 main parts:
) Alternate air valve assembly.
) Air filter housing.
) Air filter.
) Alternate air valve operating cables.
A. Alternate Air Assembly
Refer to Figure 1. The alternate air valve is attached to the aft face of the air filter housing. The air
filter attaches to the front of the alternate air valve. The alternate air valve also has an inlet direct
from the engine compartment. Rotary motion of the outer ring opens different holes to the engine
compartment. So the valve can select either fresh filtered air or unfiltered air from inside the
cowling.
B. Air Filter Housing
The air filter housing is made of CFRP. It is installed directly to the intercooler / engine air intake
duct via bolts.
C. Air Filter
Refer to Figure 1. The air filter is a high-flow air filter. The air filter is located in the middle of the
engine compartment, just forward of the firewall in the air filter box.
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D. Alternate Air Valve Operating Cables
If MÄM 42- 933 is NOT installed:
alternate air valves. A Bowden cable connects the control lever to a relay lever. The relay lever is
mounted in the relay bracket which is located on the cockpit control bulkhead, below the pilot’s
seat. Two more Bowden cables connect the relay lever to the left and right engine alternate air
valve operating levers.
If MÄM 42- 933 is installed:
alternate air valves. Two Bowden cables connect the control lever connect the relay lever to the
left and right engine alternate air valve operating levers.
3. Operation
When the pilot pulls the alternate air valve control lever aft:
If MÄM 42- 933 is NOT installed:
) The cable turns the relay lever clockwise.
) The relay lever pulls the cables of the left and right alternate valves.
) Both engine alternate air valves move to the alternate air position (unfiltered air).
If MÄM 42- 933 is installed:
) Both engine alternate air valves move to the alternate air position (unfiltered air).
When the pilot moves the alternate air valve control lever forward both alternate air valves move back
to the normal (OFF) position.
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A Outer Sheath
with Adjuster
Locking Washer
Nut
Inner Control Cable
Swivel Fitting
Air Outlet to
Turbo-Charger
Worm-Drive Worm-Drive
Clamp Clamp
Turbo-Charger
A
Air Filter Box Assy
Alternate Air Valve
Air Outlet
from Air Intake
Worm-Drive
Clamp
Alternate Air Valve

Quick Release Fasteners
Worm-Drive
Air Filter Clamp
Air Filter Box Body
Worm-Drive
Clamp
Air Intake
Bolt Washer
Figure 1: Air Filter and Alternate Air Assembly (if MÄM 42-600 installed)
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Locking Ring
Ring
O-Ring
Alternate Air Valve Body
O-Ring
Bonding Wire
Flange
Mesh Ring
Bushing
Guide Bolt
Bowden Cable Guide
Screw
Camloc Bolt
& Lock Washer
Suction Nozzle
Locking Ring
Figure 2: Air Valve Assembly (if MÄM 42-600 installed)
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Trouble-Shooting
1. General
The table below lists the defects you could have with the air intake system. If you have the trouble
An engine does not develop Air filter blocked/defective on Replace air filter. For the
full power. related engine. related engine.
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Section 71-70
Engine Drains
1. General
The DA 42 NG has a breather for the oil separator for each engine nacelle.
Refer to Chapter 72 for more data about the engine oil system and refer to Chapter 75 for more data
about the engine liquid cooling system.
2. Description
Figure 1 shows the engine drain installation of the AE E4-B engine.
The engine drain installation consists of two hoses and the breather outlet adapter. The first breather
hose connects to the injector cover outlet and to the breather outlet adapter on the other side. The
breather outlet adaptor is installed to the air filter housing with a P-clamp. The second breather hose
connects the breather outlet adapter to the guide tube which vents the breather gases clear of the
cowling.
To allow for drainage of oil / water which accumulates underneath the injector cover, a cylinder head
drain hose connects to the engine drain outlet located at the front side of the engine below the injector
cover. The other end of the cylinder end drain hose is attached to the guide tube.
Both, the breather hose assembly and the cylinder head drain hose are secured to the engine
mounting frame via cable ties and P-clamps.
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Figure 1: Engine Cylinder Head Drain and Breather Hose Assembly
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1. General
These Maintenance Practices tell you how to remove/install an oil separator breather hose.
2. Remove/Install a Breather Hose Assembly
A. Remove a Breather Hose Assembly

INJURY TO PERSONS.
(4) Remove the cable ties and P-clamp that secure Refer to Figure 1.
the breather hose assembly to the engine
Mark attachment points of oil breather
mounting frame.
hose assembly before removing it.
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(5) Remove the breather hose assembly:
S Remove the worm drive clamp that secures

the breather hose assembly to the outlet at
the top aft side of the rail cover.
S Remove worm drive clamp that secures the

breather hose assembly to the guide tube.
S Move the breather hose assembly clear of

the engine.
(6) Disassemble the breather hose assembly:
S Remove the worm drive clamps which

secure the breather outlet adaptor to the
breather hoses.
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B. Install a Breather Hose Assembly
(1) Assemble breather hose assembly: Refer to Figure 1.
S Install the short breather line to the breather Make sure to install the breather outlet
outlet adaptor and secure with worm drive adapter with correct orientation.
clamp.
S Install the long breather line to the breather

outlet adaptor and secure with worm drive
clamp.
(2) Install the breather hose assembly according to

the previously marked attachment points.
(3) Connect the breather hose assembly to the

outlet at the top aft side of the injector cover and
guide tube. Secure both connections with worm
drive clamps.
(4) Secure the breather hose assembly with cable

ties and P-clamps according to the previously
marked attachment points.
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Section 71-71
Engine Drains (if MÄM 42-600 is installed)
1. General
The DA 42 NG has a breather for the oil separator for each engine.
Refer to Chapter 72 for more data about the engine oil system and refer to Chapter 75 for more data
about the engine liquid cooling system.
2. Description
Figure 1 shows the engine drains for the AE E4-C engine.
The engine drain installation consists of hoses and the breather outlet adapter. The first breather hose
connects to the injector cover breather outlet and to the breather drain adapter on the other side. The
breather drain adaptor is installed to the engine mount with P-clamps. The second breather hose
connects the breather drain adapter to the guide tube which vents the breather gases clear of the
cowling.
To allow for drainage of oil / water which accumulates underneath the injector cover, a cylinder head
drain hose connects to the engine drain outlet located at the front side of the engine below the injector
cover. The other end of the cylinder head drain hose is attached to the guide tube.
Both, the breather hose assembly and the cylinder head drain hose are secured to the engine
mounting frame via cable ties and P-clamps.
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Nut
P-Clamp
P-Clamp
Crankcase Bolt
Drain Hose 1
Worm Drive Clamp
Crankcase
Drain Hose 2
Drain
Worm Adaptor
Drive
Clamps
Worm
Drive
Clamp
Worm Drive
Clamp
Cylinder Head
Drain Hose
Firewall
Hose Clamp
Bolt Washer
P-Clamp
P-Clamp
Washer
Nut
Guide Tube
Figure 1: Engine Cylinder Head Drain and Breather Hose Assembly (if MÄM 42-600 installed)
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1. General
These Maintenance Practices describe how to remove/install the oil separator breather hose.
2. Remove/Install a Breather Hose Assembly
A. Remove a Breather Hose Assembly

INJURY TO PERSONS.
(4) Remove the cable ties and P-clamp that secure Refer to Figure 1.
the breather hose assembly to the engine
Mark attachment points of oil breather
mounting frame.
hose assembly before removing it.
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(5) Remove the breather hose assembly:
S Remove the worm drive clamp that secures

the breather hose assembly to the outlet at
the top aft side of the rail cover.
S Remove worm drive clamp that secures the

breather hose assembly to the guide tube.
S Move the breather hose assembly clear of

the engine.
(6) Disassemble the breather hose assembly:
S Remove the worm drive clamps which

secure the breather outlet adaptor to the
breather hoses.
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B. Install a Breather Hose Assembly
(1) Assemble breather hose assembly: Refer to Figure 1.
S Install the short breather line to the breather Make sure to install the breather outlet
outlet adaptor and secure with worm drive adapter with correct orientation.
clamp.
S Install the long breather line to the breather

outlet adaptor and secure with worm drive
clamp.
(2) Install the breather hose assembly according to

the previously marked attachment points.
(3) Connect the breather hose assembly to the

outlet at the top aft side of the injector cover and
guide tube. Secure both connections with worm
drive clamps.
(4) Secure the breather hose assembly with cable

ties and P-clamps according to the previously
marked attachment points.
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CHAPTER 72
ENGINE
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Page 2
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TABLE OF CONTENTS
CHAPTER 72
ENGINE
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Engine Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Change the Engine Oil and Replace the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . 202
3. Replace the Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Read an Engine Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
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CHAPTER 72
ENGINE
1. General
This Section gives you background data about the AE E4-B or AE E4-C (if MÄM 42-600 is installed)
engines installed in the DA 42 NG airplane. This Section also tells you about the maintenance of the
oil system of the AE E4-B or AE E4-C (if MÄM 42-600 is installed) engine.
Refer to these Chapters for more data about the engine systems:
) Chapter 73. Engine fuel and control.
) Chapter 75. Liquid cooling system.
) Chapter 76. Engine controls.
) Chapter 77. Engine indicating.
) Chapter 78. Engine exhaust.
) Chapter 79. Oil cooling.
) Chapter 80. Engine starting.
) Chapter 81. Turbo charger.
Note: Only AE authorized maintenance organizations may carry out maintenance and
inspection work on the AE E4-B or AE E4-C (if MÄM 42-600 is installed) engine.
Any engine malfunction must be reported to AE.
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Engine Oil Filter Housing
Gearbox Oil
Filler Plug
Engine Oil Filler
Gearbox Oil Drain Plug

Engine Oil Drain Plug
Gearbox Oil
Level Window
Figure 1: Oil System Maintenance Locations
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2. Description
The AE E4-B or AE E4-C (if MÄM 42-600 is installed) engine is a liquid-cooled, in-line four-stroke four
cylinder engine with a double overhead camshaft (DOHC). The valves are actuated by the cam
follower. The direct fuel injection is realized with a common rail technique and the engine is charged
by a turbo charger. All engine components are controlled by an EECU system. The engine is equipped
with an electrical starter, an alternator, a water pump, an oil pump, a coolant system and an oil cooler.
The propeller is powered by a directly integrated gearbox with an integral torsional vibration damper.
3. Engine Oil System
The engine has the usual wet sump oil system. The sump has a maximum capacity of 7 liter
(7.4 US qt). Refer to the Airplane Flight Manual Chapter 2 for data about the oil types to use in the
engine.
The internal oil pump supplies oil to all bearings and other components that require oil. Oil galleries
inside the engine crankcase and cylinder head supply oil to the internal components.
Figure 1 shows the location of the items that you can maintain on the engine oil system of the
AE E4-B engine. The engine has these maintenance locations:
) A full-flow oil filter located at the top left adjacent to the cylinder head. You must replace the filter
at the times given in Chapter 05.
) An engine oil drain plug at the rear left of the engine sump.
) An oil filler located at the left of the crankcase.
) A gearbox oil filler plug located at the top of the gearbox.
) A gearbox oil level window located at the LH side of the gearbox. When the oil covers half of the
inspection window, the gearbox contains the correct quantity of oil.
) A gearbox oil drain plug located at the bottom of the gearbox.
) A oil separator is located under the injector cover.
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Trouble-Shooting
1. General
The trouble-shooting given in this Section is limited to those items that you are allowed to do on the
engine. For all other engine troubles, you must refer to an approved AE E4-B or AE E4-C (if
MÄM 42-600 is installed) repair facility or the engine manufacturer.
Engine oil pressure low. Not enough oil in the engine oil Fill the engine with oil.
sump.
Oil pressure regulator valve Refer to the engine

does not operate correctly. manufacturer.
Defective oil pump. Refer to the engine

manufacturer.
Gearbox oil temperature high. Not enough oil in the gearbox. Find the reason for the loss of
gearbox oil and correct the
problem. Fill the gearbox with
oil. Refer to the AFM for
approved oils.
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1. General
These Maintenance Practices tell you how to service the oil system on the engine. Further
maintenance practices are described in the AE service documents. You must refer to an approved
AE E4-B or AE E4-C (if MÄM 42-600 is installed) maintenance facility or the engine manufacturer for
all other engine maintenance.
CAUTION: ALWAYS PUT A CAP ON OPEN CONNECTIONS. IF YOU DO NOT PUT

A CAP ON OPEN CONNECTIONS, THEN CONTAMINATION CAN GET
INTO THE SYSTEM AND CAUSE DAMAGE.
CAUTION: DO NOT MIX OIL TYPES. IF YOU MIX OIL TYPES THE OIL CAN LOSE
ITS PROPERTIES AND THE ENGINE WILL WEAR MORE QUICKLY.
Note: A sample of the oil and the used oil filter must be stored in a clean container,
labeled, and made available to Austro Engine GmbH on request for the complete
engine life time. The label must show the airplane serial number, registration
number, engine serial number, operation time and date. Quantity of the oil sample
must be 100 ml.
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2. Change the Engine Oil and Replace the Oil Filter

INJURY TO PERSONS.
For the engine oil change and the oil filter replacement procedures refer to
AE Maintenance Manual, latest revision. If an engine oil quick drain equipment is
available, refer to Chapter 79 for more details.
(5) Do a ground test of the related engine, allow the Refer to Section 71-00 and
engine to reach normal operating temperatures. AE Maintenance Manual, latest revision.
S Look for oil leaks, specially in the areas

where you have done work.
S Install the engine cowlings. Refer to Section 71-10 or 71-11.
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3. Replace the Gearbox Oil
Note: For environment protection, changing the gearbox oil is only allowed on sealed
surfaces. Used gearbox oil has to be disposed according to the applicable
regulations. The environment and ground water must not be contaminated.
(1) The gearbox oil must have operation

temperature.
(4) Remove the gearbox oil filler plug. Refer to the AE Maintenance Manual,
latest revision.
(5) Remove the gearbox oil drain plug. Refer to the AE Maintenance Manual,
latest revision.
(6) Drain the gearbox oil. Refer to the AE Maintenance Manual,

latest revision.

INJURY TO PERSONS.
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(7) Drain the propeller un-feathering accumulator:
S Set the ELECT. MASTER ON.
S Set the ENGINE MASTER ON - OFF

3 times.
S Set the ENGINE and ELECT. MASTER

OFF.
(8) Install the gearbox oil drain plug. Refer to the AE Maintenance Manual,
latest revision.
CAUTION: YOU MUST USE A GEARBOX OIL THAT AGREES WITH THE
SPECIFICATION IN THE AIRPLANE FLIGHT MANUAL, CHAPTER 2.
(9) Fill the gearbox with appropriate oil. Refer to the AE Maintenance Manual,
latest revision.
(10) Install the gearbox oil filler plug. Refer to the AE Maintenance Manual,
latest revision.
(12) Do a ground test of the related engine Refer to Section 71-00 and
(14) If necessary, correct gearbox oil level: Refer to the AE Maintenance Manual,
latest revision.
S Remove the gearbox oil filler plug.
S Fill the gearbox oil system to the correct

level.
S Tighten the oil filler plug.
S Secure the oil filler plug with lock wire.
(15) Check for leakage, especially at the gearbox oil

drain plug and gearbox oil filler plug.
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4. Read an Engine Event Log
CAUTION: ONLY AE-AUTHORIZED PERSONNEL MAY DOWNLOAD DATA FROM

THE ENGINE.

ALWAYS CONNECT AN EXTERNAL POWER SUPPLY WITH A PRESET
VOLTAGE OF 29V TO THE AIRPLANE. OTHERWISE THE
ALTERNATORS MAY BE DAMAGED.
A. Equipment
Laptop computer. 1 Commercial.
"Wizard 300" software, latest approved revision. n/a n/a.
CAN interface. 1 Commercial.
B. Read an Engine Event Log
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DA 42 NG AMM Engine Fuel and Control
AIRCRAFT
CHAPTER 73
ENGINE FUEL AND CONTROL
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TABLE OF CONTENTS
CHAPTER 73
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Fuel Cooler (if MÄM 42-600 is installed) . . . . . . . . . . . . . . . . . 201
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CHAPTER 73
1. General
This Section describes the fuel system of the AE E4-B engines and AE E4-C engines (if MÄM 42-600
is installed). It provides general data and trouble shooting information of the system.
Refer to the engine manufacturer’s Repair Manual for the AE E4 engines. You can replace
components in the air intake system and the fuel system. Refer to the engine manufacturer for data
on the engine fuel system.
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Low Level Fuel Sensor

Fuel Temperature Sensor Drain
Inboard Chamber Main Tank
Low Pressure Fuel Pumps Finger Filter
Fuel Filter Check Valve
Finger Solenoid Valve
Fuel Pressure Filter
M
Inline Filter
Pulsation Damper M
M
Auxiliary Pump
Fuel Cooler
Drain
Fuel Level Switch
Fuel Selector Valve Check Valve with Capilare
Fuel Selector
Low Pressure
Fuel Pumps
Check Valve with Capilare
Fuel Filter
Fuel Level Switch
Fuel Pressure M
Pulsation Damper
M
Drain
Fuel Cooler
Auxiliary Pump
M Inline Filter
Finger Solenoid Valve
Filter
Check Valve
Fuel Selector Valves Finger Filter
Inboard Chamber Main Tank

Fuel Temperature Sensor Drain
Low Level Fuel Sensor
Figure 1: Engine Fuel System Schematic
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27
26
25
24 28 07
01
23
02 03 04 05 06 07
21
01 Return Line
02 Fuel Supply
03 Firewall 19 22
Trap & Drain 20
06 Prefilter
08 Wing
10 Fuel Filler
21 Drain 08
22 Finger Filter
23 Nacelle 09
24 Fuel Cooler
25 Fuselage 15
26 Crossfeed Lines
11 13
12
Figure 2: Engine Fuel System Schematic (if MÄM 42-600 is installed)
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Figure 1 shows the schematic diagram for DA 42 NG with the AE E4-B engine. Figure 2 shows the
schematic diagram for DA 42 NG with the AE E4-C engine (if MÄM 42-600 is installed).
The power generation system has two main parts:
) An air intake system. This system supplies air from the inlet to the air filter to the engine inlet
manifold.
) An engine fuel system. The engine fuel system takes fuel from the airplane fuel system and injects
it into the cylinders.
A. Air Intake System
The air intake system has an air filter located on the right of each engine nacelle, just forward of
the firewall. If MÄM 42-600 is installed, the air intake system has an air filter located in the aft
middle of the engine compartment. The filter attaches to the forward face of the alternate air valve.
The alternate air valve also has an inlet direct from the engine compartment. The valve can select
either filtered air or warm, unfiltered air. Refer to Section 71-60 for more data on the air filter and
alternate air valve. If MÄM 42-600 is installed, refer to Section 71-61 for more data on the air filter
and alternate air valve.
The outlet from the alternate air valve connects to the turbo charger. The outlet from the turbo-
charger connects to an intercooler. The outlet from the intercooler connects to the engine intake
manifold. Refer to Section 81-00 for more data on the turbo charger and intercooler. If MÄM 42-600
is installed refer to Section 81-01 for more data on the turbo charger and intercooler.
B. Engine Fuel System
The fuel from the main tank flows through the pre-filter to the electrically driven low pressure fuel
pumps. These fuel pumps supply the high pressure pump with the required fuel pressure and fuel
flow. A fine fuel filter is installed upstream of the high pressure pump to assure clean fuel supply
to the engine.
The high-pressure pump supplies fuel via the common rail to the injectors. A combined pressure
relief and regulator valve at the end of the common rail controls the fuel pressure within the rail.
Surplus fuel returns to the airplane main fuel tanks. The fuel returning from the engine is hot. The
hot fuel passes through a fuel cooler located at the rear of each engine nacelle (in the engine
compartment, if MÄM 42-600 is installed). From the fuel cooler the fuel returns to the main fuel
tanks.
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Trouble-Shooting
1. General
The table below lists the defects you could have with the engine fuel and control system. It only gives
you the data for the air intake, air filter and fuel filter. For more data on troubleshooting the engine fuel
and control system refer to the engine manufacturer.
Loss of engine power. Blocked air intake. Examine the air intake.
Remove any obstructions.
Refer to Section 71-60 or
71-61.
Dirty/damaged air filter. Replace the air filter. Refer to

Section 71-60 or 71-61.
Replace the fuel filter. Look for

Dirty/damaged fuel filter.
contaminated fuel in the
airplane fuel system.
Refer to Section 28-00 and
Section 28-20 or 28-21.
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1. General
Only an approved AE repair shop can repair the engine fuel system. For more data on the engine fuel
and control system refer to the engine manufacturer.
Refer to Section 28-20 or to Section 28-21 (if MÄM 42-600 is installed) for more data on the fuel
distribution system. Refer to Section 71-60 or to Section 71-61 (if MÄM 42-600 is installed) for
maintenance data on the air filter and alternate air valve. Refer to Section 81-00 or to Section 81-01
(if MÄM 42-600 is installed) for maintenance data on the turbo charging system.
2. Remove/Install a Fuel Cooler (if MÄM 42-600 is installed)
A. Remove a Fuel Cooler
1. Make sure that the related FUEL SELECTOR In the cockpit.

2. Disconnect the flexible hoses that connect to Refer to Figure 3. Use a suitable
the fuel cooler. container to catch spilt fuel. Put caps on
all open connections.
S Remove the wire locking from the fuel hose
connectors.
3. Remove the fuel cooler:
S Remove the 2 bolts and washers that attach Support the cooler.
the fuel cooler to the engine mount.
S Lower the cooler including spray shield from Take care! The cooler will contain fuel!
the engine mount and clear of the engine
nacelle.
S Empty the fuel from the cooler into a

suitable container.
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Engine Mounting Frame Spray Shield
Nut Washer Flexible Fuel Hose

Bolt
Shock Mount
Washer
Fitting
P-Clamp O-Ring
Bushing
Wire Locking
Fuel Cooler Assembly
O-Ring
Foam Profile
Fitting
Wire Locking
Flexible Fuel Hose
Figure 3: Fuel Cooler Installation (if MÄM 42-600 installed)
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B. Install a Fuel Cooler
1. Install the fuel cooler:
S Move the fuel cooler and spray shield into

position on the engine mount.
S Align the cooler with the mounting hole on

the engine mount and install the 2 bolts and
washers that attach the fuel cooler to the
engine mount.
2. Connect the flexible hoses to the fuel cooler. Make sure that you remove all the
Secure fuel line connections with wire locking. blanking caps.
3. Do a test for leaks. Specially at the flexible hose

connections to the fuel cooler.
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DA 42 NG AMM Liquid Cooling System
AIRCRAFT
CHAPTER 75
LIQUID COOLING SYSTEM
Doc # 7.02.15 Page 1

Liquid Cooling System DA 42 NG AMM
AIRCRAFT
Page 2
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TABLE OF CONTENTS
CHAPTER 75
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Coolant Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Remove/Install Silicate Pouch (If MÄM 42-852 is installed) . . . . . . . . . . . . . . . . 206
5. Remove/Install Coolant Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6. Remove/Install a Coolant Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
7. Fill and Bleed an Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8. Drain the Engine Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
9. Coolant System Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
10. Pressure Relief Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
11. Silicate Pouch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
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CHAPTER 75
1. General
This Section gives you the data for the liquid cooling system for the DA 42 NG airplane. It gives you
the Maintenance Practices to remove/install the system components.
Figure 1 shows the liquid cooling system schematic diagram. Figure 2 shows the installation in the
airplane.
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Thermostat Main Circuit
Expansion
Tank
Engine
Radiator
Bleed Cabin Heat

Screw Heat-
Exchanger
Bypass
Bleed Screw
Figure 1: Liquid Cooling System Schematic Diagram
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2. Description
Each engine has a water-based liquid cooling system. The liquid coolant is a mixture of water and
antifreeze. Refer to the Airplane Flight Manual for approved coolants.
The engine has an integral coolant pump. The coolant pump is located at the rear of the engine, below
the oil filter housing. The v-ribbed belt at the rear of the engine operates the coolant pump. An
automatic tensioner keeps the belt tension at the correct value. The coolant flows through passages
inside the crankcase and cylinder head and becomes hot. The coolant leaves the engine through a
thermostat valve at the top, front left of the crankcase.
A temperature sensor at the rear of the thermostat valve connects to the engine control system. The
integrated cockpit system (ICS) display shows the coolant temperature (COOLING TEMPERATURE).
The cooling system has 2 circuits. There is a main circuit and a bypass circuit.
For the main circuit, large diameter hoses and pipes connect the thermostat valve to the inlet of a
coolant radiator. The coolant radiator is located below the engine. Large hoses and pipes connect the
outlet from the coolant radiator to an inlet on the engine crankcase at the rear, top. This is the inlet to
the engine coolant pump.
For the bypass circuit, large diameter hoses and pipes connect the bypass outlet from the thermostat
valve to the inlet for the coolant pump.
A coolant expansion tank is located on top of the engine above the thermostat valve. This is the
highest point in the system. A small diameter hose connects the highest point of the system to the top
of the coolant tank. The tank has an over pressure valve which opens at too high coolant system
pressure.
A small diameter hose connects the bottom of the coolant tank to the inlet to the coolant pump.
A coolant level sensor is installed in the coolant tank. It operates the WATER LEVEL caution light in
the ICS.
Hoses connect the inner coolant circuit to the inlet of the cabin heating heat-exchanger. The return flow
from the heat exchanger connects to a tapping on the main circuit pipe on the rear side of the engine.
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Filler Cap
Pressure Worm Drive

Relief Clamps
Valve
To Coolant
Coolant Tank Bypass Pipe
with Coolant Level
Sensor
Bleed Nipple
Worm Drive
Clamp A
Thermostat Valve with Engine Mounting
Temperature Sensor Worm Drive Frame
Clamps
Silicon Hose Silicon Hose
Worm Drive Anti Vibration
Bleed Nipple Worm Drive Clamps Clamps Mount
Worm Drive Worm Drive

Clamps Clamps B
Cool Coolant
Water Pipe from Radiator
Engine Mounting
Worm Drive Frame
Clamps
Worm Drive A Anti Vibration
Clamps B Mount
Radiator
Hot Coolant
to Radiator Bonding
Wire
Coolant Drain
B C Plug C
Radiator
Guard
Assy
Engine Mounting
Frame
Anti Vibration
Bonding
Mount
Wire
Figure 2: Liquid Cooling System Installation
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Worm Drive
Clamp
Pressure Relief Valve Filler Cap
Worm Drive
Clamps
Coolant Tank
with Coolant Level Worm Drive
Sensor Clamps
Bleed Nipple
Worm Drive
Clamps
Aluminium Tube
Worm Drive
Silicon Hose Clamps
Silicon
Coolant
Hose
Bypass Pipe
Thermostat Valve
Worm Drive
Clamps
Bleed Nipple A
Aluminium Tube
Engine Mounting
Frame
Worm Drive
Clamps
Worm Drive Anti Vibration Mount
Clamps
Cool Coolant
from Radiator
Hot Coolant
to Radiator
Worm Drive Clamps
Worm Drive
Clamps A Bonding Wire
A
Coolant Drain Plug
Radiator
Figure 3: Liquid Cooling System Installation (if MÄM 42-600 is installed)
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Filler Cap
Silicate Pouch Worm Drive
Pressure Clamps
Relief Valve To Coolant
Bypass Pipe
Coolant Tank
with Coolant Level Coolant Level Sensor
Sensor
Bleed Nipple
Worm Drive
Clamp A
Thermostat Valve with Engine Mounting
Temperature Sensor Worm Drive Frame
Clamps
Silicon Hose
Silicon Hose
Worm Drive Anti Vibration
Bleed Nipple Worm Drive Clamps Clamps Mount
Worm Drive Worm Drive

Clamps Clamps B
Cool Coolant
Water Pipe from Radiator
Engine Mounting
Worm Drive Frame
Clamps
Worm Drive A Anti Vibration
Clamps B Mount
Radiator
Hot Coolant
to Radiator Bonding
Wire
Coolant Drain
B C Plug C
Radiator
Guard
Assy
Engine Mounting
Frame
Anti Vibration
Bonding
Mount
Wire
Figure 4: Liquid Cooling System Installation (if MÄM 42-852 is installed)
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Worm Drive Filler Cap

Clamp
Silicate Pouch
Pressure Relief Valve Worm Drive
Clamps
Coolant Tank
with Coolant Level Worm Drive
Sensor Clamps
Bleed Nipple
Coolant Level Sensor
Worm Drive Clamps
Aluminium Tube
Worm Drive
Silicon Hose Clamps
Silicon
Coolant
Hose
Bypass Pipe
Thermostat Valve
Worm Drive
Clamps
Bleed Nipple A
Aluminium Tube
Engine Mounting
Frame
Worm Drive
Clamps
Worm Drive Anti Vibration Mount
Clamps
Cool Coolant
from Radiator
Hot Coolant
to Radiator
Worm Drive Clamps
Worm Drive
Clamps A Bonding Wire
A
Coolant Drain Plug
Radiator
Figure 5: Liquid Cooling System Installation (if MÄM 42-600 and MÄM 42-852 are installed)
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When the engine is cold, the thermostat valve closes the main circuit. The coolant pump moves the
coolant through the engine. The coolant becomes warm. The coolant flows out of the thermostat valve
through the bypass circulation pipes directly to the inlet of the coolant pump.
As the engine becomes hot, the temperature of the coolant increases. The thermostat valve senses
the increased temperature and starts to open. Some coolant goes through the bypass circuit directly
to the coolant pump inlet. Some coolant goes through the main circuit through the coolant radiator. Air
flowing through the coolant radiator cools the liquid coolant. The cool liquid returns to the inlet of the
coolant pump and mixes with the hot coolant from the bypass circulation.
The thermostat valve adjusts the flow of coolant through the main and bypass circuit to keep the
correct temperature. It starts opening at 80 °C (176 °F) and fully opens at 95 °C (203 °F), allowing the
coolant to flow through the coolant radiator.
The connection for the cabin heat system supplies coolant at the outlet temperature from the engine
at all times, independent of the coolant temperature.
On top of the coolant expansion tank a pressure relief valve is installed. The pressure relief valve limits
the over and under pressure in the cooling circuit.
A silicate cartridge contains a replaceable silicate pouch and is situated on the bottom side of the
coolant expansion tank.
A cartridge contains a replaceable silicate pouch and is situated in the filler neck of the coolant
expansion tank.
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Trouble-Shooting
1. General
This table tells you how to troubleshoot the liquid cooling system. If you have the trouble detailed in
the Trouble column read across to the Possible Cause column. Then do the repair given in the Repair
column.
This Trouble-Shooting table gives only troubles to the airplane parts of the cooling system.
Engine overheats. Flat-belt worn or broken. Refer to the engine

manufacturer.
Coolant level low. Fill the cooling system. Refer

to Section 12-10.
Coolant leak. Look for leaks at all system

joints. Repair or replace
defective components.
Air in cooling system. Bleed the cooling system.
Radiator matrix blocked by Remove foreign objects and

foreign objects. clean radiator matrix.
Thermostat valve defective. Refer to the engine

manufacturer.
Coolant pump defective. Refer to the engine

manufacturer.
Defective cylinder head Refer to the engine

gasket. manufacturer.
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1. General
This Section tells you about the Maintenance Practices for the components in the liquid cooling
system.
2. Remove/Install a Coolant Expansion Tank
A. Remove a Coolant Expansion Tank

INJURY TO PERSONS.
Note: Use only new worm-drive clamps for hose installation of liquid cooling system.
WARNING: DO NOT REMOVE THE PRESSURE CAP FROM THE COOLANT

TANK IF THE ENGINE IS HOT. THE PRESSURE IN THE SYSTEM
CAN FORCE HOT COOLANT TO COME OUT AND BURN YOU.
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(4) Remove the filler cap from the coolant tank:
S Turn the cap counterclockwise a small

S When the pressure has fully released,

remove the cap.
S Drain coolant. Refer to Paragraph 8.
(5) Disconnect the hose that connects the Use a suitable container to collect spilt
expansion tank to the supply system: coolant.
S Remove the worm-drive-clamp that secures

the hose.
S Pull the hose from the connector at the

expansion tank.
(6) Disconnect the electrical cables for the coolant At the inline connector, at the sensor.
level sensor.
(7) Remove the hose from the coolant tank which

connects to the thermostat vent.
S Remove the wire locking from the worm-

drive-clamps.
S Remove the worm-drive-clamps and the

hose.
(8) Remove the nut which also holds cable clamps

of the fuel and electrical system on top of the
thermostat vent.
(9) Remove the two other nuts which hold the tank
on the small shock mounts.
(10) Move the expansion tank clear of the engine

nacelle.
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B. Install a Coolant Expansion Tank
(1) Place the expansion tank in the engine nacelle.
(2) Install the two nuts which hold the tank on the
small shock mounts.
(3) Install the nut which also holds cable clamps of

the fuel and electrical system on top of the
thermostat vent.
(4) Connect the electrical cables for the coolant

level sensor.
(5) Connect the balance hoses that connect the

cabin heat pipe and the bypass vent to the
expansion tank:
S Push the hoses onto the connector at the

expansion tank.
S Install the worm-drive-clamps that secure Use only new worm-drive clamps.
the hose connections and apply torque seal
(no red of white torque seal color allowed).
(6) Connect the hose that connects the expansion

tank to the supply system:
S Push the hose onto the connector at the

expansion tank.
S Install and tighten the worm-drive-clamp that Use only new worm-drive clamps.
secures the hose connection and apply
torque seal (no red of white torque seal
color allowed).
(7) Fill and bleed the liquid coolant system. Refer to Paragraph 7.

(9) Perform coolant pressure test. Refer to Paragraph 9.
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3. Remove/Install the Pressure Relief Valve
A. Remove the Pressure Relief Valve

INJURY TO PERSONS.

(3) Remove the locking wire from the pressure

relief valve.
(4) Remove the pressure relief valve.
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B. Install the Pressure Relief Valve

(1) Install the pressure relief valve. Torque 12-15 Nm (8.85-11.06 lbf.ft.).
Check O-ring for deformation and
delocation.
Apply EZ TURN.
(2) Install locking wire. Wire diameter 0.8 mm (0.032 in).
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4. Remove/Install Silicate Pouch (If MÄM 42-852 is installed)
Note: If MÄM 42-852 is NOT installed, refer to Paragraph 11.

(1) Remove the engine cowlings. Refer to Section 71-10 and 71-11.
WARNING: DO NOT REMOVE THE FILLER CAP FROM THE COOLANT TANK IF
THE ENGINE IS HOT. THE PRESSURE IN THE SYSTEM CAN FORCE
HOT COOLANT TO COME OUT AND BURN YOU.
(2) Remove the safety lock wire from the filler cap
on the coolant expansion tank.
(3) Remove the filler cap from the coolant tank to

relief any pressure which may be resident in the
system:

S When the pressure has fully released, turn

the cap fully counterclockwise.
(4) Remove retaining ring inside the filler neck.
(5) Remove max coolant level plate.
(6) Remove the used silicate pouch and replace it

with the new silicate pouch. Remove cartridge
and clean it with water. Reinstall cartridge.
(7) Install the max coolant level plate. Be sure that the engraved max coolant
marking is on the top.
(8) Install the retaining ring.
(9) Check coolant level, refill if required. Refer to Paragraph 7.
(10) Install cap on the coolant expansion tank. Refer to Section 20-70.
Check O-ring for deformation. Torque 12-15 Nm (8.85-11.06 lbf.ft.).
Renew O-Ring if necessary.
Apply EZ TURN.
(11) Install safety lock wire to secure filler cap. Wire diameter 0.8 mm (0.032 in).
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5. Remove/Install Coolant Level Sensor

(1) Remove the engine cowlings. Refer to Section 71-10 and 71-11.

Remove the safety lock wire from the filler cap
on the coolant expansion tank.

system:


(4) Drain engine cooling system. Refer to Paragraph 8.
(5) Disconnect the electrical cables for the coolant At the inline connector, at the sensor.
level sensor.
(6) Remove the coolant level sensor.
(7) Install new coolant level sensor, use new Use Loctite 243.
copper gasket. Torque: 25-30 Nm (18.44-21.13 lbf.ft.).
(8) Fill and bleed the engine coolant system. Refer to Paragraph 7.
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6. Remove/Install a Coolant Radiator
A. Remove a Coolant Radiator

INJURY TO PERSONS.


system:


(5) Drain the coolant system.
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(6) Remove the hoses from the radiator: Note the position and orientation of the
hoses on the radiator!
S Remove the worm-drive-clamps that secure
the hoses.
S Pull the hoses from the connectors on the

radiator.
(7) Remove the radiator:

attach the radiator guard assy to the
radiator.

attach the radiator to the engine mounting
frame.
S Move the radiator clear of the engine

nacelle.
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B. Install a Coolant Radiator
(1) Install the radiator:
S Install the radiator guard assy. Refer to Figure 2.
S Move the radiator into position at the bottom

of the engine nacelle.

attach the radiator to the engine mounting
frame.
(2) Install the hoses onto the radiator that you In the position and orientation noted in
removed in Paragraph 6A, step 5: Paragraph 6A, step 5.
S Install the radiator hoses onto the radiator

connections.
S Secure the hoses with worm-drive-clamps Use new worm-drive clamps.

and apply torque seal (no red of white
torque seal color allowed).
(3) Fill and bleed the liquid coolant system. Refer to Paragraph 7.

(5) Perform coolant pressure test. Refer to Paragraph 9.
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7. Fill and Bleed an Engine Cooling System
% A. Equipment
% Item Quantity Part Number
% Vacuum filler device for cooling system. 1 DAI-7500-10-ST
% Pressure tool cap. 1 D44-7521-00-00-ST
% Pressure relief valve blocking tool. 1 DAI-7500-01-00-ST
% B. Fill and Bleed an Engine Cooling System
% WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER.

% IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
% INJURY TO PERSONS.
% WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
% DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
% TURNS IT CAN CAUSE INJURY TO PERSONS.
% (1) Make sure that the engine is safe:

%
% S Set the ELECT. MASTER switch to OFF.
% S Set the ENGINE MASTER switch to OFF.
% S Set the power lever to 0%.

%
% (2) Disconnect the airplane main battery. Refer to Section 24-31.
% (3) Remove the engine cowlings. Refer to Section 71-10 or 71-11.
% WARNING: DO NOT REMOVE THE PRESSURE CAP FROM THE COOLANT

% TANK IF THE ENGINE IS HOT. THE PRESSURE IN THE SYSTEM
% CAN FORCE HOT COOLANT TO COME OUT AND BURN YOU.
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% (4) Fill the cooling system:
% If MÄM 42-852 is NOT installed:
% S Remove the filler cap.
% S Install the rubber cone of the filler device.
% If MÄM 42-852 is installed:
% S Remove lock wire.
% S Remove filler cap.
% S Install pressure tool cap. D44-7521-00-00-ST

%
% (5) Make sure that the drain plug on the coolant

% radiator is installed.
% (6) Connect the filler line of the cooling system filler DAI-7500-10-00-ST
% device with the pressure tool cap or the rubber
% Make sure that all valves are closed on
% cone.
% the filler device.
% (7) Close the pressure relief valve by installing the DAI-7500-01-00-ST

% pressure relief valve blocking tool.
% (8) Place the suction line from the filler device into a Refer to chapter 2 of the AFM for
% container with at least 8 liters of coolant fluid. approved coolant.
% Place container on a pedestal on engine level. Make sure, that the suction line is
% completely filled with coolant.
% WARNING: USE ONLY APPROVED COOLANT. A WRONG COOLANT CAN

% DAMAGE THE ENGINE.
% (9) Attach a supply hose for compressed air to the

% compressed air connector.
% (10) Open the air valve at the compressed air Make sure the filler device gauge shows
% connector for approx. 2 minutes. -0.6 to -0.8 bar.
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% (11) Close the air valve and check if the pressure on For a minimum of 30 seconds.
% the gauge stays constant.
% If the pressure changes, search for leaks and

% repair if necessary.
% Repeat steps 9 and 10 until there is no

% detectable pressure change.
% (12) Open the suction line valve completely. The filling process is finished, when
% there is no coolant flow in the suction
% line and the pressure has fully
% equalized. (Filler device gauge shows
% 0.0 bar)
% (13) Close the suction line valve and disconnect the

% filler device from the coolant tank.
% (14) Perform a coolant system pressure test. Refer to Paragraph 9.
% (15) Remove the pressure relief valve blocking tool.
% (16) If MÄM 42-852 is installed: Refer to Paragraph 10.
% S Perform pressure relief valve test.

%
% (17) If MÄM 42-852 is NOT installed:

%
% S Fill coolant to max. Coolant level marking in
%
% the filler neck.
%
%
% S Install the filler cap.
%
% If MÄM 42-852 is installed:
%
% S Fill coolant to max. Coolant level marking in
%
% the filler neck.
%
% S Check O-ring for deformation. Replace if necessary. Apply EZ TURN.
% S Install the filler cap to the coolant expansion Refer to Section 20-70.
% tank.
% Torque 12-15 Nm (8.85 - 11.06 Ibf.ft.).
%
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% (18) Do an engine ground run: Refer to the Airplane Flight Manual.

%
% S Let the coolant temperature rise up to the 85 °C (185 °F)
%
% point where the coolant flows from the
%
% thermostat valve through the main circuit.
% S After shut down, check for leaks.

%
% (19) Let the engine cool down.
% WARNING: DO NOT REMOVE THE PRESSURE CAP FROM THE COOLANT

% TANK IF THE ENGINE IS HOT. THE PRESSURE IN THE SYSTEM
% CAN FORCE HOT COOLANT TO COME OUT AND BURN YOU.
% (20) Remove the filler cap from the coolant tank:
% S Turn the cap counterclockwise a small

% distance to release the pressure.
% S When the pressure has fully released,

% remove the cap.
%
% (21) Check coolant level. Repeat steps 17 to 20 until

% the fluid level in coolant tank remains constant.
% (22) If MÄM 42-852 is installed:
% S Install safety lock wire to secure filler cap. Wire diameter 0.8 mm (0.032 in).
%
% (23) Install engine cowlings. Refer to Section 71-10 or 71-11.
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%
%
%
%
%
%
% Filler Line
%
%
%
%
%
% Suction Line
%
% Suction Line Valve
%
% Air Valve
% Compressed Air
% Connector
%
%
%
% Figure 6: Vacuum Filler Device
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8. Drain the Engine Coolant System

INJURY TO PERSONS.

system:

S When the pressure has fully released,

remove the cap.
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(5) Drain the coolant system:
S Remove the safety lock wire from the drain

plug at the coolant radiator.
S Remove the drain plug from the bottom left

side of the coolant radiator.
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9. Coolant System Pressure Test
A. Equipment
% Pressure test equipment. 1 DAI-7500-02-00-ST
% Pressure relief valve blocking tool. 1 DAI-7500-01-00-ST
B. Coolant System Pressure Test

INJURY TO PERSONS.

(4) Remove the filler cap from the coolant tank and
install the pressure test equipment instead.
% (5) Install the pressure relief valve blocking tool.
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(6) Pressurize the coolant system. Apply 2.0 bar (29 PSI) relative pressure.
Max. allowable pressure drop in
15 minutes: 0.1 bar (1.45 PSI).
(7) Check the coolant system for leaks.
(8) Remove the pressure test equipment from the

coolant tank.
S Open the pressure relief valve. If existent.
S Remove the test equipment carefully to

relieve the remaining pressure.
% (9) Remove the pressure relief valve blocking tool.
(10) Install the cap to the coolant tank.
(11) Install engine cowlings. Refer to Section 71-10 or 71-11.
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10. Pressure Relief Valve Test
A. Equipment
% Pressure test equipment. 1 DAI-7500-02-00-ST
% Pressure tool cap. 1 D44-7521-00-00-ST

(if MÄM 42-852 is
installed).
B. Pressure Relief Valve Test

INJURY TO PERSONS.
WARNING: DO NOT REMOVE THE FILLER CAP FROM THE COOLANT

EXPANSION TANK IF THE ENGINE IS HOT. THE PRESSURE IN THE
SYSTEM CAN FORCE HOT COOLANT TO COME OUT AND BURN
YOU.
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(4) Remove the filler cap from the coolant tank and Remove safety lock wire and use
install the pressure test equipment instead. pressure tool D44-7521-00-00-ST.
Torque refer to Section 20-70.
(if MÄM 42-852 is installed).
(5) Pressurize the coolant system. Apply 2.3 bar (33.4 PSI).
(6) Verify:
S Pressure relief valve (PRV) opens between

1.8 and 2.3 bar (26.1 and 33.4 PSI).
S If the PRV does not open, depressurize the

coolant system by opening the pressure
relief valve of the test equipment.
Mechanically open the PRV by pulling on
the outer ring until it moves approx. 2 mm
(0.08 in) outward. Remove the PRV.
S Clean the PRV with water.
S Install the PRV.
S Repeat the PRV test. If the PRV does not

open between 1.8 and 2.3 bar (26.1 and
33.4 PSI): Replace the PRV with a new
PRV.
(7) Remove the pressure test equipment. If existent.
(8) Install the cap to the coolant tank. Torque refer to Section 20-70.
Check O-ring, apply EZ TURN. Install
safety lock wire (diameter 0.8 mm
(0.032 in)). (if MÄM 42-852 is installed).
(9) Install engine cowlings. Refer to Section 71-10 or 71-11.
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11. Silicate Pouch Replacement

INJURY TO PERSONS.
(1) Drain the engine cooling system. Refer to Paragraph 6.
(2) Remove the coolant expansion tank. Refer to Paragraph 2.
(3) Remove the lock wire from the cartridge cap.
(4) Remove the cartridge cap.
(5) Remove the used silicate pouch and replace it

with the new silicate pouch.
(6) Replace the used O-ring with a new O-ring. Grease O-ring with EZ TURN lubricant.
(7) Install the cartridge cap. Torque: 32.5 ± 2.5 Nm (24.0 ± 1.8 lbf.ft.)
(8) Secure the cartridge cap with lock wire.
(9) Install the coolant expansion tank. Refer to Paragraph 2.
(10) Fill and bleed the engine coolant system. Refer to Paragraph 5.
(11) Perform a coolant system pressure test. Refer to Paragraph 7.
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DA 42 NG AMM Engine Controls
AIRCRAFT
CHAPTER 76
ENGINE CONTROLS
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Engine Controls DA 42 NG AMM
AIRCRAFT
Page 2
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TABLE OF CONTENTS
CHAPTER 76
ENGINE CONTROLS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install a Hall Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install an Engine Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . 208
4. Remove/Install an Engine Control System Electrical Harness . . . . . . . . . . . . . . 210
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CHAPTER 76
ENGINE CONTROLS
1. General
This Section tells you about the DA 42 NG with the AE engines installed. Each engine has only one
control lever. Electrical cables connect the power levers to the engine control systems.
Figure 1 shows the schematic diagram of an engine control system. The system contains an electronic
engine control unit (EECU).
Each electronic engine control unit has two independent computers (ECU A and ECU B), either of
which can provide all control functions for the engine and propeller.
Each engine control system consists of the following componants:
) One EECU located in the engine nacelle.
) An electrical harness that connects the ECUs to the engine, the power lever, the annunciator
panel, control buttons and some instruments.
) Sensors that measure engine parameters.
) An electrical power lever located in the center console.
) Control buttons for setting the second ECU in an emergency and testing the control system.
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Integrated Cockpit System (Display)

Annunciation
on G1000 PFD
RPM
L/R ECU A FAIL OIL PRESS
L/R ECU B FAIL OIL TEMP
Control Buttons
L/R GLOW ON COOLANT TEMP
ECU VOTER L/R
L/R FUEL PRESS GEARBOX TEMP
ECU TEST L/R
L/R OIL PRESS LOAD
FUEL FLOW L/R
Throttle
FUEL QTY L/R From
FUEL LOW L/R Airframe
Fuel
FUEL TEMP L/R System
ALTERNATOR L/R From

Electrical
System
Electronic Engine Control Unit Ambient Pressure
28 VDC ECU A ECU B

28 VDC
Controlled
Components
Injector 1
Injector 2
Engine Sensors
Injector 3
Injector 4 Crankshaft 1 Coolant Temp
Glow Plugs Crankshaft 2 Oil Pressure
Fuel Pump A Camshaft 1
Oil Temp
Fuel Pump B Camshaft 2
Boost Pressure Gearbox Temp
Fuel Rail Pressure
Actuator
Intake Air Temp 1 Fuel Pressure
Rail Pressure
Control Valve Intake Air Temp 2
Governor Actuator Boost Pressure 1

Fuel Metering Unit Boost Pressure 2
Figure 1: Engine Control System Schematic Diagram
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A. Engine Control Units
The ECU A and ECU B are contained in one box located in each engine nacelle, aft of the firewall.
A harness connects the box to the engine, the power lever and the integrated cockpit system (ICS).
In the usual operation, the alternator supplies power for the system. If the alternator fails, the
ECU B automatically takes over and the ECU backup battery provides power. Refer to Section
24-00 for more data about the electrical supply for the engine control systems.
The annunciator panel of the ICS has two amber caution lights for the engine control system
(marked ECU A and ECU B).
The ECU VOTER switch on the left of the instrument panel let you toggle between ECU A and
ECU B. For all normal operation, the VOTER switch is set to AUTO and one ECU controls the
engine.
The ECU TEST buttons on the left of the instrument panel let you test the systems. Refer to Section
71-00 for the ECU test procedure.
B. Electrical Harness
Each engine has a dedicated engine electrical harness. The electrical harness is an engine
component. The harness connects the power lever and sensors to the ECU A and ECU B. It also
provides connections for the ECU buttons and the ICS.
The electrical harness comes through the engine firewall. P-clamps and tie-wraps attach the
electrical harness to the engine. The harness goes forward and divides to go down both sides of
the engine.
The cables on the right side pass mainly along the cylinder head. They connect to the fuel pressure
regulator, fuel pressure sensor, fuel injectors and camshaft position sensors. A cable goes to the
inter-cooler outlet. Cables also go forward and down to the glow plugs, waste gate, right and left
crankshaft position sensors, gearbox temperature sensor, coolant temperature sensor, and
propeller governor.
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Power Lever, RH
Power Lever, LH
Throttle Knob
Push Rod Assy, RH
Cover Plate
Screw
Washer
Nut
Thumb Switch
Connector,
2 Signal Hall Angle Sensors, RH 2 Pins
Push Rod Assy, LH
2 Signal Hall Angle Sensors, LH
Figure 2: Engine Power Levers
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The left side of the engine has cables to the sensors for oil pressure and oil temperature and cables
for the starter and alternator.
The repair of the electrical harness is limited to damage that occurs near the ends of the cables,
outside of the isolated section. If a cable fails within the isolated section, then you must replace the
complete harness.
C. Manifold Pressure
Manifold pressure is measured by two sensors for each ECU located at the air intake manifold.
D. Power Levers
Each engine has a dedicated power level. Figure 2 shows the installation of the engine power
levers. Each power lever is located in the center console. The power levers assemble as a unit to
the engine control assembly in the center console.
Each power lever has two separate and independent electrical systems. One system provides
signals to the ECU A. The other system provides signals to the ECU B. Either system can control
the engine.
The levers operate electrical sensors (HALL effect) that give signals in proportion to the power lever
position. The signals are used by the engine control system to set the power output. The control
system also sets the propeller governor to give best RPM for the power setting. Refer to Section
61-20 for more data on the propeller control function.
Push rods connect the throttle levers to the Hall-sensors. You can adjust the relative position of
each power lever relative to its sensor by adjusting the length of the related push rod. You can
make this adjustment so that the power levers align with each other when the engines are giving
the same power output.
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E. Sensors
Both ECUs of each engine get data about engine performance from the following sensors mounted
on each engine:
Sensor Location
Crankshaft 1. Front, right of the crankcase.
Crankshaft 2. Front, left of the crankcase.
Camshaft 1. Front between camshafts.
Camshaft 2. Aft between camshafts.
Coolant temperature. Beneath the air intake manifold.
Oil temperature. On the top side of the oil sump.
Oil pressure. Behind the oil filter.
Manifold air temperature 1 On the air intake manifold.

and 2.
Manifold air pressure 1 and 2. On the air intake manifold.
Fuel rail pressure. At the front of the fuel rail.
Gearbox temperature. At the back side of the gearbox next to the starter.
Fuel inlet pressure. At the inlet of the high pressure pump.
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Trouble-Shooting
1. General
The table below lists the defects you could have with the engine control system. If you have the trouble
For all other engine control trouble, refer to the engine manufacturer.

An ECU caution light comes The related ECU defective. Read engine event log (refer to
ON. Section 72-00). Refer to the
An engine does not respond Run diagnostic routine in

correctly to power lever ECU Operator software (refer
movement. to Section 72-00). Refer to the
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1. General
These Maintenance Practices tell you how to remove and install the main components in an engine
control system. All other work on the engine control systems can only be done by a AE approved
maintenance shop or the manufacturer.
2. Remove/Install a Hall Angle Sensor
A. Remove a Hall Angle Sensor
S Set both ENGINE MASTER switches to

OFF.
(2) Lift the power lever control quadrant from the

center console:
S Remove the 4 screws that attach the top

covers to the power lever quadrant.
S Remove the 2 top cover plates from the

power lever quadrant.
S Remove the 2 screws that attach the aft end

of the power lever quadrant to the fuel
selector mounting.
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(3) Remove a hall angle sensor: The flexible cables attached to the other
control levers in the quadrant and the
S Lift the complete power lever quadrant
electrical cables for the sensor are long
assembly out of the center console and
enough for you to just lift the quadrant
support the quadrant.
clear of the center console.
S Disconnect the electrical cables for the hall
angle sensor that you will remove.

the hall angle sensor that you will remove to
the power lever quadrant.
S Pull the hall angle sensor of its drive-shaft

and clear of the quadrant.
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B. Install a Hall Angle Sensor
(1) Install the hall angle sensor:
S Move the new sensor into position at the

power lever quadrant.
S Make sure that the drive of the sensor aligns

with the quadrant drive-shaft.
S Push the sensor onto the quadrant drive-

shaft.
S Install the 2 washers and bolts that attach

the sensor to the quadrant.
(2) Connect the electrical cables for the hall angle At the inline connector.
sensor.
(3) Install the power lever quadrant into the center Make sure that all the flexible cables
console: and the electrical cables are in the
correct position and orientation.
S Lower the quadrant into position in the
center console.
S Install the 2 screws that attach the aft end of

the quadrant to the fuel selector mounting.
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(4) Start the engines and allow to reach normal Refer to Section 71-00.
operating temperatures:
S Make sure that the power control levers

align:
S Set both engines to give 1800 RPM.
S Both power levers must align ± 2 mm

(0.08 in).
S If they do not align, make a note of the Use the power lever for which you did
mis-alignment. NOT replace the hall angle sensor as
the datum.
S Set both engine to 0%.
S Stop the engines. Refer to Section 71-00.
(5) If necessary, adjust the power lever alignment:
S Lift the power lever control quadrant from Refer to Paragraph 2 A, step 2 in this
the center console. Section.
S Loosen the 2 jam nuts on the sensor link rod

for the hall angle sensor that you replaced.
S Turn the drive rod to adjust the length of the Hold the input lever to the sensor
link rod to align the power levers. stationary and turn the control rod to
move the power lever the distance noted
in step 4 of this procedure.
S Tighten the jam-nuts on the sensor link rod.
S Install the power lever control quadrant into Refer to step 3 in this procedure.
the center section.
(6) Repeat steps 4 and 5 of this procedure as

necessary, until the power levers align correctly.
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(7) Install the top covers on the power lever

quadrant:
S Move the top covers into position on the

power lever control quadrant.
S Install the 4 screws that attach the top

covers to the power lever control quadrant.
(8) Do a full test of the engine for which you Refer to Section 71-00.
replaced the hall angle sensor.
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Bolt
Washer
Bolt
Washer
Inner ECU Mounting Bracket

Bolt
Washer
Bolt
Outer ECU Mounting Washer
Bracket
ECU
Electrical Connections
Figure 3: ECU Installation
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Inner ECU Mounting

Bracket
Outer ECU Mounting

Bracket
ECU
Electrical Connections
Figure 4: ECU Installation
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3. Remove/Install an Engine Control Unit (ECU)
A. Remove an Engine ECU

INJURY TO PERSONS.
DO WORK ON THE ENGINE. IF THE PROPELLER TURNS IT CAN
(1) Read out and write down the ECU IQA-Codes Refer to the AE Maintenance Manual,
and engine serial number. latest revision.
(4) Remove the access panel for the ECU on the Refer to Section 52-40.
related engine nacelle.
(5) Release the 3 electrical connectors from the Refer to Figure 4.

ECU.
(6) Remove the ECU from the mounting bracket: Refer to Figure 4.
S Release the 2 bolts and washers that hold

the ECU to the mounting bracket.
S Slide the ECU forward until it comes free of

the bracket.
(7) Remove the inner and outer mounting bracket Refer to Figure 3.
from the ECU.
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B. Install an Engine ECU
CAUTION: YOU MUST CONTACT THE ENGINE MANUFACTURER BEFORE YOU

INSTALL A NEW ECU.

(2) Install the inner and outer mounting bracket to Refer to Figure 3.
the ECU.
(3) Install the ECU: Refer to Figure 4.
S Move the ECU into position in the related

engine nacelle by sliding the ECU into the
bracket.

the ECU to the mounting bracket and use
Loctite 243 to secure the bolts.
(4) Connect the 3 electrical connectors to the ECU. Refer to Figure 4.
(5) Install the access panel. Refer to Section 52-40.
(6) Connect the airplane main battery.
(7) Check that IQA-Codes and engine serial Refer to the AE Maintenance Manual,
number at the new ECU match the ones of the latest revision.
related engine.
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4. Remove/Install an Engine Control System Electrical Harness
A. Remove an Engine Control System Electrical Harness

INJURY TO PERSONS.
DO WORK ON THE ENGINE. IF THE PROPELLER TURNS IT CAN
(3) Remove the access panel for the ECU on the Refer to Section 52-40.
(4) Release the 3 electrical connectors from the Refer to Figure 3.

ECU.
(5) Remove the related engine access panels. Refer to Section 71-10 or 71-11.
(6) Release the cable connections at the related In the engine nacelle, aft of the firewall.
ECU relay panel.
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Direction
of Flight
Fuel High Fuel Line

Propeller
Flange
Radiator
Exhaust
Figure 5: Engine Sensors - RH Side of Engine
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(7) Disconnect the engine wire harness and bonding

cables from these electrical sensors:
S Crankshaft 1. At the front right crank case.
S Crankshaft 2. At the front left crank case.
S Camshaft 1. On inlet valve cover between cyl. 3 and 4.
S Coolant temperature.
S Oil temperature. At the bottom of the oil case.
S Oil pressure. At the rear side of the oil filter housing.
S Manifold air temperature 1 and 2.
S Manifold air pressure 1 and 2.

At the rear end of the fuel rail.
S Fuel rail pressure regulator.
At the front side of the fuel rail.
S Fuel rail pressure sensor.
At the inlet of the high pressure pump.
S Fuel inlet pressure.
S Propeller governor.
S Gear temperature. At the backside of the gearbox next to the

S Waste gate valve solenoid. starter.
S Glow plugs. At the lower camshaft.
S Waste gate control valve. At the rear camshaft cover.
(8) Remove the cable ties and clamps that attach Make a note of the type and location of
the cable harness to the engine and structure. each attachment.
(9) Remove the shields for the feed-through at the

firewall.
(10) Carefully move the harness aft through the Take care not to damage the
firewall. connectors.
(11) Remove the harness from the nacelle.
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Coolant Thermostat
Housing
Camshaft Sensor
Fuel Rail
Temperature
Sensor
Air Temperature
Sensor
Coolant Temperature
Sensor
O-Ring
Oil Filter
Housing
Screw
Oil Temperature
Sensor
Crankshaft Sensor
Screw
Gearbox Temperature
Sensor Oil Pressure Sensor
Crankshaft Sensor
Figure 6: Engine Sensors - LH Side of Engine
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B. Install the Engine Control System Electrical Harness
(1) Carefully move the engine end of the harness Take care not to damage the
forward through the firewall. connectors. Adjust the harness position
so that all connections can be made
without stress.
(2) Connect the engine wire harness and bonding

cables to these electrical sensors:
S Crankshaft 1. At the front right crank case.
S Crankshaft 2. At the front left crank case.
S Coolant temperature. Beneath the air intake manifold.
S Oil temperature. At the bottom of the oil case.
S Oil pressure. At the rear side of the oil filter housing.
S Manifold air temperature 1 and 2. On the intercooler outlet pipe.
S Manifold air pressure 1 and 2.
S Fuel rail pressure regulator. At the rear end of the fuel rail.
S Fuel rail pressure sensor. At the front side of the fuel rail.
S Fuel inlet pressure. At the inlet of the high pressure pump.
S Propeller governor. At the right side of the reduction gear.
S Gear temperature. At top left of front bearing reduction gear.
S Waste gate valve solenoid. At the lower crankshaft cover.
S Glow plugs. At the lower crankshaft cover.
S Waste gate control valve. At the lower crankshaft cover.
(3) Connect the cables at the related ECU relay In the engine nacelle, aft of the firewall.
panel.
(4) Connect the 2 electrical connectors to the ECU. Refer to Figure 3. Make sure that the
bayonet locks are correctly engaged.
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(5) Install the cable-ties and clamps that attach the Refer to the notes that you made during
cable harness to the engine and structure. removal for the type and location of each
attachment.
(6) Install the shields for the feed-through at the Seal with PR 812 or equivalent.
firewall.
(8) Install the access panels in the engine nacelle. Refer to Section 52-40.
(9) Connect the main airplane battery. Refer to Section 24-31.
(10) Do an engine run up of the engine for which you Refer to Section 71-00.
replaced the control system electrical harness.
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DA 42 NG AMM Engine Indicating
AIRCRAFT
CHAPTER 77
ENGINE INDICATING
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Engine Indicating DA 42 NG AMM
AIRCRAFT
Page 2
22 Dec 2021 77-TITLE Doc # 7.02.15
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TABLE OF CONTENTS
CHAPTER 77
ENGINE INDICATING
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 77-40
Engine Indicating System
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble–Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Replace/Install a Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
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CHAPTER 77
ENGINE INDICATING
1. General
This Section tells you about the engine indicating system for the DA 42 NG airplane. An integrated
cockpit system (ICS) with two large display screens located in the instrument panel show all engine
related indications.
Engine control units (EECUs) provide most of the indications for the engine. Figure 1 shows a
schematic diagram of the engine control and indication system. Refer to Section 76-00 for data about
the engine control system. The ICS also shows airframe fuel system data. Refer to Section 28-40 for
data about the airframe parts of the system.
The ICS gives all engine indications. The ICS displays are located in the left and right sides of the
instrument panel. Each display has a combination of digital and analogue displays.
Either display can show all the engine indications. Refer to Section 77-40 for more data about the
system sensors. Refer to Section 31-40 for more data about the ICS.
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Rev. 5 77-00-00 22 Dec 2021
AIRCRAFT
Integrated Cockpit System (Display)

Annunciation
on G1000 PFD
RPM
L/R ECU A FAIL OIL PRESS
L/R ECU B FAIL OIL TEMP
Control Buttons
L/R GLOW ON COOLANT TEMP
ECU VOTER L/R
L/R FUEL PRESS GEARBOX TEMP
ECU TEST L/R
L/R OIL PRESS LOAD
FUEL FLOW L/R
Throttle
FUEL QTY L/R From
FUEL LOW L/R Airframe
Fuel
FUEL TEMP L/R System
ALTERNATOR L/R From

Electrical
System
Electronic Engine Control Unit Ambient Pressure
28 VDC ECU A ECU B

28 VDC
Controlled
Components
Injector 1
Injector 2
Engine Sensors
Injector 3
Injector 4 Crankshaft 1 Coolant Temp
Glow Plugs Crankshaft 2 Oil Pressure
Fuel Pump A Camshaft 1
Oil Temp
Fuel Pump B Camshaft 2
Boost Pressure Gearbox Temp
Fuel Rail Pressure
Actuator
Intake Air Temp 1 Fuel Pressure
Rail Pressure
Control Valve Intake Air Temp 2
Governor Actuator Boost Pressure 1

Fuel Metering Unit Boost Pressure 2
Figure 1: Engine Control and Indication Schematic Diagram
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22 Dec 2021 77-00-00 Rev. 5
AIRCRAFT
Section 77-40
Engine Indicating System
1. General
This Section tells you about the engine indicating system for the DA 42 NG airplane. The integrated
cockpit system (ICS) display screens which are located in the instrument panel give all engine and
related airplane system indications. For normal operations the left display is the primary flight display
(PFD) and the right is the multi-function display (MFD). Both displays are similar, except the autopilot
control buttons.
Refer to Section 31-40 for more data about the ICS.
The engine control units (EECUs) provide most of the indications for the engines. Refer to Section 76-
00 for data about the engine control system. The ICS also shows fuel and systems data. Refer to
Section 28-40 for data about the airframe parts of the system.
The ICS displays the engine indications for both engines on the MFD screen. The MFD gives the
following engine indications:
) LH and RH engine load. Indicates the engine loads from 0 to 100%.
) LH and RH engine RPM. Indicates the engine RPM from 0 to 2500 RPM.
) LH and RH engine gearbox temperature in °C.
) LH and RH engine coolant temperature in °C.
) LH and RH engine oil temperature in °C.
) LH and RH engine oil pressure in bar.
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Rev. 5 77-40-00 22 Dec 2021
AIRCRAFT
NAV1 108.00 117.95 GS 120KT XTK 0.09NM ETE 10:11 ESA 3700FT 136.975 118.000 COM1
VOL PUSH
VOL PUSH SQ
ID
NAV2 108.00 117.95 MAP - NAVIGATION MAP 136.975 118.000 COM2
NAV 100
EMERG
COM
80
60
40
20
75 LOAD % 73
PUSH 3000 PUSH
1-2 2000 1-2
1000
HDG CRS BARO
600
1800 RPM 1800
FUEL FLOW
7.2 GPH 8.1
PUSH PUSH
OIL TEMP CRS CTR
HDG SYNC L
R RANGE
OIL PRESS
L
R
L
PUSH
R
PAN
FUEL TEMP
L D MENU
R
FUEL QTY GAL FPL PROC

L
R
0 5 10 15 20 25
150NM CLR ENT
MAP WPT AUX NRST 0000
ALT DFLT MAP FMS
ENGINE MAP DCLTR CHKLIST
Figure 1: Display Screen - Integrated Cockpit System
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AIRCRAFT
The MFD also gives these auxiliary displays with the engine displays:
) LH and RH engine voltages.
) LH and RH engine generator output, in AMPS.
The MFD can also display the following fuel system information:
) LH and RH main fuel tank quantity (Refer to Section 28-40).
) LH and RH main fuel tank temperature in °C (Refer to Section 28-40).
) LH and RH engine fuel flow in gals/hour (Refer to Section 28-40).
Engine alerts are given on the PFD screen. A flashing warning annunciator appears in the PFD when
an alert is activated. Pressing the WARNING softkey at the bottom of the PFD opens an alert window
in the PFD. The alerts window gives more details of the alert. The ICS alert system gives alerts and
warning captions for both engine and airplane systems. Refer to Section 31-40 for more data about
the ICS.
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22 Dec 2021 77-40-00 Rev. 5
AIRCRAFT
Trouble–Shooting
1. General
The table below lists the defects you could have with the engine indication system. For more data on
the system refer to the equipment manufacturer’s manual.
One of the indicators in an Sensor/transducer defective. Do a test for continuity of the

integrated instrument does not cables for the relevant sensor.
indicate correctly.
If the cables are serviceable,
then refer to the engine
manufacturer.
Refer to Section 28-40 for the

fuel quantity indicating system.
Refer to Section 76-00 for the

location of engine sensors.
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1. General
These Maintenance Practices tell you how to replace the following sensors:
) Crankshaft (RPM).
) Gearbox oil temperature.
) Liquid coolant temperature.
) Engine oil temperature.
) Engine oil pressure.
Refer to the related Chapter for maintenance data on the sensors.
Where the engine control system provides data for the engine indicating system, only the engine
manufacturer or a AE-approved maintenance shop can replace sensors.
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Screw
Crankshaft Sensor
Screw
Crankshaft Sensor
Figure 2: Crankshaft (RPM) Sensor Installation
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AIRCRAFT
2. Replace/Install a Sensor
Figures 2 through 6 show the sensors for the engine indications.
Use the following general procedure for replacing all of the sensors on both engines. If any of the
sensors has a different procedure then the procedure will be described.
A. Replace a Sensor

INJURY TO PERSONS.
Refer to AE Maintenance Manual, latest revision for replace a sensor procedures.
(6) Do a ground test of the related engine and Refer to Section 71-00.
monitor the related engine indication.
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Fuel Metering Valve
Figure 3: Fuel Metering Valve Installation
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Coolant Thermostat
Housing
Coolant Temperature
Sensor
O-Ring
Figure 4: Engine Coolant Temperature Sensor Installation
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Oil Temperature Sensor
Figure 5: Engine Oil Temperature Sensor Installation
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Oil Filter Housing
Oil Pressure Sensor
Figure 6: Engine Oil Pressure Sensor Installation
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DA 42 NG AMM Exhaust
AIRCRAFT
CHAPTER 78
EXHAUST
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Exhaust DA 42 NG AMM
AIRCRAFT
Page 2
22 Dec 2021 78-TITLE Doc # 7.02.15
Rev. 5
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 78
EXHAUST
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install an Engine Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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CHAPTER 78
EXHAUST
1. General
The DA 42 NG has a simple exhaust systems for the engines. Each engine has a single short exhaust
pipe that bolts to the turbo charger outlet and passes through the engine cowling at the bottom.
2. Description
Figure 1 shows the engine exhaust system. You cannot do any maintenance on the exhaust pipe.
The exhaust pipe does not have a muffler.
If MÄM 42-600 is installed, Figure 2 shows the engine exhaust system. The exhaust system has a
fixed integral muffler.
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LH engine shown,
RH engine similar
Gasket
Mounting Flange
Washer
Nut Turbocharger
Engine Exhaust Manifold
Exhaust Heatshield
Nut
Washer
Anti-Vibration Mount
Washer
Nut
Exhaust Pipe
Figure 1: Exhaust System Installation
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AIRCRAFT
LH engine shown,
RH engine similar
Gasket
Mounting Flange
Washer
Turbocharger
Nut
Engine Exhaust Manifold
Bolt
Washer
Shock Mount
Heat Shield
Engine Mounting Frame Washer
Nut
Muffler
Bracket on Muffler
Exhaust Pipe
Figure 2: Exhaust System Installation (if MÄM 42-600 is installed)
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22 Dec 2021 78-00-00 Rev. 5
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the exhaust system. If you have the trouble
More noise than usual. Exhaust pipe cracked. Look for signs of exhaust gas
leaks. Replace cracked pipes.
Signs of exhaust gas leaks in Exhaust pipe cracked. Look for signs of exhaust gas
the engine compartment. leaks. Replace cracked pipes.
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1. General
These Maintenance Practices tell you how to remove and install an engine exhaust pipe. Refer to
Section 81-00 or 81-01 (if MÄM 42-600 is installed) for data about the turbo-chargers.
2. Remove/Install an Engine Exhaust Pipe
WARNING: MAKE SURE THAT THE EXHAUST SYSTEM IS COOL BEFORE YOU
TOUCH IT. THE EXHAUST SYSTEM CAN BE VERY HOT, THIS CAN
A. Remove an Engine Exhaust Pipe

INJURY TO PERSONS.
(4) Remove the exhaust pipe:
S Remove the 4 special nuts that attach the

exhaust pipe to the turbo charger.
S Remove the anti-vibration mount of the

exhaust (if MÄM 42-600 is installed).
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B. Install an Engine Exhaust Pipe
(1) Install the exhaust pipe:
S Move the exhaust pipe into position in the

engine nacelle.
S Move the exhaust pipe flange over the studs

on the turbo charger outlet.
S Install the 4 special nuts that attach the Use new nuts.
exhaust pipe to the turbo charger outlet.
S Install the anti-vibration mount to the

exhaust.
(3) Connect the airplane main battery.
(4) Do an engine ground run-up and then check the Specially around the gasket at the turbo
exhaust pipe for leaks. charger outlet.
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22 Dec 2021 78-00-00 Rev. 5
DA 42 NG AMM Oil Cooling
AIRCRAFT
CHAPTER 79
OIL COOLING
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Oil Cooling DA 42 NG AMM
AIRCRAFT
Page 2
22 Dec 2021 79-TITLE Doc # 7.02.15
Rev. 5
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 79
OIL COOLING
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install the Gearbox Cooling System (if MÄM 42-600 is Installed) . . . . 201
3. Drain the Engine Oil (with the Engine Oil Quick Drain) . . . . . . . . . . . . . . . . . . . . 203
4. Refill the Engine Oil (with the Engine Oil Quick Drain) . . . . . . . . . . . . . . . . . . . . 204
5. Remove/Install the Quick Oil Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
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CHAPTER 79
OIL COOLING
1. General
Each engine has the usual wet-sump lubrication system. The bottom part of the engine crankcase
makes the sump. An oil filler tube with a screw cap connects to the crankcase on the left of the engine.
The oil cooler is an integrated oil water heat exchanger which is located under the oil filter case and
is part of the engine.
The oil breather system has an oil separator located under the injector cap. A flexible hose at the rear
of the oil separator vents blow-by gases and any remaining oil mist overboard. A small hose connects
the bottom of the oil separator to the oil sump.
To protect the breather system from blockage due to icing of the moistured blow by gases an engine
integrated over pressure valve is provided below the injector cover.
An oil pump in the engine takes oil from the sump. The oil flows through a filter to the oil water heat
exchanger. Air passing through the oil cooler cools the oil. The cool oil returns to the engine. Oil
galleries in the engine take the oil to all bearings.
The gearbox oil is cooled via airflow over the gearbox housing.
If MÄM 42-600 is installed, additional aluminum fins are installed to the gearbox housing to enhance
cooling. On top of the aluminum fins a composite duct with an air inlet and an air outlet is installed.
Refer to Figure 1.
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Distance Bolt
Bushing Distance Bolt
Gearbox Cooler Cap
Distance Bolt
Bushing
Washer Gearbox Cooling Fins

Nut
Washer
Nut
Bushing
Washer
Nut
Figure 1: Gearbox Oil Cooling Fins (if MÄM 42-600 is installed)
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22 Dec 2021 79-00-00 Rev. 5
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the oil system. If you have the trouble detailed
in the Trouble column read across to the Possible Cause column. Then do the repair given in the
Repair column.
An engine oil temperature is Oil cooler blocked internally. Contact engine manufacturer.
too high.
Low oil level. Refill oil. Refer to Section

12-10.
An engine oil pressure too Defective oil pressure sensor. Refer to AE Maintenance
high. Manual.
An engine oil pressure too low Low oil level. Replenish oil system. Refer to
at normal operating Section 12-10.
temperatures.
Defective oil pressure sensor. Refer to AE Maintenance
Manual.
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22 Dec 2021 79-00-00 Rev. 5
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1. General
This Section describes the Maintenance Practices of the gearbox cooling system (if MÄM 42-600 is
installed).
2. Remove/Install the Gearbox Cooling System (if MÄM 42-600 is Installed)
A. Remove the Engine Gearbox Cooling System

INJURY TO PERSONS.
(4) Remove the 3 nuts and washers on the cooler Refer to Figure 1.
duct.
(5) Remove the GFRP gearbox cooler duct. Refer to Figure 1.
(6) Remove the 3 bushings. Refer to Figure 1.
(7) Remove the aluminum cooling fins from the Refer to Figure 1.
gearbox.
(8) Clean the backside of the cooling fins and the

gearbox.
(9) Remove the 3 distance bolts from the gearbox. Refer to Figure 1.
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Rev. 5 79-00-00 22 Dec 2021
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B. Install the Engine Gearbox Cooling System

(1) Install the 3 distance bolts and secure with
Loctite 262: Torque: 28 ± 3 Nm (20.6 ± 2.2 lbf.ft).
S Short bolt on the lower LH side.
S Medium bolt on the upper LH side.
S Long bolt on the RH side.
(2) Install the aluminum cooling fins to the gearbox:
S Position the cooling fin assy on the gearbox;

Verify that the cutout matches the gearbox
oil inspection window. If not rework the
cutout on the cooling fin to match the
gearbox oil inspection window.
S Apply heat transfer compound Keratherm Use a notched spattle.

KP 98 to the backside of the cooling fins
assy.
S Install the 3 bushings, length according to

the bolts.
S Install 3 nuts on the 3 bolts.
S Remove the excess heat compound.
S Remove the 3 nuts from the 3 bolts.
(3) Install the GFRP duct:
S Position the GFRP cooling duct on the

cooling fin assy; use the bolts to guide into
position.
S Install the 3 washers and 3 self locking heat

resistant nuts to the 3 bolts.
S Apply sealing compound ‘easy gasket’ or

equivalent heat conducting paste to the
cooling fins assy / gearbox.
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(5) Do a ground test of the related engine. Refer to Section 71-00 and
3. Drain the Engine Oil (with the Engine Oil Quick Drain)

INJURY TO PERSONS.
(4) Put a drain hose on the oil quick drain.
(5) Put a container (min. capacity 8.5 l) below the

drain hose.
(6) Open th oil dip stick.
(7) Open the oil quick drain.
(8) Let the oil drain off.
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4. Refill the Engine Oil (with the Engine Oil Quick Drain)

(1) Close the oil quick drain.
(2) Remove the drain hose.
CAUTION: USE ONLY APPROVED ENGINE OIL. REFER TO CHAPTER 2 OF THE

AIRPLANE FLIGHT MANUAL FOR APPROVED ENGINE OIL
SPECIFICATION. IF YOU DO NOT USE APPROVED ENGINE OIL,
THE ENGINE CAN BE DAMAGED.
(3) Refill engine oil.
(4) Install oil dipstick and check oil level.
(5) Install the engine cowlings. Refer to Section 71-10 or 71-11
(6) Do a ground test of the related engine, allow the Refer to Section 71-00 and
engine to reach normal operating temperatures. AE Maintenance Manual, latest revision.

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AIRCRAFT
5. Remove/Install the Quick Oil Drain Valve
A. Remove the Quick Oil Drain Valve

(1) Drain the engine oil. Refer to Paragraph 3.
(2) Remove the safety wire.
(3) Remove the quick oil drain valve.
B. Install the Quick Oil Drain Valve

(1) Turn in the oil quick drain with new O-ring and
torque it with 14 Nm (10.3 lbf.ft).
(2) Secure the oil quick drain with safety wire

diameter 0.8 mm (0.032 in).
(3) Refill engine oil.

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DA 42 NG AMM Starting
AIRCRAFT
CHAPTER 80
STARTING
Doc # 7.02.15 Page 1

Starting DA 42 NG AMM
AIRCRAFT
Page 2
22 Dec 2021 80-TITLE Doc # 7.02.15
Rev. 5
AIRCRAFT
TABLE OF CONTENTS
CHAPTER 80
STARTING
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install an Engine Master Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Remove/Install the Engine Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Remove/Install an Engine Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5. Replace the Glow Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
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CHAPTER 80
STARTING
1. General
This Section tells you about the system that cranks the AE E4-B engine for starting.
Refer to Section 24-60 for more data on the electrical supplies to the system Refer to Section 76-00
for data about the engine control system.
Figure 1 shows the simplified schematic diagram of the starter system. The system operates off a
24 Volts DC supply.
The AE E4-B engine has a small, high-powered electric starter. The starter motor is located on the left
side of the engine near the front. It has an integral solenoid to connect the starter motor to the relay
junction box bus. Either the airplane battery or the external power system can supply the bus for the
starter.
The ELECT. MASTER rocker switch is located on the bottom left of the instrument panel. Push the
rocker to supply power to the main left and right bus bars.
LEFT ENGINE and RIGHT ENGINE switches located on the bottom left of the instrument panel
controls the ground connection for the related engine starter relays. This switch must be set to ON for
the starter system to operate. A key operated START switch located between the LEFT ENGINE and
RIGHT ENGINE master switches operates the related engine starter. Turn the key to LEFT START
or RIGHT START to operate the related engine starter. A spring returns the key to the neutral position
when the key is released.
A START warning light on the ALERT panel of the integrated cockpit display comes ON when there
is power to the starter. If this light stays on after the engine has started, set the LEFT ENGINE/RIGHT
ENGINE MASTER switch to OFF.
If necessary during starting, the engine control unit operates the glow plugs to heat intake air for the
engine.
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External R
Power Relay E
L
A
Y
External
J
Power
U Connector
N
C Main Battery
T
I
O
N
B
O 5A
Battery Relay
X
Starter Relay
B
U
S
RH Main Bus
5
Start Switch RH Starter
Terminal
Block
To ICS
Engine Master RH
LH Starter
Engine Master LH
To ICS
Figure 1: Engine Starter System Schematic Diagram
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22 Dec 2021 80-00-00 Rev. 5
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the starting system. If you have the trouble
WARNING: DO NOT ALLOW PERSONS TO ENTER THE DANGER AREA OF A

PROPELLER. THE PROPELLER MAY TURN AND CAUSE INJURY TO
PERSONS.
WARNING: DISCONNECT AND ISOLATE THE STARTER POWER CABLES

BEFORE DOING TESTS IN THIS SECTION. THE ENGINE MAY TURN
AND CAUSE INJURY TO PERSONS.
The starter does not operate The airplane main battery is Charge airplane main battery.
when the ELECT. MASTER discharged.
switch is set to ON, the related
ENGINE MASTER and the The related ENGINE MASTER Replace the related ENGINE
related engine START key switch is defective. MASTER switch.
switch is set to START LEFT
or START RIGHT.
The ENGINE START key Replace the ENGINE START
switch is defective. key switch.
The starter relay is defective. Replace the starter relay.
The related engine starter Replace the related engine

motor assembly is defective. starter motor assembly.
A cable in the related engine Do a test of the electrical

start system is defective. cables. Refer to Chapter 92
Repair/Replace the defective
cable. Refer to Section 71-50
for repair limits of the engine
harness.
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A starter power-on light stays The related starter relay is Replace the related starter
on after the key is released defective. relay.
from the START LEFT/START
RIGHT position.
The related starter solenoid is Refer to the engine
defective. manufacturer.
Difficult cold starting. Glow plugs worn. Replace the glow plugs. Refer
to the engine manufacturer.
Glow fuse defective. Replace the fuse.
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1. General
This Section gives you only Maintenance Practices for the airplane part of the starter system. No
repairs are permitted on the AE E4-B engine. Only an AE authorized repair shop or the manufacturer
can repair the engine part of the system.
2. Remove/Install an Engine Master Switch
A. Remove an Engine Master Switch
Use this procedure for both left and right engine switches.
WORK ON THE STARTER SYSTEM. IF THE ENGINE STARTS THE
(1) Disconnect the airplane main battery and the Refer to Section 24-30 and 24-31.
ECU backup batteries too!
(3) Remove the lower placard panel from the Refer to Section 11-30.
instrument panel.
(4) Remove the related ENGINE MASTER switch: Refer to Figure 2.
S Remove the nut and washer from the front

S Move the switch forward and clear of the

instrument panel.
S Hold the switch and disconnect the electrical Note the position of the cables.
cables.

panel.
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Engine Master
Switch, RH
Engine Start Switch
Engine Master
Switch, LH
Placard Panel
Screw
Figure 2: Engine Master Switch and Start Switch Installation
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B. Install an Engine Master Switch
S Move the switch into position by the

instrument panel and hold the switch.
S Connect the electrical cables to the Refer to Chapter 92 for the wiring
terminals on the switch. diagrams.
S Move the switch fully into position in the

instrument panel.
S Install the washer and nut onto the front of Make sure that the switch is correctly
the switch. orientated.
(2) Install the lower placard panel onto the Refer to Section 11-30.
instrument panel.
(3) Install the instrument panel cover and connect Refer to Section 24-30 and 25-10.
the ECU backup batteries too!
(5) Do an engine ground run-up and do a test for Refer to Section 71-00.
the correct operation of the related engine
MASTER switch and the lower placard panel.
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3. Remove/Install the Engine Start Switch
A. Remove the Engine Start Switch
(3) Remove the lower placard panel from the Refer to Section 11-30.
instrument panel.
(4) Remove the START switch: Refer to Figure 2.
S Remove the nut and washer from the front

S Move the switch forward and clear of the

instrument panel.
S Hold the switch and disconnect the electrical Note the position of the cables.
cables.

panel.
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B. Install the Engine Start Switch
S Move the switch into position by the

instrument panel and hold the switch.
S Connect the electrical cables to the Refer to Chapter 92 for the wiring
terminals on the switch. diagrams.
S Move the switch fully into position in the

instrument panel.
S Install the washer and nut onto the front of Make sure that the switch is correctly
the switch. orientated.
(2) Install the lower placard panel onto the Refer to Section 11-30.
instrument panel.
the correct operation of the related engine
START switch and the lower placard panel.
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Bolt
Washer
Washer
Starter Relay
Figure 3: Engine Starter Relay Installation
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4. Remove/Install an Engine Start Relay
A. Remove an Engine Start Relay
(2) Open the front baggage compartment door, left Refer to Figure 3.
side for access to the relay panel.
(3) Disconnect the control cables from the starter At the terminal block.
relay.
(4) Remove the starter relay:

the relay to the relay panel.
S Move the relay up and clear of the relay

panel and the airplane.
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B. Install an Engine Start Relay
(1) Install the starter relay:
S Move the new relay into position in the relay

panel.

the relay to the relay panel.
(2) Connect the control cables to the relay. At the terminal block.
(4) Close and secure the front baggage

compartment door.
(5) Start the related engine and do a test for the Refer to Section 71-00.
correct operation of the engine starting system.
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LH shown,
RH similar
Fuse Holder
Fuse Relay Panel
Washer
Nut
Washer Relay
Bolt
Figure 4: Engine Glow Fuse Installation
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5. Replace the Glow Fuse
(2) Remove the relay panel access panel from the Refer to Section 52-40.
(3) Remove the fuse: Refer to Figure 4.
S Loosen the nut that attaches the electrical Top side. Do not remove the nut.
cable and fuse to the fuse holder.
S Loosen the nut that attaches the bus bar link Bottom side. Do not remove the nut.
and fuse to the fuse holder.
S Pull the fuse clear of the fuse holder.
(4) Install a new fuse:
S Move the new fuse into position at the fuse

holder.
S Tighten the 2 nuts.
(5) Install the relay panel access panel onto the Refer to Section 52-40.
(7) Do an engine ground run-up and make sure that Refer to Section 71-00.
the glow plugs operate correctly.
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DA 42 NG AMM Turbo Charger
AIRCRAFT
CHAPTER 81
TURBO CHARGER
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Turbo Charger DA 42 NG AMM
AIRCRAFT
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TABLE OF CONTENTS
CHAPTER 81
TURBO CHARGER
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install an Engine Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Section 81-01
Turbo Charger (if MÄM 42-600 is installed)
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble-Shooting
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Remove/Install an Engine Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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CHAPTER 81
TURBO CHARGER
1. General
This Section describes the turbo-charging system of the AE E4-B engine.
If MÄM 42-600 is installed, refer to Section 81-01 for data about the turbo-charging system with the
AE E4-C engine installed.
2. Description
Each engine air intake system has an air filter located on the right side of each engine nacelle. The
filter attaches to the front face of the alternate air valve. The alternate air valve also has an inlet which
takes air from the engine nacelle. A rotating cage in the alternate air valve can be set to take air into
the air inlet system through the filter or it can be set to take unfiltered air directly from the engine
nacelle. Refer to Section 71-60 for more data about the air filter and the alternate air valve.
The outlet from the alternate air valve connects to the turbo charger inlet. The turbo charger
compresses the air. This makes the air hot. The outlet from the turbo charger connects to the
intercooler.
The intercooler is located at the top rear of the engine and is attached to the engine mounting frame.
The outlet from the intercooler connects to the engine intake manifold. A manifold pressure sensor and
manifold air temperature sensor are attached to the engine intake manifold.
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Figure 1: Engine Turbo Charger Schematic Diagram
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3. Operation
Figure 1 shows the turbo charger system schematic diagram.
When the engine is running the exhaust gases from the engine flow through a manifold to the turbo
charger turbine. A waste gate in the turbo charger turbine inlet can open to allow some of the exhaust
gases from the engine to bypass the turbine and flow directly in to the engine exhaust pipe. The waste
gate opening is controlled by the engine EECU.
Ambient air flows through the air filter (normal operation) or from the engine nacelle (alternate air
operation) into the turbo charger compressor. The air gains heat while being compressed in the turbo
charger. The hot compressed air flows through an aluminum tube and a flexible hose to the intercooler.
In the intercooler the hot compressed air is cooled down.
To provide cooling of the hot compressed air the intercooler is supplied with cold outside air via a
composite air intake duct.
The cool compressed air from the intercooler flows through a flexible hose to the engine intake
manifold.
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Note: Apply torque seal on all worm drive clamps.
Figure 2: Intercooler Installation
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Intercooler
Worm Drive Clamps Guard Assy
Turbocharger
A
Air Intake
Protective Pads
Clamp
Worm Drive
Clamps Inlet Hose
Outlet Hose Intercooler
A Worm Drive
Tube
Clamps
A
Worm Drive Anti-Vibration
Clamps Worm Drive Mount
Clamps
Engine Inlet Manifold Engine Mounting Frame
Figure 3: Intercooler Installation (if MÄM 42-792 is installed)
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Trouble-Shooting
1. General
The table below lists the defects you could have with the turbo charging system. If you have the trouble
An engine inlet manifold Waste gate valve defective. Refer to the engine
pressure is too low/ too high. manufacturer.
Inlet air temperature too high. Intercooler matrix Clear intercooler matrix of
blocked/damaged. obstructions. Replace
intercooler if necessary.
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1. General
This Section tells you how to remove/install the intercooler.
CAUTION: YOU CANNOT DO MAINTENANCE ON THE INTERCOOLER.
CAUTION: DO NOT TRY TO ADJUST THE WASTE GATE CONTROL PUSH ROD.
ANY ADJUSTMENT WILL AFFECT THE CHARACTERISTICS OF THE
ELECTRONIC CONTROL SYSTEM.
Refer to Section 71-60 for maintenance data on the air filter and the alternate air valve.
2. Remove/Install an Engine Intercooler
Note: All hose clamp connections (except such secured with self locking nuts) in the
charge air system must be secured with lock wire.
A. Remove an Engine Intercooler

INJURY TO PERSONS.
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(4) Remove the composite air intake duct:

the composite air intake duct to the
intercooler.
S Move the composite air intake duct clear of

the engine.
(5) Remove the intercooler guard assy. Refer to Figure 2.
(6) Disconnect the flexible hose that connects the Refer to Figure 2.
intercooler to the turbo charger and the turbo
charger to the engine air intake manifold: At the intercooler.
S Remove the worm-drive-clamps.
S Pull the hoses off the intercooler connectors

and the turbo charger inlet.
(7) Remove the intercooler:

attach the intercooler to the engine mount.
S Move the intercooler clear of the engine Take care not to damage the intercooler
nacelle. matrix!
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B. Install an Engine Intercooler
CAUTION: MAKE SURE THAT TURBO CHARGER HOSES ARE ROUTED

CORRECTLY WITHOUT KINKS. FALSE INSTALLED HOSES MAY
RESULT IN DAMAGE TO THE TURBO CHARGER.
(1) Install the intercooler:
S Position the intercooler on the appropriate

engine mount brackets.
S Install the nuts and washers that attach the Refer to Figure 2.
intercooler to the engine mount via anti-
vibration mounts.
(2) Connect the flexible hoses that connect the

intercooler to the turbo charger and engine air
intake manifold:
S Move the worm-drive-clamps into position Do not tighten the worm-drive-clamps!
on the flexible hoses. Use only new worm-drive-clamps.
S Push the flexible hoses onto the intercooler

connectors.
S Move the worm-drive-clamps into the correct Torque: 5.0 ± 0.5 Nm (3.7 ± 0.4 lbf.ft.).
position and tighten the worm-drive-clamps
and apply torque seal (no red of white
torque seal color allowed).
S If MÄM 42-792 is installed, bond the Use Dow Corning 736 to the red turbo
protective pad underneath the houses of the charger hoses.
worm-drive-clamps.
Refer to Figure 3.
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(3) If MÄM 42-963/a is installed:
S Install the nut BN175-M6-PZ on the end of

the screw of the new v-clamp so that there
is no gap.
S Put the v-clamp in position on the flanges.
Note: Do not pull the v-clamp over the turbo

charger tube since the v-clamp will be
permanently deformed.
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S Before tightening the v-clamp make sure

that there is no gap between the aluminum
charged air tube and the turbo charger
flange. When correctly installed the
aluminum charged air tube must fit into the
turbo charger flange without tension.
S Tighten v-clamp on turbo-charger. Make Torque: 5.5 ± 0.5 Nm (4.0 ± 0.4 lbf.ft).
sure the circumferential gap to the turbo
charger is equal (if not, use rubber mallet to
tap v-clamp into position). If tapping with a
rubber mallet was required, retighten the
v-clamp.
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S Make sure that the distance between

V-flanges on the lock is between 6 and
10 mm (0.24 - 0.39 in). If necessary insert
turbo connector shims to obtain the required
distance.
6 - 10 mm (0.24 - 0.39 in)
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If MÄM 42-963/a is NOT installed:

S Tighten v-clamp on turbo-charger. Torque: 5.0 ± 0.5 Nm (3.7 ± 0.4 lbf.ft).
S Secure bolt of v-clamp with lock wire.
S Make sure the circumferential gap to the

turbo charger is equal (if not, use rubber
mallet to tap v-clamp into position). If tapping
with a rubber mallet was required, retighten
the v-clamp.
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(4) Install the composite air intake duct:
S Position the composite air intake duct on the

intercooler.
S Install the bolts and washers that attach the

composite air intake duct to the intercooler.
(5) Install the intercooler guard assy. Refer to Figure 2.
the correct operation of the engine intercooler.
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Section 81-01
Turbo Charger (if MÄM 42-600 is installed)
1. General
This Chapter describes the turbo-charging system of the AE E4-C engine.
2. Description
Each engine air intake system has an air filter located in the middle of the engine compartment. The
filter attaches to the front face of the alternate air valve. The alternate air valve also has an inlet which
takes air from the engine compartment. A rotating cage in the alternate air valve can be set to take air
into the air inlet system through the filter or it can be set to take unfiltered air directly from the engine
compartment. Refer to Section 71-61 for more data about the air filter and the alternate air valve.
The outlet from the alternate air valve connects to the turbo charger inlet. The turbo charger
compresses the air. This makes the air hot. The outlet from the turbo charger connects to the
intercooler.
The intercooler is located in the upper rear part of the engine compartment. The intercooler is attached
to the engine mount via the intercooler duct and mounting brackets. The outlet from the intercooler
connects to the engine intake manifold. A manifold pressure sensor and manifold air temperature
sensor are attached to the engine intake manifold.
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Waste Gate
Compressor
Turbocharger
Nacelle Cooling Air, Out

Turbine
Intercooler
Ambient Air, In
Engine
Exhaust Compressed Air, Out
Gases
Air Intake Duct

Exhaust Gases
from Engine Engine Intake
Manifold Manifold
Nacelle Cooling Air, In
Figure 1: Engine Turbo Charger Schematic Diagram (if MÄM 42-600 installed)
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22 Dec 2021 81-01-00 Rev. 5
AIRCRAFT
3. Operation
Figure 1 shows the turbo charger system schematic diagram.
When the engine is running the exhaust gases from the engine flow through a manifold to the turbo
charger turbine. A waste gate in the turbo charger turbine inlet can open to allow some of the exhaust
gases from the engine to bypass the turbine and flow directly in to the engine exhaust pipe. The waste
gate opening is controlled by the engine EECU.
Ambient air flows through the air filter (normal operation) or from the engine compartment (alternate
air operation) into the turbo charger compressor. The air gains heat while being compressed in the
turbo charger. The hot compressed air flows through a flexible hose to the intercooler.
The hot compressed air flows through the matrix of the intercooler. Cooling air is guided from the left
side of the nacelle to the intercooler and flows around the intercooler matrix. The hot compressed air
is cooled. The cooled compressed air from the intercooler matrix flows through a flexible hose to the
engine air intake manifold.
The cooling air from around the intercooler matrix flows to the cooling air outlet at the rear of the
engine nacelle.
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AIRCRAFT
Outlet Hose
Hose Clamp Hose
Clamp
Intercooler
Air Outlet to Hose
Turbo-Charger Clamp Hose Clamp
Inlet Hose
Hose Clamp
Turbocharger
Hose Clamp
Nut
Washer
Washer
Bolt
Air Intake
Note: Apply torque seal on all

worm drive clamps Engine Mounting Frame
Figure 2: Intercooler Installation (if MÄM 42-600 installed)
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22 Dec 2021 81-01-00 Rev. 5
AIRCRAFT
Worm Drive Clamps
A
Outlet Hose Hose Clamps
Protective Pads
Intercooler
Hose Clamps
Air Outlet to
Turbo-Charger A
Hose Clamp
Hose Clamp
Turbocharger
Flexible
Charge Air
Hose
Nut
A Washer
Washer
Bolt
Turbo Connector Assy
Air Intake
Figure 3: Intercooler Installation (if MÄM 42-600 and MÄM 42-1004 are installed)
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22 Dec 2021 81-01-00 Rev. 5
AIRCRAFT
Trouble-Shooting
1. General
The table below lists the defects you could have with the turbo charging system. If you have the trouble
An engine intake manifold Waste gate valve defective. Refer to the engine
pressure is too low/ too high. manufacturer.
Intake air temperature too high. Intercooler matrix Clear intercooler matrix of
blocked/damaged. obstructions. Replace
intercooler if necessary.
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22 Dec 2021 81-01-00 Rev. 5
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1. General
This Section tells you how to remove/install the intercooler.
CAUTION: YOU CANNOT DO MAINTENANCE ON THE INTERCOOLER.
CAUTION: DO NOT TRY TO ADJUST THE WASTE GATE CONTROL PUSH ROD.
ANY ADJUSTMENT WILL AFFECT THE CHARACTERISTICS OF THE
ELECTRONIC CONTROL SYSTEM.
Refer to Section 71-61 for maintenance data on the air filter and the alternate air valve.
2. Remove/Install an Engine Intercooler
Note: All hose clamp connections (except such secured with self locking nuts) in the
charge air system must be secured with lock wire.
A. Remove an Engine Intercooler

INJURY TO PERSONS.
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(4) Remove the intercooler air duct, the air filter box
and intercooler:
S Remove the air filter box with alternate air

valve.
S Remove the charge air hoses which are

connected to the intercooler.
S Remove the bolts which fix the intercooler air

duct to the engine mount.

the composite air intake duct to the
intercooler.
S Move the composite air intake duct clear of

the engine.
B. Install the Engine Intercooler
CAUTION: MAKE SURE THAT TURBO CHARGER HOSES ARE ROUTED

CORRECTLY WITHOUT KINKS. FALSE INSTALLED HOSES MAY
RESULT IN DAMAGE TO THE TURBO CHARGER.
(1) Install the intercooler to the intercooler air duct.:
S Position the intercooler on the intercooler air

duct.
S Install the nuts and washers that attach the Refer to Figure 2.
intercooler to the intercooler air duct..
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(2) Connect the flexible hoses that connect the

intercooler to the turbo charger and engine air
intake manifold:
S Move the intercooler air duct with intercooler

into position.
S Move the worm-drive-clamps into position on Use only new worm-drive-clamps.

the flexible hoses.
S Apply water to the inside of the hoses to

ease hose installation.
S Push the flexible hoses onto the intercooler

connectors.
S If MÄM 42-1004 is installed: Refer to Figure 3.
S Make sure that the position of the support

rings of the bellows are in front of the
aluminum connector and not on it. Check
that the bellows of the hose are not
compressed or stretched. If necessary
realign charge air hose.
S Move the worm-drive-clamps into the correct Do not tighten the worm-drive-clamps!
position.
S If MÄM 42-1004 is installed, bond the

protective pad using Dow Corning 736 to the
red turbocharger hoses underneath the
housings of the worm-drive-clamps.
S Install the airfilter box to the intercooler air

duct.
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(3) If MÄM 42-963/a is installed:
S Install the nut BN175-M6-PZ on the end of

the screw of the new v-clamp so that there is
no gap.

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S Before tightening the v-clamp make sure that

there is no gap between the aluminum
charged air tube and the turbo charger
flange. When correctly installed the
aluminum charged air tube must fit into the
turbo charger flange without tension.
S Tighten v-clamp on turbo-charger. Make Torque: 5.5 ± 0.5 Nm (4.0 ± 0.4 lbf.ft).
sure the circumferential gap to the turbo
charger is equal (if not, use rubber mallet to
tap v-clamp into position). If tapping with a
rubber mallet was required, retighten the
v-clamp.
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S Make sure that the distance between

V-flanges on the lock is between 6 and
10 mm (0.24 - 0.39 in). If necessary insert
turbo connector shims to obtain the required
distance.
6 - 10 mm (0.24 - 0.39 in)
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If MÄM 42-963/a is NOT installed:

S Tighten v-clamp on turbo-charger. Torque: 5.0 ± 0.5 Nm (3.7 ± 0.4 lbf.ft).
S Secure bolt of v-clamp with lock wire.
S Make sure the circumferential gap to the

turbo charger is equal (if not, use rubber
mallet to tap v-clamp into position). If tapping
with a rubber mallet was required, retighten
the v-clamp.
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(4) Install the intercooler air duct:
S Position the intercooler air duct on the

intercooler such that it aligns with the engine
mounting brackets.
S Install the bolts and washers that attach the

intercooler air duct to the engine mount.
(5) Install the alternate air valve:
S Tighten the worm drive clamps on the Torque: 5.0 ± 0.5 Nm (3.7 ± 0.4 lbf.ft.).
flexible hoses of the intercooler and apply
Use only new worm-drive clamps.
torque seal (no red of white torque seal color
allowed).
the correct operation of the engine intercooler.
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DA 42 NG AMM Wiring Diagrams
AIRCRAFT
CHAPTER 92
WIRING DIAGRAMS
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Wiring Diagrams DA 42 NG AMM
AIRCRAFT
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AIRCRAFT
TABLE OF CONTENTS
CHAPTER 92
WIRING DIAGRAMS
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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CHAPTER 92
WIRING DIAGRAMS
1. General
This Chapter contains the wiring diagrams for each system. The wiring diagrams use the ATA
Chapter/Section numbering system.
Title Drawing No. Rev. No. of

No. Sheets
Schematic, Twin NG Equipment Cooling D64-9221-20-01 - 1
Schematic, RACC Wiring D64-9221-50-01 - 1
Schematic, RACC Wiring (if OÄM 42-193/d or D64-9221-50-01 A 1

later is installed)
Schematic, GFC 700 Wiring D64-9222-10-02 - 1
Schematic, GSR 56 Wiring D64-9223-15-00 - 1
Schematic, Electrical System D64-9224-30-01 A 2
Schematic, Electrical System, ECU Split Bus D64-9224-30-01_01 - 2
Schematic, Electrical System D64-9224-30-01_02 - 2
Schematic, RH ECU Backup Battery, Tail Fin D64-9224-30-01x01 - 1

Installation
Schematic, Second Alternator D64-9224-30-02 - 1
Schematic, Accessory Power Plug D64-9224-60-01 - 1
Schematic, Emergency Power D64-9225-60-01 - 1
Schematic, ELT ME 406 D64-9225-60-02 - 1
Schematic, ELT Kannad 406 Wiring D64-9225-60-03 - 1
% Schematic, ELT Kannad AF-Integra Wiring D64-9225-60-04 - 1
Schematic, Removable Co-Pilot Stick Wiring D64-9227-03-00 - 1
Schematic, Rudder Pedal Adjust D64-9227-20-01 - 1
Schematic, Stick Limiter D64-9227-30-01 A 1
Schematic, Flaps D64-9227-50-01 A 1
Schematic, LH Aux Fuel Wiring D64-9228-10-01 B 1
Schematic, RH Aux Fuel Wiring D64-9228-11-01 A 1
Schematic, Pitot and Stall Heat Warning D64-9230-30-01 A 1
Doc # 7.02.15 Page 1

Rev. 5 92-00-00 22 Dec 2021
AIRCRAFT

No. Sheets
Schematic, De-Ice Control System D64-9230-40-01 A 1
Schematic, Door Warning Switches D64-9231-00-01 A 1
Schematic, De-Ice Warning System D64-9231-00-02 A 1
Schematic, G1000 D64-9231-60-01 A 6
Schematic, G1000 D64-9231-60-01_01 - 6
% Schematic, G1000 NXi D64-9231-60-04 D 6
% Schematic, TAS 6xxA Wiring D64-9231-60-04x02 A 1
Schematic, Landing Gear D64-9232-00-01 - 1
Schematic, Flood Light D64-9233-10-01 - 1
Schematic, Dimming Regulator & Placards D64-9233-10-07 A 1
Schematic, Map/Reading Lights D64-9233-20-01 A 1
Schematic, Map/Reading Lights, LED D64-9233-20-01_02 - 1
Schematic, Map/Reading Light, Wiring RACC D64-9233-20-01x01 - 1
Schematic, Map/Reading Lights Wiring (LED), D64-9233-20-01x02 - 1

RACC
Schematic, Exterior Lighting D64-9233-40-01 C 1
Schematic, LED Position / Anti-Collision Lights D64-9233-40-01x01 - 1
Schematic, Attitude Gyro D64-9234-10-01 - 1
Schematic, MD302 Wiring D64-9234-10-02 - 1
Schematic, Drum Altimeter D64-9234-20-01 - 1
Schematic, GWX 68 Weather Radar Wiring D64-9234-40-01 - 1
Schematic, GWX 70 Weather Radar Wiring D64-9234-40-02 - 1
Schematic, ADF D64-9234-50-01 A 1
Schematic, Feathering System D64-9261-20-01_01 - 1
Schematic, LH ECU D64-9277-40-02_01 - 2
Schematic, RH ECU D64-9277-40-03_01 - 2
Schematic, LH ECU D64-9277-40-02_02 - 2
Schematic, RH ECU D64-9277-40-03_02 - 2
Page 2 Doc # 7.02.15

22 Dec 2021 92-00-00 Rev. 5
AIRCRAFT

No. Sheets
Doc # 7.02.15 Page 3

Rev. 5 92-00-00 22 Dec 2021
AIRCRAFT
Page 4 Doc # 7.02.15

22 Dec 2021 92-00-00 Rev. 5
8 7 6 5 4 3 2 1
REVISIONS
Rev. Zone Description
"-" all new drawing
REF D64-9231-60-01 21005A22

J2102
J2413 P2413 AVIONICS COOLING FAN
21002A22 10 21002B22 1
E 2
21003A22N 9 21003B22N 3
AV/CDU GS-IP 13
FAN
RH MAIN
BUS 3A
REF D64-9231-60-01 21008A22
MFD COOLING FAN

21000A22 1
REF D64-9231-60-01 21006A22 2
21001A22N 3
GS-IP 4
PFD COOLING FAN
C 21001B22N 3
REF D64-9231-60-01 21007A22 2
21000B22 1
Approved : Checked : General Tolerance : Scale:

I S O 2768
Date Name Date Name
NTS
Next Higher Assembly :
Title :
D64-9200-00-00
Schematic, Twin NG
A Diamond
AIRCRAFT
Equipment Cooling
Industries GmbH
Drawing Number: Sheet 1

DA42 NG
Weight: N\A "-" VÄM 42-004 14.07.08 M. Spanton
Twin Star D64-9221-20-01 from 1
Calculated Weight: N\A Rev. Change Date Name Saved under :
This Drawing is the Property of Diamond Aircraft.

Unauthorized Reproduction or Disclosure to
Third Parties is Prohibited.
D64-9221-20-01.dft
Confidential 8 7 6 5 4 3 2 1
REVISION
FUSELAGE REAR BAGGAGE COMPARTMENT REV SH ZONE DESCRIPTION DATE APPROVAL
COMP
OÄM 42-193
- 01 ALL 13.01.11 SEE TB
50 21512A10
FIRST RELEASE
2
n EVAP
d
20
F A F
COND
L
T CABIN
20 FAN
21507A14
GL-F700 B
U
CN2 P2150 A/C DISP S HI
MED
21511A14
A/C POWER 8 21500B22 1 21500A22 3
A/C GROUND 4 21501B22N 2 21501A22N FAN HI RELAY LO
87A
21508C16
30
21509C16
21508A16
87
21510C16
CN1 J2151
86 85 1 2 3 4
FAN HI 5 21505A20 5 21505B20
J2152
E FAN MED 3 21503A20 3 21503B20 21512B16N E
21508B16
FAN LO 6 21506A20 6 21506B20 EVAP
21509B16
FAN
21510B16
CONDENSER 2 21502A20 2 21502B20 FAN MED RELAY
87A
9 21504B20 HI
30
CN2 21509A16 MED
87
PRESSURE SWITCHES 5 21504A20 LO
86 85
TEMPERATUR
SENSOR
TEMP SENSOR 2
D TEMP SENSOR 6 FAN LO RELAY D
87A COOLING
21510A16
30 FAN
87
86 85 21511C22
21513A22N
CONDENSER
3A
CONDENSER RELAY
87A
30
21511B14
C 87 C
86 85
21514B14N
ELECTRIC
COMPRESSOR RELAY COMPRESSOR
THERMOSTAT
87A
RED
30
WHITE
87
86 85
B B
H L
PRESSURE
SWITCHES
IDENTIFICATION MARKINGS
Diamond N. A. Otto-Straße 5
DIMENSIONS METRIC Airc raft Diamond Aircraft Industries A-2700 Wiener Neustadt
Indust ries GmbH
DP-S-17-00001 - DEPARTMENT SIGN DATE PROJECT
FIRST ANGLE PROJECTION FORMAT DA 42 N G
CLASSIFICATION: - DRAWN 13.01.11 TITLE
A2
N ON E CHECKED:
Schem atic, RACC
A INTERCHANGEABLE PART NO QA: N/A A
UNLESS OTHERWISE SPECIFIED Wiring
DIMENSIONS ARE IN MM
3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
DIMENSION TOLERANCES
SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
2 DECIMAL u0,25
1DECIMAL u0,5 FINISH
DECIMAL u1 IN FILENAME SYSTEM: N/A DAIA D64-9221-50-01 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D64-9221-50-01.dft APPROVED: TL CODE SCALE SH OF
710197 NTS 01 01
Confidential
ALL RIGHTS RESERVED FOR THIS DOCUMENT WHICH MAY NOT BE REPRODUCED
OR DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
DIAMOND AIRCRAFT INDUSTRIES
8 7 6 5 4 3 2 1
REVISION
FUSELAGE REAR BAGGAGE COMPARTMENT REV SH ZONE DESCRIPTION DATE APPROVAL
COMP
OÄM 42-193
- 01 ALL 19.08.10 SEE TB
TB 21520A8 50 21512A10
FIRST RELEASE
OÄM 42-193/d
EVAP A 01 ALL 20.06.12 SEE TB
Wire numbers analog to DA 40 NG updated,
2 cabin fan removed, connectors J2152,
20 J2153, J2154, J2155 amd terminal block
F n F
d COND
added.
21521A8
A 20
L
21507A16
GL-F700 T
CN2 P2150 A/C DISP
B
U
21511A14
A/C POWER 8 21500B22 1 21500A22 3
S FAN HI RELAY
A/C GROUND 4 21501B22N 2 21501A22N
87A
30
87
CN1 J2151
86 85
FAN HI 5 21505A20 5 21505B20
E FAN MED 3 21503A20 3 21503B20 E
21508A16
FAN LO 6 21506A20 6 21506B20 EVAP
FAN
CONDENSER 2 21502A20 2 21502B20 FAN MED RELAY
87A J2152 J2154
9 21504B20 1 21508B16 1 OR HI
30
CN2 21509A16 2 21509B16 2 RD MED
87
PRESSURE SWITCHES 5 21504A20 3 21510B16 3 YE LO
4 21512B16N 4 BLK
86 85
TEMPERATUR
21512A16N
SENSOR
TEMP SENSOR 2 COOLING
D TEMP SENSOR 6 FAN LO RELAY D
FAN
87A
21510A16
30
87 J2153
1 red
86 85 2
black
21517A22
21513A22N
CONDENSER
3
CONDENSER RELAY
87A
J2152 J2155
30
21511B14 21511C14 5 21511D14 1 21511E14
C 87 C
6 21514B14N 2 BLK
86 85
21514A14N
ELECTRIC
COMPRESSOR
J1 JP6
COMPRESSOR RELAY + DC IN IN 1 TO TEMP.
THERMOSTAT OUT 2 SWITCH
87A
J2152 J2152 JP5 J3
30
21515A20 9 21515B20 21515C20 10 21515D20 3 PWR ON/OFF PHASE
87 A
6 +5V
J4
7 SPEED SET POINT PHASE
86 85
21516D22 B
J2
B J5 B
21518A10N - GROUND PHASE
21516A22
C
J2152 H L J2152
7 21516B22 21516C22 8
PRESSURE
SWITCHES
Indust ries GmbH
A2
N ON E CHECKED:
Schem atic, RACC
UNLESS OTHERWISE SPECIFIED Wiring
2 DECIMAL u0,25
DECIMAL u1 IN FILENAME SYSTEM: N/A DAIA D64-9221-50-01 "A"
ANGLE u1° MICRO-
RAD u0,5 METER D64-9221-50-01a.dft APPROVED: TL CODE SCALE SH OF
710197 NTS 01 01
Confidential
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
No. 1 GIA 63 FUSELAGE INSTRUMENT PANEL FUSELAGE

INTEGRATED AVIONICS 1P604 P2208 GO AROUND P2406 GSA 81
P2406 2J801 PITCH TRIM SERVO
DISCRETE IN* 4 12 22074A22 2 22074B24 21 22205A22N
F 22205B22N 1 22205C24N
GS IP-6
22000A20 7 22302B20 N AIRCRAFT POWER 1
22305A20N 18 22305B20N V POWER GROUND
1P603
22309A24BL T RS 485 1 B
GS IP-12
SERVO RS 485 B 7 22207A24BL 22309A24WH J RS 485 1 A
SERVO RS 485 A 5 22207A24WH S
S
22308A24BL E RS 485 2 B
SERVO RS 485 B 6 22108A24BL 22308A24WH S RS 485 2 A
SERVO RS 485 A 4 22108A24WH S
S F SERVO PROGRAM 3
P2205
UP 22 AWG U PROGRAM GROUND
22026A22 1 22071A20 P SERVO ENABLE
22027A22 2
1P605 MANUAL DOWN
22028A22
ELECTRIC
DISCRETE IN* 3A 39 22033A22 TRIM SWITCH
P2406 ARM
DISCRETE IN* 4A 40 22034A22 3
GSA 81
22030A22N 27 22030B22N 4 3J801 ROLL SERVO
S
S
P2406
E 1P604 GS IP-11
22025A22 6 22000A20 5 22200B20 N AIRCRAFT POWER 1
CWS
DISCRETE IN* 5 13 22025A22 22204A20N 17 22204B20N V POWER GROUND
22029A22N 9 22029B22N 5
GS IP-5
GS IP-11 28 22016D20 7 22207A24BL T RS 485 1 B
DISCRETE IN* 9 19 22035A22 22207A24WH J RS 485 1 A
P2209
AFCS DISCONNECT IN 11 22036A22 DISC
S
1.
DISCRETE IN* 6 14 22041A22 22037A22 1 22037B22 9
22038A22 22206A24BL E RS 485 2 B
22072A20 8 22206A24WH S RS 485 2 A
3.
S
G SERVO PROGRAM 2
P2207
22 AWG U PROGRAM GROUND
No. 2 GIA 63
INTEGRATED AVIONICS 22072A20 2 2. 22071B20 P SERVO ENABLE
2P604
22038A22 3
DISCRETE IN* 6 14 22042A22
AFCS DISCONNECT IN 11 22036A22
D DISCRETE IN* 9 19 22035A22 22306A22N 3 22306B22N 4
22071A20 1
GS IP-12 GSA 81
2P605 P2406 1J801 PITCH SERVO
DISCRETE IN* 4A 40 22034A22 22000A20 6 22100B20 N AIRCRAFT POWER 1

DISCRETE IN* 3A 39 22033A22 22102A20N 16 22102B20N V POWER GROUND
P2209 3.
2. 22108A24BL T RS 485 1 B
GS IP-5
22073A20 2 22073B20 22071A20 22108A24WH J RS 485 1 A
2. S
2P603 1.
22016C20 22016C20
SERVO RS 485 B 6 22109A24BL 22109A24BL E RS 485 2 B
SERVO RS 485 A 4 22109A24WH 22109A24WH S RS 485 2 A
S S
H SERVO PROGRAM 1
SERVO RS 485 B 7 22206A24BL 22 AWG U PROGRAM GROUND
S
S
SERVO RS 485 A 5 22206A24WH 22071C20 P SERVO ENABLE

S
C 2.
GSA 80
P2406 4J801 YAW SERVO
22016C20
7.5 22000A20 22000A20 8 22400B20 N AIRCRAFT POWER 1
22401A20N 19 22401B20N V POWER GROUND
22407A24BL T RS 485 1 B
GS IP-6
22407A24WH J RS 485 1 A
S
22406A24BL E RS 485 2 B
22406A24WH S RS 485 2 A
S
H SERVO PROGRAM 1
22 AWG G SERVO PROGRAM 2
B 22 AWG U PROGRAM GROUND
22071D20 P SERVO ENABLE

I S O 2768
Date Name Date Name
NTS
Title :
D64-9200-00-00
Schematic, GFC700 Wiring
A Diamond
AIRCRAFT
Industries GmbH
REVISIONS Drawing Number: Sheet 1

DA42 NG
Weight: N/A "-" VÄM 42-004 14.07.08 M. Spanton
"-" all new drawing
Calculated Weight: N/A Rev. Change Date Name Saved under :

D64-9222-10-02.dft
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL
OÄM 42-213
- 01 ALL 20.09.12 SEE TB
FIRST RELEASE
F F
P2403 J2403
GSR 56 1P561 P3471 GMA 1347
AUDIO IN LO 5 23100A24BL 35 23100B24BL 23 TEL MIC AUDIO OUT HI
AUDIO IN HI 4 23100A24WH 34 23100B24WH 62 TEL MIC AUDIO OUT LO
36
S
AUDIO OUT LO 2 23101A24BL 43 23101B24BL 42 TEL AUDIO IN HI
E 42
E
AUDIO OUT HI 1 23101A24WH 23101B24WH 43 TEL AUDIO IN LO
44
S
IRIDIUM
A/C POWER 32 23112A22 26 23112B22 1A AV BUS

A/C POWER 33
A/C POWER GND 3 23113A22N 30 23113B22N
A/C POWER GND 17
GS-IP 7
D D
34422A24OR
REF D64-9231-60-01_01 SH 6/6
34423A24OR 2P603
No.2 GIA 63W
RS-232 OUT 12 23109A22WH 23109A22WH 41 MAIN RS-232 IN 1
SIGNAL GROUND 14 23109A22BL 23109A22BL 42 SIGNAL GROUND
RS-232 IN 13 23109A22OR 23109A22OR 43 MAIN RS-232 OUT 1
S S
2P604
IRIDIUM REMOTE POWER ON 16 23108A22 23108A22 1 ANNUNCIATE* 22

STATUS DISCRETE OUT 31 23107A22 23107A22 9 DISCRETE IN* 3
C C
P2315 J2315
23102A400 IRIDIUM ANTENNA
B B
DIMENSIONS METRI C Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
FIRST ANGLE PROJECTION FORMAT DA 42 N G /M-N G
A3
N ON E CHECKED:
Schematic, GSR 56
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Wiring
A SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV A
2 DECIMAL u0,25
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D64-9 2 2 3 -1 5 -0 0 "-"
ANGLE u1° MICRO-
710197 NTS 01 01
Confidential
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
REVISIONS
"-" all new drawing

EPU RELAY connected the alternator excitation fuses to the ECU Bus CBs,
"A" all removed master-slave wire (24015C22).
F FRONT BAGGAGE COMPARTMENT
EPU PLUG
24401A22
PILOT MAP
LIGHT 24403A6
H
REF D64-9233-20-01 33200A22 5A GS-RP
O
T 24405A6N
REF D64-9225-60-02 25601B22 1A JUMPER, 14 AWG
B
ELT BATTERY RELAY GS-RP
U
S
24000A2
MAIN
24001A6 BATTERY
B1
24010A22
24V 13.6Ah
ALT RH RELAY
ALT LH RELAY
5A GS-RP
E 24005A8
24003A8 24002A6
STARTER RELAY
TB1
TO TERMINAL BLOCK 24318A14 5A
80108A2 2
5A 24317A14 (CENTER FUSELAGE)
GS-RP
5A
80101A22 80102A22N
8 AWG
5A
24020A22
GS-RP
8 AWG
24017B22 J2418
J2418 J2418
L J C N
ALT. RH
BATTERY 50A 32000A10 REF D64-9232-00-01 BATTERY
24004A4 24006A4
60
90 START 90 24020B22
SWITCH
LDG LT.
80101B22
ALT. LH 80105A22 START
L
ECU BUS RH
H 80100A22 5 ENGINE MASTER
60
D 30 24305A8 RH
M
J2404
A
I 80105A22 80106A22 19
24304A8
24017A22
N
ECU BUS LH
MASTER SWITCH 24020A22
B 10A
30 U
S 24010B22 24011A22N
10A
ALT LH
GS-IP-15
ENGINE MASTER R
LH H
24009A22 24012A22N
J2402 M
41 80104A22 80103A22 80103A22 GS-IP-15 A
I 24022B20
REF SHEET 2
N
24013A22N 24022A20 24311A22
B
GS-IP-15 U J2404
ALT RH
S
REF SHEET 2
REF D64-9231-60-01 31006A22 25

C 24022B20 26
24014A22
18 24016B20
24307A22 24016A20
20 31004A22 REF D64-9231-60-01
A AVIONICS MASTER RELAY R
V H
87A AVIONIC BUS
L I 24108A10 REF D64-9277-40-03
REF D64-9277-40-02 H O 30 E
N 24107A10 25 C
FUSELAGE LH ECU BACKUP E I U RH ECU BACKUP FUSELAGE
BATTERY RELAY C C BATTERY RELAY
AV CONT.
87A 85 86 OFF B
U AP WRN. 87A BACKUP
B 24106A22N 24105A22 U
30 BATTERY RH
BACKUP 32A 24315A14 24319A14 B U S 30
GS-IP-13 ON 24104A22 2 24320A14 24316A14 32A
BATTERY LH U S
S AVIONICS MASTER B6
86 85 SWITCH 12V 7.2AH
24308A22N 85 86
B4 24312A22N
B7
12V 7.2AH GS-IP-20 GS-IP-20
12V 7.2AH
B5
B 12V 7.2AH
INSTRUMENT PANEL

I S O 2768
Date Name Date Name
NTS
Title :
D64-9200-00-00
Schematic,
A Diamond
AIRCRAFT
Electrical System
Industries GmbH

"A" VÄM 42-004 10.11.08 Kowarsch
DA 42 NG
Weight: N/A "-" 04.08.08 Kowarsch
D64-9224-30-01 from 2

D64-9224-30-01a.dft
8 7 6 5 4 3 2 1
REVISIONS
"-" all new drawing

added pinout of alternator regulators, removed
F "A" all master-slave wire (24015X22), added pull-up resistor.
LH ENGINE LH NACELLE FUSELAGE FUSELAGE RH NACELLE RH ENGINE

COMPARTMENT COMPARTMENT
TB1 TB1
24004B4 24004A4 24006A4 3 24006B4 50A REF D64-9277-40-03
REF D64-9277-40-02 50A 1
E 24004C4 REF D64-9231-60-01 REF D64-9231-60-01

ALT LH 24006C4 ALT RH
P2404 P2422 P2420

19 80106B22 19 80106C22 28 80106D22
TO RH STARTER
TB1 REF D64-9231-60-01 74002D22
START 80108B2 2 TO START RELAY
LH
74000D22 REF D64-9231-60-01
TO LH STARTER
P2419 P2421 P2402 START
TO START RELAY 2 80109A2
80104D22 28 80104C22 41 80104B22 41
TB1 RH
1.0 kΩ / 1W
ALTERNATOR ALTERNATOR
D 1.0 kΩ / 1W REGULATOR RH
REGULATOR LH
P2404 P2422
REF SHEET 1
25 31006B22 25 31006C22 4 LAMP CPC 2
CPC 2 IN
26 24022C20 26 24022D20 3 ENABLE FIELD 2 24028A22 4
4 24027A22 2 FIELD
ENABLE 3 24016D20 18 24016C20 18
IN
OUT
LAMP 4 31004C22 20 31004B22 20
24019A22N 1 GROUND
GROUND 1 24018A22N

I S O 2768
Date Name Date Name
NTS
Title :
D64-9200-00-00
Schematic,
A Diamond
AIRCRAFT
Electrical System
Industries GmbH

"A" VÄM 42-004 10.11.08 Kowarsch
DA 42 NG
Weight: N/A "-" 04.08.08 Kowarsch
D64-9224-30-01 from 2

D64-9224-30-01a.dft
REVISION
MÄM 42-403
EPU RELAY - ALL ALL 24.11.09 SEE TB
FIRST RELEASE
FRONT BAGGAGE COMPARTMENT
EPU PLUG
24401A22
F PILOT MAP
F
LIGHT 24403A6
H
REF D64-9233-20-01 33200A22 5A GS-RP
O
T 24405A6N
B
U
S
24000A2
MAIN
24001A6 BATTERY
B1
24010A22
24V 13.6Ah
ALT RH RELAY
ALT LH RELAY
5A GS-RP
24005A8
24003A8 24002A6
STARTER RELAY
TB1
80108A2 2
GS-RP
5A
80101A22 80102A22N
8 AWG
E 5A E
24020A22
GS-RP
8 AWG
24017B22 J2418
J2418 J2418
L J C N
ALT. RH
24004A4 24006A4
60
90 START 90 24020B22
SWITCH
LDG LT.
80101B22
L ECU BUS
60
30 24305A8 RH
M
J2404
A
I 80105A22 80106A22 19
24304A8
24017A22
N
ECU BUS
MASTER SWITCH 24020A22
B 10A
30 U
S 24010B22 24011A22N
10A
ALT LH
GS-IP-14
ENGINE MASTER R
LH H
24009A22 24012A22N
D J2402
D
M
41 80104A22 80103A22 80103A22 GS-IP-15 A
I
REF SHEET 2
N
24013A22N 24022A20 24022B20
B
GS-IP-16 U J2404
ALT RH
S
REF SHEET 2
REF D64-9231-60-01 31006A22 25

24022B20 26
24014A22
18 24016B20 24016A20
20 31004A22 REF D64-9231-60-01 ECU A

ECU A A R
AVIONICS MASTER RELAY
V H
87A AVIONIC BUS
L I 24108A10
REF D64-9277-40-03_02
REF D64-9277-40-02_02 H O 30 E
N 24107A10 25 C FUEL PUMP A
FUEL PUMP A E I U
C C AV CONT.
85 86 OFF B
U AP WRN.
B 24106A22N 24105A22 U
B U S
GS-IP-15 ON 24104A22 2
U S
C S AVIONICS MASTER C
SWITCH
ECU B
L R
H H 24387A14
ECU B 24380A14 24380A14 20A
E E REF D64-9277-40-03_02
C C
24382A14 20A 24385A14
REF D64-9277-40-02_02
U U FUEL PUMP B
B B 24386A14
FUEL PUMP B
B B
24383A14 U 24381A14 20A 20A 24384A14 24384A14 U
S S
FUSELAGE LH ECU BACKUP RH ECU BACKUP FUSELAGE

BATTERY RELAY BATTERY RELAY
87A 87A BACKUP
P2410 P2410 BATTERY RH
30 30
BACKUP 32A 24315A14 1 24315B14 24319A14 24320A14 24316B14 2 24316A14 32A
BATTERY LH
B6
86 85 12V 7.2AH
B 24307A22 24308A22N INSTRUMENT PANEL 85 86 B
B4 24312A22N 24311A22
REF D64-9277-40-02_02 REF D64-9277-40-03_02 B7
12V 7.2AH
B5
12V 7.2AH
Indust ries GmbH
DE-S-10-00003 - DEPARTMENT SIGN DATE PROJECT
CLASSIFICATION: - DRAWN K owarsch 24.11.09 TITLE
A2
N ON E CHECKED: K owarsch Schem atic, Ele ctrical
UNLESS OTHERWISE SPECIFIED System, ECU Split Bus
2 DECIMAL u0,25
DECIMAL u1 IN FILENAME SYSTEM: N/A DAIA D64-9224-30-01_01 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D64-9224-30-01_01.dft APPROVED: TL CODE SCALE SH OF
710197 NTS 01 02
Confidential
8 7 6 5 4 3 2 1
F F
E E
TB1 TB1
24004B4 24004A4 24006A4 3 24006B4 50A REF D64-9277-40-03
REF D64-9277-40-02 50A 1
24004C4 REF D64-9231-60-01 REF D64-9231-60-01

ALT LH 24006C4 ALT RH
P2404 P2422 P2420

19 80106B22 19 80106C22 28 80106D22
TO RH STARTER
TB1 REF D64-9231-60-01 74002D22
LH
74000D22 REF D64-9231-60-01
D TO LH STARTER D
P2419 P2421 P2402 START
80104D22 28 80104C22 41 80104B22 41
TB1 RH
1.0 k / 1W
ALTERNATOR ALTERNATOR
1.0 k / 1W REGULATOR RH
REGULATOR LH
P2404 P2422
REF SHEET 1
25 31006B22 25 31006C22 4 LAMP CPC 2
CPC 2 IN
26 24022C20 26 24022D20 3 ENABLE FIELD 2 24028A22 4
4 24027A22 2 FIELD
ENABLE 3 24016D20 18 24016C20 18
IN
OUT
LAMP 4 31004C22 20 31004B22 20
24019A22N 1 GROUND
GROUND 1 24018A22N
C C
B B
A A
Diamond PROJECT DA 42 N G TITLE DWG.ORIG. DWG.NO. REV

Airc raft
Indust ries GmbH
Schem atic, Ele ctrical DAIA D64-9224-30-01_01 "-"
N. A. Otto-Straße 5
Diamond Aircraft Industries A-2700 Wiener Neustadt System, ECU Split Bus CODE 710197 SCALE NTS SH 02 OF 02
Confidential
8 7 6 5 4 3 2 1
REVISION
MÄM 42-551
EPU RELAY - ALL ALL 26.08.11 SEE TB
FIRST RELEASE
FRONT BAGGAGE COMPARTMENT
EPU PLUG
24401A22
F PILOT MAP
F
LIGHT 24403A6
H
REF D64-9233-20-01 33200A22 5A GS-RP
O
T 24405A6N
B
U
S
24000A2
MAIN
24001A6 BATTERY
B1
24010A22
24V 13.6Ah
ALT RH RELAY
ALT LH RELAY
5A GS-RP
24005A8
24003A8 24002A6
STARTER RELAY
TB1
80108A2 2
GS-RP
5A
80101A22 80102A22N
8 AWG
E 5A E
24020A22
GS-RP
8 AWG
24017B22 J2418
J2418 J2418
L J C N
ALT. RH
24004A4 24006A4
60
90 START 90 24020B22
SWITCH
LDG LT.
80101B22
L ECU BUS
60
30 24305A8 RH
M
J2404
A
I 80105A22 80106A22 19
24304A8
24017A22
N
ECU BUS
MASTER SWITCH 24020B22
B 10A
30 U
S 24010B22 24011A22N
24392A10
10A
ALT LH
GS-IP-17
ENGINE MASTER R
24390A10
LH H
24009A22 24012A22N
D J2402
D
M
41 80104A22 80103A22 80103A22 GS-IP-18 A
I
REF SHEET 2
N
24013A22N 24022A20 24022B20
B
GS-IP-19 U J2404
ALT RH
S
REF SHEET 2
REF D64-9231-60-01 31006A22 25

24022B20 26
24014A22
18 24016B20 24016A20
20 31004A22 REF D64-9231-60-01 ECU A

A AVIONICS MASTER RELAY R
V H 24394A14
ECU A 87A AVIONIC BUS
L I 24108A10
REF D64-9277-40-03_02
H O 30 E
24391A14 N 24107A10 25 C FUEL PUMP A
REF D64-9277-40-02_02 E I U
C C AV CONT. 24395A14
FUEL PUMP A 85 86 OFF B
U AP WRN.
B 24106A22N 24105A22 U
24393A14 B U S
GS-IP-18 ON 24104A22 2
U S
C S AVIONICS MASTER C
SWITCH
ECU B
L R
H H 24387A14
ECU B 24380A14 24380A14 20A
E E REF D64-9277-40-03_02
C C
24382A14 20A 24385A14
REF D64-9277-40-02_02
U U FUEL PUMP B
B B 24386A14
FUEL PUMP B
B B
24383A14 U 24381A14 20A 20A 24384A14 24384A14 U
S S
FUSELAGE LH ECU BACKUP RH ECU BACKUP FUSELAGE

BATTERY RELAY BATTERY RELAY
87A 87A BACKUP
P2410 P2410 BATTERY RH
30 30
BACKUP 32A 24315A14 1 24315B14 24319A14 24320A14 24316B14 2 24316A14 32A
BATTERY LH
B6
86 85 12V 7.2AH
B 24307A22 24308A22N INSTRUMENT PANEL 85 86 B
B4 24312A22N 24311A22
REF D64-9277-40-02_02 REF D64-9277-40-03_02 B7
12V 7.2AH
B5
12V 7.2AH
Indust ries GmbH
A2
N ON E CHECKED:
Schem atic, Ele ctrical
UNLESS OTHERWISE SPECIFIED System
2 DECIMAL u0,25
ANGLE u1° MICRO-
710197 NTS 01 02
Confidential
8 7 6 5 4 3 2 1
F F

TB1 TB1
ALT. REG. ALT. REG.
CURRENT REF D64-9277-40-02 24004B4 1 24004A4 24006A4 3 24006B4 50A REF D64-9277-40-03
50A CURRENT
SENSOR 1 SENSOR 2
E 24004C4 REF D64-9231-60-01 REF D64-9231-60-01 E
ALT LH 24004D4 24006C4 24006D4 ALT RH
24031A22 24032A22
BLK
RED
BLK
WHT
RED
WHT
P2404 P2422 P2420

P2443 19 80106B22 19 80106C22 28 80106D22
1 2 3
TO RH STARTER P2442
TB1
1 2 3
LH
REF D64-9231-60-01 74002D22
74000D22 REF D64-9231-60-01
TO LH STARTER
P2419 P2421 P2402 START
80104D22 28 80104C22 41 80104B22 41
TB1 RH
ALTERNATOR
D REGULATOR RH D
P2404 P2422 JA JB
REF SHEET 1
ALTERNATOR 25 31006B22 25 31006C22 12 LAMP USENSE 5 24032A22
REGULATOR LH 26 24022C20 26 24022D20 6 SUPPLY
JB JA
24019A20N 4 GROUND JA CPC 2
5 USENSE SUPPLY 6 24016D20 18 24016C20 18
EXCITATION 7 24028A20 4
24030A22BL 2 SENSOR 1 GND
24030A22WH 4 SENSOR 1 SIG LAMP 12 31004C22 20 31004B22 20
24030A22OR 1 SENSOR 1 + GROUND 4 24018A20N
CPC 2 JA
4 24027A20 7 EXCITATION JB P2441 P2440
SENSOR 2 + 12 24015A22OR 1 24015B22OR 1 24015C22OR
SENSOR 2 SIG 9 24015A22WH 2 24015B22WH 2 24015C22WH
SENSOR 2 GND 11 24015A22BL 3 24015B22BL 3 24015C22BL
4 4
C C
B B
A A
Diamond PROJECT DA 42 N G TITLE DWG.ORIG. DWG.NO. REV

Airc raft
Indust ries GmbH
Schem atic, Ele ctrical DAIA D64-9224-30-01_02 "-"
Diamond Aircraft Industries A-2700 Wiener Neustadt System CODE 710197 SCALE NTS SH 02 OF 02
Confidential
8 7 6 5 4 3 2 1
REVISION
OÄM 42-247
- 01 ALL 06.03.14 SEE TB
FIRST RELEASE
F F
E E
INSTRUMENT PANEL LH FUSELAGE LOWER TAIL FIN
REF D64-9224-30-01_02
RH ECU BACKUP
BATTERY RELAY
87A
P2410
30
2 24316A14 32A
D D
B6
RH ECU 12V / 12Ah
85 86
BACKUP
BATTERY B7
12V / 12Ah
24316A14N
GS-IP-RH
C C
B B
DIMENSIONS METRIC Aircraft Diamond Aircraft Industries A-2700 Wiener Neustadt
Industries GmbH
FIRST ANGLE PROJECTION FORMAT DA 42 NG /M-NG
A3
NONE CHECKED:
Schematic, RH ECU Backup
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A
Battery, Tail Fin Installation
2 DECIMAL u0,25
DECIMAL u1 IN FILENAME SYSTEM: N/A DAIA D64-9224-30-01x01 "-"
ANGLE u1° MICRO-
RAD u0,5 METER D64-9224-30-01x01.dft APPROVED: TL CODE SCALE SH OF
710197 NTS 01 01
Confidential
8 7 6 5 4 3 2 1
LH ENGINE COMPARTMENT FWD BAGGAGE COMPARTMENT

ALT ALT. REGULATOR REF D64-9224-30-01_01
100 / 3W J2432
AUX
F 24357A20 3 BROWN AUX F
F2 F1 EPU RELAY
+ 24358A20 2 BLUE FIELD
24359A20N 8 BLACK GROUND

6 YELLOW VOLTAGE SENSE
24353C20 1 RED ALT CONTROL
24401A22
24354C20 7 ORANGE ALT PROTECTION
24403A6
24600A4
24601A22 4 GRAY ALT OUT
24360A20N
GS-RP 24405A6N
100A
E LH NACELLE INSTRUMENT PANEL E
3 2 4 1
24413B6
24411A22
J2433 ALT
24600B4
ELECTRIC
LH
OFF OFF
MASTER
24601B22 ON ON
24354B20 REF D64-9224-30-01_01 24017A22 24009A22 24012A22N
24353B20
24350A22
J2417
20
FUSELAGE
D TB D
24600C4
AUX
POWER
OFF
24353B20
24354B20
REAR BAGGAGE COMPARTMENT ALT. ON
EXCITATION RELAY CONTROL RELAY J2435
87A 87A 5A 24353A20 3

30 30
24355A14 24356A14 10A 24352A20 5A 24354A20 4 P2434
87 87
2 1
86 85 86 85
24351C22 24351B22 2 24351A22 24350B22
MAIN RELAY
32A
C C
5A 24603A22
12V ALT. FAIL RELAY

1.3Ah
24602A22 87A
30
12V
87
1.3Ah
85 86
24601C22 1 24601B22
2nd EPU
TO ADDITIONAL RELAY
ELECTRICAL LOADS TB
24413A6 24413A6 24413B6
24411B22 24411B22 9 24411A22

B B
Indust ries GmbH
A2
N ON E CHECKED:
Schem atic,
UNLESS OTHERWISE SPECIFIED Second Alternator
REVISION 3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
REV SH ZONE DESCRIPTION DATE APPROVAL SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV
2 DECIMAL u0,25
OÄM 42-204 1DECIMAL u0,5 FINISH
- 01 ALL 13.04.11 SEE TB SYSTEM: N/A D64-9224-30-02 "-"
FIRST RELEASE DECIMAL u1 IN FILENAME DAIA
ANGLE u1° MICRO-
710197 NTS 01 01
Confidential
8 7 6 5 4 3 2 1
REVISION
MÄM 42-878
- 01 ALL NEW DRAWING, DOES NOT SUPERSEDE
07.11.14 SEE TB
F ANOTHER DRAWING. F
E E
INSTRUMENT PANEL
R
H
M
A
I
N
24200A22 3A 24200B22 + ACCESSORY
D POWER PLUG D
B 24201A22N -
U
S GS-IP-7
C C
B B
Industries GmbH
FIRST ANGLE PROJECTION FORMAT DA 42 NG
A3
NONE CHECKED:
Schematic, Accessory
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Power Plug
A SOFTWARE: SOLID EDGE ST6 MANUF.: N/A DWG.ORIG. DWG.NO. REV A
2 DECIMAL u0,25
ANGLE u1° MICRO-
RAD u0,5 METER D64-9224-60-01.dft APPROVED: CODE SCALE SH OF
710197 NTS 01 01
Confidential
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
REVISIONS
"-" all new drawing
EMERGENCY BATTERY
30 VDC / 1300 mAh
EMERGENCY POWER SWITCH
B4
J2430 P2430
ON
red 1 24303B20 33204B22 D64-9233-10-01
black 2 24302B20N REF.
OFF
D64-9233-10-01 33204A22
REF.
34903B22 D64-9234-10-01
D REF.
D64-9234-10-01 34903A22
REF.
GS IP-2

I S O 2768
Date Name Date Name medium
NTS
Title :
D64-9200-00-00
Schematic, Emergency Power
A Diamond
AIRCRAFT
Industries GmbH

DA 42 NG
Weight: N/A "-" VÄM 42-004 05.08.08 Kowarsch
D64-9225-60-01 from 1

D64-9225-60-01.dft
8 7 6 5 4 3 2 1
REVISIONS
"-" all new drawing
REMOTE
ELT UNIT HOT BUS SWITCH
E J2562 P2418 P2563 J2561
G-SWITCH LOOP 5 1A 25601B22 2 25601A22 1 22 AWG 3 +28 VDC
G-SWITCH LOOP 12
RESET 2 13 25603A22 25603A22 2 RESET 2
RESET 1 6 25604A22 25604A22 5 RESET 1
EXTERNAL ON 14 25605A22 25605A22 7 EXTERNAL ON
LIGHT 2 25606A22 25606A22 8 LIGHT
GROUND 7 25607A22N 25607A22N 6 GROUND
25608A22N P2563
25602A22N 2 22 AWG 9 GROUND
D LOCAL
GS-IP 12
HORN POWER 8 25609A22 +

BUZZER
-
LOCAL

I S O 2768
Date Name Date Name
NTS
Title :
D64-9200-00-00
Schematic, ELT ME 406
A Diamond
AIRCRAFT
Industries GmbH

DA42 NG

D64-9225-60-02
REVISION
OÄM 42-226
- 01 ALL 27.02.12 SEE TB
FIRST RELEASE
F F
KANNAD 406
AF COMPACT
E ELT E
P2 P1
J2 25602A400 25602A400 J1 ANTENNA
RC200
J1 J2561 J2562
RCP
RCP RESET A 25601A24WH 25601A24WH 4 RESET/TEST
5 ON
D RCP COMMON G 25601A24BL 25601A24BL 8 GND D

RCP LED J 25601A24OR 25601A24OR 9 LED
C C
B B
Industries GmbH
FIRST ANGLE PROJECTION FORMAT DA 42 N G / M-N G
A3
N ON E CHECKED:
Schematic, Kanna d
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A 4 0 6 AF-Compa ct ELT
2 DECIMAL u0,25
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D64-9 2 2 5 -6 0 -0 3 "-"
ANGLE u1° MICRO-
710197 NTS 01 01
Confidential
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
REVISIONS
"-" all new drawing
INSTUMENT PANEL CABIN SWITCH ASSEMBLY RUDDER PEDALS ASSEMBLY
PEDAL SWITCH LH
E J2722 P2722
R J2402 P2402 J2721 P2721 FORWARD 27024A22 1 27024B22 -
H 1b M
5A 27020A20 22 27020B20 1 27020C20 3A 27023A20 27025A22 2 27025B22 +
M RUDDER 1
27021B20N BACK 1a J2725 P2725
A 27021A20N 23 2 27021C20N PEDAL MOTOR LH
I 27026A22 1 27026B22 S1
N FORWARD 27027A22 2 27027B22
2b
GS-IP-7 27028A22 3 27028B22
B 2 S2
U BACK 27029A22 4 27029B22
2a
S
D PEDAL SWITCH RH
J2724 P2724
J2404 P2404 J2723 P2723 FORWARD 27034A22 1 -
1b 27034B22
27030A20 27030B20 1 27030C20 27033A20 27035A22 2 +
M
5A 53 3A 27035B22
RUDDER 1
BACK J2727 P2727
27031A20N 54 27031B20N 2 27031C20N 1a PEDAL MOTOR RH
27036A22 1 27036B22 S1
FORWARD 27037A22 2 27037B22
2b
GS-IP-7 27038A22 3 27038B22
2 S2
BACK 27039A22 4 27039B22
C 2a

I S O 2768
Date Name Date Name
NTS
Title :
D64-9200-00-00
Schematic, Rudder Pedal
A Diamond
AIRCRAFT
Adjust
Industries GmbH

DA42 NG

D64-9227-20-01.dft
8 7 6 5 4 3 2 1
REVISIONS
"-" all new drawing
"A" all removed flaps position logic.

F
THROTTLE
L 32021A22 SWITCHES
REF D64-9232-00-01
H 32014A22
P2415 P3202 S1
M
A P2730 STICK LIMITER
5A 27300A22 4 27300B22 4 27300C22 27301A22
I
N 27303A22N 3 27303B22N 3 27303C22N 27301A22 1 black
GEAR ANNUN
ELEV LIMIT S2 27302A22 2
E B
U GS-IP-10 27302A22
S
M
red
PC BOARD, KRUTZ
DAI-9027-30-01
RL 1
S3
A 22 AWG
E 27304A22
D GEA 71 P702
P2415 P2731
DISCRETE IN* 20 43 31270A22 13 31270B22 1 31270C22 B C 27306A22
SIGNAL GROUND 78 27307A22N 14 27307B22N 2 27307C22N
RL 2
S4
D 22 AWG
27307C22N
B
NOTES:
1. WIRING SHOWN WITH STICK LIMITER DEACTIVATED (THROTTLE IN IDLE POSITION) Approved : Checked : General Tolerance : Scale:
AND POWERED.
I S O 2768
Date Name Date Name
NTS
Title :
D64-9200-00-00
Schematic, Stick Limiter
A Diamond
AIRCRAFT
Industries GmbH

"A" VÄM 42-004 28.11.08 Kowarsch
DA 42 NG
Weight: N/A "-" 14.07.08 M. Spanton
D64-9227-30-01 from 1

D64-9227-30-01a.dft
8 7 6 5 4 3 2 1
REVISIONS
"-" all new drawing
"A" all removed wire 27310A22 for stick limiter.

F
INSTRUMENT PANEL CENTRE FUSELAGE

FLAP POSITION
SWITCH ASSEMBLY
J2704 P2704
SW14 SW15 SW16 SW17 SW18
E 14 AWG 1
2
S1 S5 S2 S4 S3
FLAP-SWITCH
PC-BOARD
FLAPS J2412 P2412
R J2415 P2415 J2700 P2700 J2703 P2703
H
5A 27008A20 27007A20 28 27007B20 2 27007C20 1 x2a_1 x3_2 2
M 27001A22 19 27001B22 4 27001C22 3 x2a_3 x3_3 3
A LDG 27000A22 18 27000B22 3 27000C22 2 x2a_2 x3_4 4
2 1
I APP
27002A22 20 27002B22 5 27002C22 4 x2a_4 x3_5 5
N UP LDG
27003A22 21 27003B22 6 27003C22 5 x2a_5 x3_6 6
3
B 27004A22 26 27004B22 7 27004C22 6 x2a_6 x3_1 1
U SW13 UP
D 27005A22 27 27005B22 8 27005C22 7 x2a_7
S 4
5 27006A20N 29 27006B20N 1 27006C20N 8 x2a_8
APP 32041B22 32041C22
22 9 9
6
UP L2
REF.DWG. 33026A22 x4_2 2 RED
D64-9233-10-07
M
GS-IP-6 x4_1 1 BLK
APP L3
J2702 P2702
FLAP MOTOR
LDG L4
32041D22 2 22 AWG
1
REF.DWG. D64-9232-00-01 32041A22 J3203 P3203
C

I S O 2768
Date Name Date Name
NTS
Title :
D64-9200-00-00
Schematic, Flaps
A Diamond
AIRCRAFT
Industries GmbH

"A" VÄM 42-004 28.11.08 Kowarsch
DA 42 NG
D64-9227-50-01 from 1

D64-9227-50-01a.dft
REVISION
OÄM 42-056/p, CB value changed and
B 01 ALL 18.11.10 SEE TB
Flag Note clarified, new standard
F F
I-PANEL CENTER FUSELAGE LH ENGINE NACELLE LH WING LH AUX FUEL MODULE

LEFT FUEL LEVEL
OVER FILL
AUX FUEL VALVE
J2400 P2400 J3105 FULL

E NOT FULL E
28016B22 14 28016A22 1
28012C22 18 28012D22 2 1 2
20 AWG
1 FUEL 20 AWG
XFR LH
LOCAL
P2810 OFF
XFR PUMP 31025B22N 1 31025C22N AUX FUEL PUMP

REF D64-9231-60-01 ON RELAY
DE-ICE J2415 31038B22 2 31038C22 J2421 P2421 J2419 P2419 J2815 87A J2815
L
H 30 87
7A 28008A20WH 7 28008B20WH 3 OFF 30 28008D20WH 16 28008E20WH 1 28008F20 28010A20 4 20 AWG
7.5/
M 10 8 28008C20WH 4 28018A20 31 17
A ON
GS-IP 1
22 AWG
I 86 85
28018B20 LOCAL
N
3A
REF D64-9230-40-01
20 AWG
20 AWG
B
U
REF
P2811 OFF LEFT AUX FUEL
S D64-9231-60-01
31027B22N 1 31027C22N 31036C22 10 31036D22 2 31036E22 J3109 LEVEL LOW
D REF D64-9231-60-01 ON D
31026B22 31026C22 28016B22 28016C22 28016D22 28010B20 LOW
2 7 3 1
FUEL NOT LOW
3 OFF 28012C22 5 28012B22 28012B22 2
XFR RH
28009A20WH 4 28019A20 REF 31032C22
ON D64-9231-60-01
28019B20
REF LOCAL
D64-9228-11-01
FLAG NOTES
C C
1 DEPENDING ON THE INSTALLED OPTIONS,
THE INSTALLATION OF THE CIRCUIT PROTECTIVE
DEVICES IS DIFFERENT.
AUX FUEL SYSTEM ONLY: 7.5A CIRCUIT BREAKER, NO FUSE
AUX FUEL SYSTEM AND DE-ICE SYSTEM: 10A CIRCUIT BREAKER

AND 7A SLOWBLOWFUSE FOR THE AUX FUEL SYSTEM.
B B
Industries GmbH
FIRST ANGLE PROJECTION FORMAT DA 42 N G / M-N G
A3
N ON E CHECKED:
Schematic, LH Aux Fuel
2 DECIMAL u0,25
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D64-9 2 2 8 -1 0 -0 1 "B"
ANGLE u1° MICRO-
RAD u0,5 METER D64-9228-10-01b.dft APPROVED: TL CODE SCALE SH OF
710197 NTS 01 01
Confidential
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
REVISIONS
"-" all new drawing
"A" all added connector at relay.

F
E
CENTER FUSELAGE RH ENGINE NACELLE RH WING RH AUX FUEL MODULE
RIGHT FUEL LEVEL
OVER FILL
AUX FUEL VALVE
J2401 P2401 J3112 FULL

NOT FULL
28017B22 14 28017A22 1
28015C22 18 28015D22 2 1 2
20 AWG
FUEL 20 AWG
XFR RH
LOCAL
P2811 OFF
31027B22N 1 31027C22N AUX FUEL PUMP

REF D64-9231-60-01 ON RELAY
31026B22 2 31026C22 J2422 P2422 J2420 P2420 J2816 87A J2816
30 87
3 OFF 12 28009B20WH 16 28009C20WH 1 28009D20 28011A20 4 20 AWG
D 28009A20WH 4 28019A20 13 17
ON
22 AWG
86 85
28019B20 LOCAL
3A
20 AWG
20 AWG
REF
P2810 OFF
D64-9231-60-01 RIGHT AUX FUEL
31025B22N 1 31025C22N 31037C22 10 31037D22 2 31037E22 J3110 LEVEL LOW
REF D64-9231-60-01 ON
31038B22 31038C22 28017B22 28017C22 28017D22 28011B20 LOW
2 7 3 1
FUEL NOT LOW
28008B20WH 3 OFF 28015C22 5 28015B22 28015B22 2
REF D64-9228-10-01 XFR LH
28008C20WH 4 28018A20 REF 31034C22
ON D64-9231-60-01
28018B20
LOCAL

I S O 2768
Date Name Date Name
NTS
Title :
D64-9200-00-00
Schematic, RH Aux Fuel
A Diamond
AIRCRAFT
Wiring
Industries GmbH

"A" VÄM 42-004 22.11.08 Kowarsch
DA 42 NG
D64-9228-11-01 from 1

D64-9228-11-01a.dft
8 7 6 5 4 3 2 1
REVISIONS
"-" all new drawing
"A" C4-5 added WOW wiring for EECU´s

F
3A 30011A22
REF D64-9231-60-01
3A 30010A22
PITOT HEAT
L PITOT / STATIC PROBE
H PITOT
J2417 J2427 J2400 J3002 t°1 t°2
M 10A 30000A14 30001A14 1 30001B14 1 30001C14 29 30001D14 1
A H1
I 2 4 30002A14N 11 30002B14N 11 30002C14N 19 30002D14N 2
N 0.01 Ohm / 3W
E H2
B
U
GS-IP-22 31015A24WH
S REF D64-9231-60-01
31015A24BL
3A VANE
30013A22
REF D64-9231-60-01 HEATER
3A 30012A22
STALL
WRN 87A PLATE
R J2417 J2427 J2400 J3000 HEATER
H 30
10A 30003A14 30006A14 30004A14 3 30004B14 3 30004C14 22 30004D14 10
87
M 18 Ohm / 50W 1 3 30005A14N 13 30005B14N 13 30005C14N 15 30005D14N 12
A
I 0.01 Ohm / 3W 6
D 86 85
N 30007A22 5
B 31014A24WH CASE
GS-IP-22 HEATER
U REF D64-9231-60-01
S 31014A24BL
SQUAT SWITCH RH
REF D64-9231-60-01
S13 NO
J2415 34428A22 J2412
C NC
30008A22 11 30008B22 11 30008C22
J2403
30009A22N 12 30009B22N 12 30009C22N
23027B22 52 REF D64-9231-60-01
REF D64-9277-40-02 32050A22

STALL
WARNING GS-IP-10 REF D64-9277-40-03 32051A22
C
PSW SWITCH
+ -
J2402 J2421 J2400 J3000
34922A22 34920A22 54 34920B22 54 34920C22 12 34920D22 1
34921A22N 49 34921B22N 49 34921C22N 32 34921D22N 2
GS-IP-14
1. WIRING SHOWN WITH AIRPLANE ON GROUND AND NOT POWERED. Approved : Checked : General Tolerance : Scale:
I S O 2768
2. S13 OPENED WHEN THE AIRPLANE IS AIRBORNE, PSW SWITCH WILL CLO SE WHEN AIRPLANE STALLS. NTS
Date Name Date Name

Title :
D64-9200-00-00
Schematic, Pitot and
A Diamond
AIRCRAFT
Stall Heat Warning
Industries GmbH

"A" VÄM 42-004 20.11.08 Kowarsch
DA 42 NG
D64-9230-30-01 from 1

D64-9230-30-01a.dft
REVISION
VÄM 42-004
- 01 ALL 14.07.08 SEE TB
FIRST RELEASE
F OÄM 42-053/j F
A 01 C-6 04.05.09 SEE TB
corrected 33120E20 and 33121E20 to
33120D20 and 33121D20
INSTRUMENT PANEL FRONT BAGGAGE COMPARTMENT
L DE-ICE CONTROL BOX

H
M WINDSHIELD PUMP 1
E A P3011 J3011 P3013
E
I XFR PUMP 5s
N DE-ICE P2418 J2418 J3011 P3011 12 30104A20 1 RED 28 VOLT
30401B20 13 30106A20 2 BLU 0 VOLT

B 30401A20 d 1
U 30107B20N 3
S 30400A20
5/10A
REF D64-9228-10-01
WINDSHIELD VALVE 1
e 30402C20 2 J2418 P2418
P3015 J3015 WHT 28 VOLT
U 30107A20N
WINDSHIELD DE-ICE Case
DE-ICE CONTROL PANEL 1 30400A20 WHT 0 VOLT
Ground
Case
30400B20 6 30406A20 Ground
GS-IP 3
30402A20 2 30402B20 WINDSHIELD PUMP 2
W 30403C20 3
30403A20 3 30403B20
PUMP 1 3 OFF RED 28 VOLT
30404A20 4 30404B20
2 HIGH
7 30407A20 BLU 0 VOLT
PUMP 2 1 90 s 30 s
30405A20 5 30405B20 X 30404C20 4
PUMP SELECTOR 6 OFF
JMPR
5 WINDSHIELD VALVE 2
30410A20 9 30410B20
D 4 NORMAL MAX D
WHT 28 VOLT
MAIN 0 VOLT
30408A20 8 30408B20 WHT
DE-ICE
AMBER WHITE AMBER
Y 30405C20 5
P3011 J3011 MAIN PUMP 1
Case Case P3012
Ground Ground
14 30120A20 1 HI (RED) HIGH FLOW
30124A20N 12 30124B20N
15 30121D20 2 LOW FLOW
30125A20N 13 30125B20N
Z 30406B20 6 30122B20N 3 0V (BLK) 0 VOLTS
30126A20N 14 30126B20N GS-IP 1 120 s
ANNUN- TEST
GND (WHT) GROUND
30422B20 17 30422A20 REF D64-9231-60-01 GS-IP 4
GS-IP 2 a 30407B20 7 J2418 P2418
33120F20 15 33120D20 REF D64-9233-40-01
33121F20 16 33121D20 REF D64-9233-40-01 V 30122A20N MAIN PUMP 2
ALTERNATE OFF 7
b 30408C20 8 HI (RED) HIGH FLOW
ICE LIGHT Case GS-IP 3
ON Ground LOW FLOW
30412A20 11 30412B20
0V (BLK) 0 VOLTS
30411B20 10 30411A20 Case
Ground GND (WHT) GROUND
H 30410C20 9
C c 30412C20 10 C
30123A20N K 30123B20N 16
Case
R GS-IP 1 Ground
H
5A
M
A
I
N
B
U
S
B B
Industries GmbH
A3
N ON E CHECKED:
Schematic, De-Ice
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Cont rol System
2 DECIMAL u0,25
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D64-9 2 3 0 -4 0 -0 1 A
ANGLE u1° MICRO-
710197 NTS 01 01
Confidential
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
REVISIONS
"-" all new drawing
"A" D5 corrected pinout of P2402 and P2418

F
P3113
31040A22 1 FRONT BAGGAGE
GEA 71 31041A22N 2 COMPARTMENT LH
ENGINE/AIRFRAME
P702 P2418
P3112
DISCRETE IN 19A 42 31028A22 D 31028B22 1 FRONT BAGGAGE
SIGNAL GROUND 37 31029A22N E 31029B22N 2 COMPARTMENT RH
CANOPY
P2402 FWD AFT
P3111
D REF D64-9231-60-01 31023A22 42 31023B22 1
31024A22N 44 31024B22N 2

I S O 2768
Date Name Date Name
NTS
Title :
D64-9200-00-00
Schematic, Door
A Diamond
AIRCRAFT
Warning Switches
Industries GmbH

"A" VÄM 42-004 12.08.08 Kowarsch
DA 42 NG
D64-9231-00-01 from 1

D64-9231-00-01a.dft
8 7 6 5 4 3 2 1
REVISIONS
"-" all new drawing
"A" E6 corrected pinout of P2418

F
GEA 71
ENGINE/AIRFRAME DE-ICE LEVEL
P701 P2418 P3020
LOW
DISCRETE IN* 1 70 30110A22 F 30110B22 1
E SIGNAL GROUND 4 30111A22N G 30111B22N OK
2
DE-ICE PRESS HIGH

P3021
HIGH
DISCRETE IN* 2 71 30112A22 M 30112B22 1
SIGNAL GROUND 19 P 30113B22N OK
30113A22N 2
DE-ICE PRESS LOW DE-ICE PRESS LOW DE-ICE PRESS LOW

P2402 P3022
D LOW LOW LOW
DISCRETE IN* 3 76 30114A22 45 30114B22 1
SIGNAL GROUND 32 30115A22N 46 30115B22N 2 OK OK OK

I S O 2768
Date Name Date Name
NTS
Title :
NOTES: D64-9200-00-00
Schematic, De-Ice
A Diamond
AIRCRAFT
Warning System
Industries GmbH
1. SWITCHES SHOWN IN UNPOWERED STATE AND NO FLUID IN DE-ICE TANK
"A" VÄM 42-004 12.08.08 Kowarsch
DA 42 NG
D64-9231-00-02 from 1

D64-9231-00-02a.dft
REVISION
VÄM 42-004
- 01 ALL 06.08.08 SEE REV
FIRST RELEASE
F OÄM 42-214 F
A 05 ALL 21.07.11 SEE TB
EVS3 WIRING ADDED
NOTES:
1. SYMBOL DESIGNATIONS
E E
TWISTED SHIELDED SINGLE CONDUCTOR
SHIELD TERMINATED TO GROUND TWISTED SHIELDED 4 CONDUCTOR
SHIELD TERMINATED TO GROUND
SHIELD FLOATS
TWISTED SHIELDED PAIR

SHIELD FLOATS
SHIELD FLOATS
AIRCRAFT GROUND
D D
TWISTED SHIELDED 3 CONDUCTOR GARMIN (SHIELD BLOCK) GROUND
S
SHIELD TERMINATED TO GROUND REFER TO DOC. 190-00313-09
WIRE SPLICE CONNECTION
TWISTED SHIELDED 3 CONDUCTOR

SHIELD FLOATS COAXIAL CABLE
N/C = NO CONNECTION
2. USE DOUBLE-SHIELDED WIRING: BOTH SHIELDS SHOULD BE GROUNDED ON THE RECEIVING SIDE;
C ON THE TRANSMITTING SIDE, ONLY THE OUTER SHIELD SHOULD BE GROUNDED, WHILE THE INNER C
SHIELD SHOULD FLOAT.
B B
Industries GmbH
A3
N ON E CHECKED:
Schematic, G1000
2 DECIMAL u0,25
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D64-9 2 3 1 -6 0 -0 1 "A"
ANGLE u1° MICRO-
710197 NTS 01 06
Confidential
8 7 6 5 4 3 2 1
GMA1347 P3471
AUDIO PANEL TO P3471, PIN 39, REF SHEET 3 NO. 2 GIA63
2
J2414 P2414 2P604 INTEGRATED AVIONICS
F F
23029A22BL 45 23029B22BL 3 VOICE ALERT 500 AUDIO LO (GND)
UNSWITCHED AUDIO IN 3 HI 38 23029A22WH 46 23029B22WH 2 VOICE ALERT 500 AUDIO HI
47
S
S 48 S
NO. 1 GIA63
2
1P604 INTEGRATED AVIONICS
56
S AUDIO
S 57 S
23010A22 5A
23018A22 23017A22 AVIONICS

BUS J2413 P2413
100 10W 1P601
+28 V ANR TIP POWER
ON SIDE COM MIC AUDIO OUT HI 26 23202B24WH 6 23202A24WH 7 COM MIC AUDIO IN HI
ON SIDE COM MIC 27 23202B24BL 7 23202A24BL 4 COM MIC KEY
8
S
E E
ON SIDE COM AUDIO IN HI 7 23203B24WH 44 23203A24WH 9 COM AUDIO OUT HI
ON SIDE COM AUDIO LO 8 23203B24BL 45 23203A24BL 10 COM AUDIO OUT LO
46 8 COM MIC AUDIO IN LO
S COM 1
LH MAIN
BUS 5A 23200A20 26 23200B20 17 AIRCRAFT POWER 1
P3472
19 AIRCRAFT POWER 1
23201A20N 27 23201B20N 30 POWER GROUND
POWER 53 31 POWER GROUND
GS IP-4
ON SIDE COM MIC DIGI AUDIO OUT 8 23210B24WH 52 23210A24WH 14 COM MIC DIGITAL AUDIO IN
ON SIDE COM DIGI AUDIO IN 9 23210B24BL 53 23210A24BL 13 COM DIGITAL AUDIO OUT
54
S S
GPS/NAV 1 0.499 20W 1P605
LH MAIN 37
5A 34000A22 34000B22 34000E22 29 AIRCRAFT POWER 1
BUS
GS IP-4 3.2
GS AVB 1P602
53V
ON SIDE NAV DIGI AUDIO IN 28 34002B24WH 15 34002A24WH 59 VOR/LOC DIGI AUDIO OUT
D AIRCRAFT GROUND 71 34002B24BL 16 34002A24BL 61 SIGNAL GROUND
D
17
S S
POWER GROUND 14 23011A22N

1P603
GS IP-10
RS 232 OUT 1 6 23012B24WH 18 23012A24WH 59 MAIN RS 232 IN 7
RS 232 IN 1 7 23012B24BL 19 23012A24BL 62 MAIN RS 232 OUT 7
20
S S
J3481 P3481 P3482 J3482
MKR ANTENNA HI 78 MARKER

34890A400 34890B400
ANTENNA
MKR ANTENNA LO 59
J2404 P2404
P2301 J2301
SPKR AUDIO OUT HI 42 23008A24WH 23008A24WH 43 23008B24WH 1
SPEAKER
SPKR AUDIO OUT LO 41 23008A24BL 23008A24BL 44 23008B24BL 2
45
S
2P601 NO. 2 GIA63
J2414 P2414 INTEGRATED AVIONICS
C CROSS SIDE COM MIC DIGI AUD OUT 47 23302B24WH 6 23302A24WH 14 COM MIC DIGITAL AUDIO IN C
CROSS SIDE COM DIGI AUDIO IN 48 23302B24BL 7 23302A24BL 13 COM DIGITAL AUDIO OUT
COM 2 8
S S
AVIONICS 15 17 AIRCRAFT POWER 1
5A 23300A20 23300B20
BUS
19 AIRCRAFT POWER 1
31 POWER GROUND
GS IP-15
2P602
CROSS SIDE NAV DIGI AUDIO IN 68 34102B24WH 9 34102A24WH 59 VOR/LOC DIGI AUDIO OUT
AIRCRAFT GROUND 69 34102B24BL 10 34102A24BL 61 SIGNAL GROUND
11
S S
2P603

19
S S
GPS/NAV 2 0.499 20W 2P605
B AVIONICS 23 29 AIRCRAFT POWER 1
B
5A 34100A22 34100B22 34100E22
BUS
GS IP-19 3.2
GS AVB 53V
28V LIGHTING HI 52 33004B22 REF D64-9233-10-07
A Diamond PROJECT DA 42 N G TITLE DWG.ORIG. DWG.NO. REV A

Aircraft
Industries GmbH
Schematic, G1000 DAI A D64-9 2 3 1 -6 0 -0 1 "A"
Diamond Aircraft Industries A-2700 Wiener Neustadt CODE 710197 SCALE SH 02 OF 06
Confidential
8 7 6 5 4 3 2 1
J2403 P2403
OPTIONAL
CR 900 P2 GOODRICH
34413A22
34411B22 51 34411A22 22 INHIBIT WX-500
34412A22 STORMSCOPE
+28 V ANR TIP POWER
23026A24WH PILOT
F 23026A24BL HAND F
23026A24OR MIC
GMA1347 P3471
S
AUDIO PANEL J2405 P2405
PILOT MIC AUDIO IN HI 28 23000A24WH 1 23000B24WH PILOT

PILOT MIC AUDIO IN LO 30 23000A24BL 2 23000B24BL MIC
23000A24OR 3 23000B24OR
PILOT MIC KEY IN 29 S 4 PILOT PTT
23014A24WH 55 23014B24WH 1
23014A24BL 56 23014B24BL 2
57
PILOT PHONE AUDIO LT HI OUT 9 23001A24WH 5 23001B24WH
PILOT
PILOT PHONE AUDIO RT HI OUT 10 23001A24OR 49 23001B24OR
PHONE
PILOT PHONE AUDIO LO OUT 11 23001A24BL 6 23001B24BL
S 7
PASS 1 MIC AUDIO IN HI 46 23004A24WH 15 23004B24WH PASS #1
PASS 1 MIC AUDIO IN LO 47 23004A24BL 16 23004B24BL MIC
S 17

S 23
E PASS PHONE L OUT HI 67 23005A24WH 18 23005B24WH E
PASS #1
PASS PHONE R OUT HI 68 23005A24OR 50 23005B24OR
PHONE
PASS PHONE AUDIO LO OUT 48 23005A24BL 19 23005B24BL
S 20
23007A24WH 24 23007B24WH
PASS #2
23007A24OR 51 23007B24OR
PHONE
+28 V ANR 23007A24BL 25 23007B24BL
S 33
COPILOT MIC AUDIO IN HI 49 23002A24WH 13 23002B24WH CO-PILOT
COPILOT MIC AUDIO IN LO 51 23002A24BL 12 23002B24BL MIC
23002A24OR 11 23002B24OR
S 14 CO-PILOT PTT
COPILOT MIC KEY IN 50 23015A24WH 53 23015B24WH 1

23015A24BL 54 23015B24BL 2
48
COPILOT PHONE AUDIO LT OUT HI 69 23003A24WH 8 23003B24WH

CO-PILOT
COPILOT PHONE AUDIO RT OUT HI 70 23003A24OR 40 23003B24OR
PHONE
COPILOT PHONE AUDIO OUT LO 71 23003A24BL 9 23003B24BL
S 10
MUSIC IN 2 LEFT 56 23025A24WH 27 23025B24WH

D MUSIC IN 2 RIGHT 57 23025A24OR 26 23025B24OR D
MUSIC IN 2 LO 76 23025A24BL 28 23025B24BL OPTIONAL
29 P692
S GDL 69
VHF - 6T ANTENNA
(AAE) DATA LINK
J2403 P2403
P691
MUSIC IN 1 LO 37 23025A24BL 23016A24WH 45 23016B24WH 19 AUDIO LEFT
MUSIC IN 1 RIGHT 18 23025A24OR 23016A24OR 47 23016B24OR 18 AUDIO RIGHT
MUSIC IN 1 LEFT 17 23025A24WH 23016A24BL 46 23016B24BL 17 AUDIO OUT LO
S 48
DATA LINK
AVIONICS
5A 23400A22 1 23400B22 35 AIRCRAFT POWER
BUS
REF D64-9230-30-01 52 23027A22 64 AUDIO INHIBIT

MUSIC IN 2 LEFT 56
MUSIC IN 2 RIGHT 57 GS IP-6
J2414 P2414
MUSIC IN 2 LO 76
VOLUME
1 23022A22 73 VOLUME INCREMENT
J2405 P2405
2
36 3 23023A22 74 VOLUME DECREMENT
23016A24BL 23024A24BL
23016A24OR 37 23024A24OR
23016A24WH 35 23024A24WH
1 23020A22 71 CHANNEL INCREMENT
38
C 2 23024A22N 75 SIGNAL GROUND C
27 23025B24WH 3 23021A22 72 CHANNEL DECREMENT
23025A24WH
CHANNEL
23025A24OR 26 23025B24OR
23025A24BL 28 23025B24BL
29 OPTIONAL
BECKER
RA 3502-(01)
J2413 P2413 ADF RECEIVER
P2
REF D64-9234-50-01
ADF AUDIO IN HI 35 34206A24WH 23 34206B24WH 2 AUDIO OUT HI
ADF AUDIO IN LO 36 34206A24BL 29 34206B24BL 3 AUDIO OUT LO
30
S
OPTIONAL
P631 HONEYWELL
KN 63
DME AUDIO IN HI 15 34300A24WH 36 34300B24WH C AUDIO HI DME
DME AUDIO IN LO 16 34300A24BL 47 34300B24BL N AUDIO LO
51
S
J2414 P2414
OPTIONAL
P1 AVIDYNE
9900BX
UNSWITCHED AUDIO IN 1 HI 19 34430A24WH 42 34430B24WH 3 AUDIO TAS
B UNSWITCHED AUDIO IN LO 39 34430A24BL 43 34430B24BL 4 AUDIO GROUND
B
44
S
REF SHEET 2

Aircraft
Industries GmbH
Confidential
8 7 6 5 4 3 2 1
GEA71 J2402 P2402 J2421 P2421 J2400 P2400
GEA71 P701 ENGINE / AIRFRAME P702
J2402 P2402 J2421 P2421 J2419 P2419 LH START INITIATE
ENGINE/AIRFRAME 28V (STARTER POWERED) ANALOG IN 1A HI 52 31300A22WH 37 31300B22WH 37 31300C22WH 23 31300D22WH LEFT FUEL
ANALOG IN 1 HI 22 74000A22 50 74000B22 50 74000C22 6 74000D22 ANALOG IN 1A LO 53 31300A22BL 38 31300B22BL 38 31300C22BL 24 31300D22BL TEMP SENSOR
STARTER NOT POWERED SIGNAL GROUND 38 39 39 25
S
MAIN FUEL LEVEL LEFT

RH START INITIATE J3101
J2404 P2404 J2422 P2422 J2420 P2420 OK
28V (STARTER POWERED)
ANALOG IN 2 HI 24 74002A22 DISCRETE IN 1 A 60 31018A22 11 31018B22 11 31018C22 9 31018D22 1 LOW
32 74002B22 32 74002C22 6 74002D22
STARTER NOT POWERED
F SIGNAL GND 31 31019A22N 12 31019B22N 12 31019C22N 10 31019D22N 2 F
ENG INST LH MAIN CURR MON IN 3 A HI 48 31005A22 REF D64-9277-40-02
BUS
AIRCRAFT POWER 1 35 77015A22 5A CURR MON IN 3 A LO 49 31008A22N
GS IP-xx AUX FUEL LEVEL LEFT
POWER GROUND 20 77016A22N GS IP-19 J2419 P2419 J3109 LOW
DISCRETE IN 5 A 64 31032A22 32 31032B22 32 31032C22 5 28012B22 2 OK
J2413 P2413 1P603 NO. 1 GIA63 28012C22 TO AUX FUEL
INTEGRATED AVIONICS SIGNAL GND 35 31033A22N 28010A20 1
REF D64-9228-10-01 RELAY
RS 485 1 A 5 77010A24WH 11 77010C24WH 23 GEA RS 485 1 A REF D64-9228-10-01
GS IP-10
3A
LH AUX FUEL XFER (MOTOR)
RS 485 1 B 6 77010A24BL 12 77010C24BL 24 GEA RS 485 1 B
28V
S 28 DISCRETE IN 7 A 66 25 25
31036A22 31036B22 31036C22 10 31036D22
2P603 NO. 2 GIA63
INTEGRATED AVIONICS
RS 485 2 A 7 77011A24WH 55 77011C24WH 23 GEA RS 485 1 A LH ALT WARNING
RS 485 2 B 8 77011A24BL 56 77011C24BL 24 GEA RS 485 1 B OK 28V
S 57 ANALOG IN 3 A HI 56 31004A22 20 31004B22 20 31004C22
FAIL
P702
DISCRETE IN 19A 42 LH START REQUEST

REF D64-9231-00-01 J2402 P2402 J2421 P2421 J2400 P2400 J2419 P2419
SIGNAL GROUND 37 J2801 28V (POWERED)
FUEL LEVEL LEFT
28001A22BL 15 15 28001C22BL 3 DISCRETE IN 13 A 27 31002A22 5 31002B22 5 31002C22 9 31002D22
TRANSDUCER PWR OUT LO 11 28001B22BL 6 28001D22BL GROUND RELAY NOT POWERED
E +12V TRANSDUCER POWER 16 28001A22OR 16 28001B22OR 16 28001C22OR 7 28001D22OR 2 EXCITATION
E
DIGITAL IN 1A 74 28001A22WH 14 28001B22WH 14 28001C22WH 5 28001D22WH 1 OUT HI
FUEL LEVEL LEFT LH ENGINE FIRE
S 17 17 8 J2803 J2805
LONG RANGE OK
28003A22BL 27 28003B22BL 27 28003C22BL 35 28003D22BL 3 28003E22BL 3 GROUND
DISCRETE IN 15 A 29 26100A22 43 26100B22 43 26100C22 26 26100D22 FIRE
28003A22OR 28 28003B22OR 28 28003C22OR 36 28003D22OR 1 28003E22OR 2 EXCITATION
26102A22 52 26102B22 4 26102C22 4 26102D22
DIGITAL IN 2A 75 28003A22WH 26 28003B22WH 26 28003C22WH 34 28003D22WH 2 28003E22WH 1 OUT HI TEST
2 1
DIGITAL IN 4A 77 S 29 29 37 4 26104A22N
REF RH 4 5 LH ENGINE WATER
DIGITAL IN 3A 76 REF D64-9232-00-01 32033A22N OK
J2404 P2404 J2422 P2422 J2401 P2401 J2802 DISCRETE IN 17 A 40 77403A22 51 51 8 77403D22
77403B22 77403C22 LOW
FUEL LEVEL RIGHT
28002A22BL 15 28002B22BL 15 28002C22BL 26 28002D22BL 3 GROUND
28002A22OR 16 28002B22OR 16 28002C22OR 27 28002D22OR 2 EXCITATION
28002A22WH 14 28002B22WH 14 28002C22WH 25 28002D22WH 1 OUT HI J2404 P2404 J2422 P2422 J2401 P2401
S 17 17 28 J2804 J2806 FUEL LEVEL RIGHT
LONG RANGE ANALOG IN 2A HI 54 31200A22WH 37 31200B22WH 37 31200C22WH 11 31200D22WH RIGHT FUEL
28004A22BL 29 28004B22BL 29 28004C22BL 35 28004D22BL 3 28004E22BL 3 GROUND ANALOG IN 2A LO 55 31200A22BL 38 31200B22BL 38 31200C22BL 12 31200D22BL TEMP SENSOR
28004A22OR 30 28004B22OR 30 28004C22OR 36 28004D22OR 1 28004E22OR 2 EXCITATION SIGNAL GROUND 39 S 39 39 13
28004A22WH 28 28004B22WH 28 28004C22WH 34 28004D22WH 2 28004E22WH 1 OUT HI

MAIN FUEL LEVEL RIGHT
4 J3102
S 31 31 37 OK
DISCRETE IN 2 A 61 31016A22 5 31016B22 5 31016C22 9 31016D22 1 LOW
P701 SIGNAL GND 32 31017A22N 6 31017B22N 6 31017C22N 10 31017D22N 2
D ANALOG IN 8 HI 66 30011A22
CURR MON IN 4 A HI 50 31007A22 REF D64-9277-40-03
D
3A
CURR MON IN 4 A LO 51 31009A22N
PITOT HEAT AMPS REF D64-9230-30-01 GS IP-xx
SENSOR
28V
ENGINE TEMP ANALOG IN 7 HI 48 31015A22WH
AUX FUEL LEVEL RIGHT
ENGINE TEMP ANALOG IN 7 LO 49 31015A22BL HEATER J2420 P2420
J3110 LOW
S GS IP-18 DISCRETE IN 6 A 65 31034A22 40 31034B22 40 31034C22 5 28015B22 2 OK
SIGNAL GND 36 31035A22N 28015C22 TO AUX FUEL

28011A20 1
REF D64-9228-11-01 RELAY
ANALOG IN 7 HI 64 30010A22 3A
GS IP-11 REF D64-9228-11-01
3A
RH AUX FUEL XFER (MOTOR)

28V
STALL WARNING HEATER DISCRETE IN 8 A 71 31037A22 24 31037B22 24 31037C22 10 31037D22
AMPS SENSOR
28V
ENGINE TEMP ANALOG IN 8 LO 51 31014A22BL HEATER
RH ALT WARNING
S GS IP-18 REF D64-9230-30-01 OK 28V
ANALOG IN 4 A HI 58 31006A22 25 31006B22 25 31006C22
ANALOG IN 9 HI 72 30012A22 3A FAIL
RH START REQUEST
J2420 P2420
28V (POWERED)
LH BUS VOLTS DISCRETE IN 14 A 28 31022A22 33 31022B22 33 31022C22 9 31022D22 RELAY NOT POWERED
C ANALOG IN 5 HI 46 31030A22WH 3A HI C
ANALOG IN 5 LO 47 31030A22BL
S RH ENGINE FIRE
GS IP-1
GS IP-1 OK
RH BUS VOLTS DISCRETE IN 16 A 30 26101A22 22 26101B22 22 26101C22 26 26101D22 FIRE
ANALOG IN 6 HI 62 31031A22WH 3A HI
26103A22 10 26103B22 4 26103C22 4 26103D22
ANALOG IN 6 LO 63 31031A22BL TEST
2 1
S GS IP-1 26104A22N
GS IP-1 REF LH 4 5
REF D64-9232-00-01 32033A22N RH ENGINE WATER
J2415 P2415 LH ALT AMPS SENSOR OK
P7750 DISCRETE IN 18 A 41 77404A22 77404B22 77404C22 8 77404D22
RED V+ 41 41 LOW
+10V TRANSDUCER POWER 14 24331A24OR 32 24331B24OR 1
ANALOG IN 3 HI 42 24331A24WH 30 24331B24WH 2 WHT OUT HI
LH FUEL XFR SWITCH
ANALOG IN 3 LO 43 24331A24BL 31 24331B24BL 3 BLK OUT LO
J2415 P2415 OFF
TRANSDUCER LO (GND) 11 S 33
DISCRETE IN 3 A 62 31038A22 40 31038B22
RH ALT AMPS SENSOR ON REF D64-9228-10-01
P7751 SIGNAL GROUND 33 31025A22N 42 31025B22N
24332A24OR 37 24332B24OR 1 RED V+
OFF
DISCRETE IN 4 A 63 31026A22 41 31026B22
ANALOG IN 4 LO 45 24332A24BL 36 24332B24BL 3 BLK OUT LO ON REF D64-9228-11-01
SIGNAL GROUND 34 31027A22N 43 31027B22N
TRANSDUCER LO (GND) 12 S 38 RH FUEL XFR SWITCH
DISCRETE IN *1 70 30110A22
B SIGNAL GROUND 4 30111A22N B
REF D64-9231-00-02
SIGNAL GROUND 19 30113A22N
J2418 P2418
P702 P3024 DE-ICE FLUID LEVEL
ANALOG/CURR MON IN 2 A HI 46 30117A22WH 18 30117B22WH 1
1,5 - 192 OHMS
ANALOG/CURR MON IN 2 A LO 47 30117A22BL 19 30117B22BL 2
TRANSDUCER POWER OUT LO 13 S 20
DISCRETE IN* 20 43 31270A22 DE- ICE POWER

REF D64-9227-30-01
SIGNAL GROUND 78 27307A22N 28V (POWERED)
ANALOG / CURR MON IN 1A HI 44 30422A20 NOT POWERED
DISCRETE IN* 11A 25 31320A22 REF D64-9232-00-01

Aircraft
Industries GmbH
Confidential
8 7 6 5 4 3 2 1
F F
GRS77 CONFIG MODULE
P771
012-00605-00
AHRS
CONFIG MODULE GROUND 1 BLK 1 GND
CONFIG MODULE POWER 17 RED 4 VCC
CONFIG MODULE DATA 16 YEL 3 DATA SAFE 128 1P10001 NO. 1 GDU1040 PFD
CONFIG MODULE CLOCK 31 WHT 2 CLK PFD FAN
FAN FAIL 2 21007A22 21007A22 14 FAN MONITOR VALID
P2403 J2403 AHRS

0.499 20W LH MAIN
AIRCRAFT POWER 1 18 27 BUS GMA1347 P3472
34902E22 34902B22 34902A22 5A AUDIO PANEL
POWER GROUND 22 34903A22N 28 34903B22N REVERSIONARY MODE 1 36 31101A24WH 31101A24WH 58 REVERSIONARY MODE SEL 1
GS IP-5 REV MOD COMMON 1 37 31101A24BL 31101A24BL 38 AIRCRAFT GROUND
3.2
S S
53V GS AVB J2416 P2416 J2428 P2428 J2401 P2401
J441 P441 GMU44
MAGNETOMETER NO. 1 GIA63 1P603 P2413 J2413
RS 485 IN A 25 34701E24WH 7 34701D24WH 8 34701C24WH 8 34701B24WH 15 34701A24WH 4 RS 485 OUT A INTEGRATED AVIONICS
RS 485 IN B 39 34701E24BL 8 34701C24BL 9 34701C24BL 9 34701B24BL 21 34701A24BL 2 RS 485 OUT B ETHERNET IN B 77 31100A24WH 2 31100B24WH 3 ETHERNET OUT 1 B
9 RS 485 OUT B ETHERNET IN A 76 31100A24OR 1 31100B24OR 2 ETHERNET OUT 1 A
S 12 12 22 1
ETHERNET OUT B 3 31100A24GR 4 31100B24GR 5 ETHERNET IN 1 B
RS 232 OUT 2 10 34700E24WH 11 34700D24WH 4 34700C24WH 4 34700B24WH 5 34700A24WH 8 RS 232 IN 3
ETHERNET OUT A 2 31100A24BL 31100B24BL 4 ETHERNET IN 1 A
MAGNETOMETER POWER OUT 9 34700E24OR 13 34700D24OR 6 34700C24OR 6 34700B24OR 23 34700A24OR 9 +12VDC POWER
S 5 S
MAGNETOMETER GROUND 40 34700E24BL 12 34700D24BL 3 34700C24BL 3 34700B24BL 17 34700A24BL 6 POWER GROUND
S 14 7 7 16 3 LH MAIN PFD
E 0,5 , 25W
BUS E
5A 31105A22 31105B22 35 AIRCRAFT POWER 1
31106A22N 27 POWER GROUND
REF D64-9233-10-07 33000B22 59 LIGHTING BUS HI
GS IP-11 CONFIG MODULE

012-00605-00 BLK
1P603 NO. 1 GIA63 GND 1 1 CONFIG MODULE GROUND
INTEGRATED AVIONICS VCC 4 RED 23 CONFIG MODULE POWER
ARINC 429 OUT 1 A 14 34904A24WH 14 MAIN ARINC 429 IN 6 A 3 YEL 22 CONFIG MODULE DATA
DATA
ARINC 429 OUT 1 B 29 34904A24BL 15 MAIN ARINC 429 IN 6 B 2 WHT 43 CONFIG MODULE CLOCK
CLK
S
GDC74 P741
RS 232 OUT 1 26 34905A24WH 56 MAIN RS 232 IN 6 AIR DATA
SIGNAL GROUND 41 34905A24BL 57 SIGNAL GROUND ARINC 429 OUT 3 A 32 31103A24WH 31103A24WH 16 ARINC 429 IN 2 A
RS 232 IN 1 11 34905A24OR 58 MAIN RS 232 OUT 6 ARINC 429 OUT 3 B 33 31103A24BL 31103A24BL 17 ARINC 429 IN 2 B
S S S
ARINC 429 OUT 2 A 13 34906A24WH ARINC 429 OUT 3 A 47 31151A24WH 31102A24BL 6 ETHERNET OUT 2 A
ARINC 429 OUT 2 B 28 34906A24BL ARINC 429 OUT 3 B 48 31151A24BL 31102A24GR 7 ETHERNET OUT 2 B
S S 31102A24OR 8 ETHERNET IN 2 A
RS 232 OUT 4 21 34907A24OR 31102A24WH 9 ETHERNET IN 2 B
SIGNAL GROUND 35 34907A24BL GRS77 P771 S
P2403 J2403
RS 232 IN 4 6 AHRS
34907A24WH
P2403 J2403 ARINC 429 OUT 3 A 12 31104A24WH 55 31104B24WH 18 ARINC 429 IN 1 A
S
ARINC 429 OUT 3 B 27 31104A24BL 56 31104B24BL 19 ARINC 429 IN 1 B
ARINC 429 IN 1 A 15 34908A24WH 4
S 57 S
ARINC 429 IN 1 B 30 34908A24BL 5
D S 6
D
41 MAIN RS 232 IN 1 P2414 J2414
42 SIGNAL GROUND 2P10001 NO. 2 GDU1043/1045 MFD
43 MAIN RS 232 OUT 1 ARINC 429 OUT 3 A 33 31152A24WH 20 31152B24WH 18 ARINC 429 IN 1 A
GDC74 P741 22
S S
AIR DATA
ARINC 429 OUT 1 B 42 34908B24BL 31102A24WH 7 ETHERNET OUT 2 B
ARINC 429 OUT 1 A 41 34908B24WH 31102A24OR 6 ETHERNET OUT 2 A
J2413 P2413 31102A24GR 9 ETHERNET IN 2 B
S
31102A24BL 8 ETHERNET IN 2 A
ARINC 429 OUT 1 A 26 34909B24WH 31 34909A24WH 12 MAIN ARINC 429 IN 5 A
ARINC 429 OUT 1 B 27 34909B24BL 32 34909A24BL 13 MAIN ARINC 429 IN 5 B S
S 33 31151A24WH 16 ARINC 429 IN 2 A

GMA1347 P3472 31151A24BL 17 ARINC 429 IN 2 B
J2404 P2404 AUDIO PANEL
J3122 P3122 GTP 59 S
OAT PROBE REVERSIONARY MODE 2 56 31153A24WH 31153A24WH 58 REVERSIONARY MODE SEL 1
TEMP PROBE POWER OUT 2 31203C24WH 48 31203B24WH 1 31203A24WH POWER
REV MOD COMMON 2 57 31153A24BL 31153A24BL 38 AIRCRAFT GROUND
TEMP PROBE IN HI 3 31203C24BL 49 31203B24BL 2 31203A24BL SENSE
S S
TEMP PROBE IN LO 4 31203C24OR 50 31203B24OR 3 31203A24OR LOW
S 51 4
2P603 NO. 2 GIA63 57 CDU ID PROG 3

INTEGRATED AVIONICS NO. 2 GIA63 2P603 P2414 J2414
ADC 14 MAIN ARINC 429 IN 6 A INTEGRATED AVIONICS
0,5 , 25W
LH MAIN 15 MAIN ARINC 429 IN 6 B ETHERNET OUT A 2 31150A24WH 2 31150B24WH 4 ETHERNET IN 1 A
AIRCRAFT POWER 1 55 34900B22 34900A22 5A
C BUS ETHERNET OUT B 3 31150A24OR 1 31150B24OR 5 ETHERNET IN 1 B C
POWER GROUND 17 34901A22N ETHERNET IN A 76 4
31150A24GR 31150B24GR 2 ETHERNET OUT 1 A
GS IP-5 56 MAIN RS 232 IN 6 ETHERNET IN B 77 31150A24BL 3 31150B24BL 3 ETHERNET OUT 1 B
57 SIGNAL GROUND S 5 S
J2403 P2403 58 MAIN RS 232 OUT 6
ARINC 429 OUT 2 A 29 18 12 MAIN ARINC 429 IN 5 A MFD GS IP-13
34910B24WH 34910A24WH
19 0,5 , 25W
ARINC 429 OUT 2 B 30 34910B24BL 34910A24BL 13 MAIN ARINC 429 IN 5 B RH MAIN
BUS 5A 31155A22 31155B22 35 AIRCRAFT POWER 1
S 20
RS 232 OUT 1 11 34911B24OR 23 34911A24OR

AIRCRAFT GROUND 12 SAFE 128
34911B24BL 22 34911A24BL MFD FAN
RS 232 IN 1 10 34911B24WH 21 34911A24WH FAN FAIL 2 21006A22 21006A22 14 FAN MONITOR VALID
S 24
CONFIG MODULE OPTIONAL

BLK 012-00605-00
CONFIG MODULE GROUND 1 1 GND FLIR EVS3 P3445 J3445 P3444 J3444
YEL VIDEO 9 34453B179 34453A179 28 COMP VIDEO IN 1 HI
CONFIG MODULE DATA 40 3 DATA
WHT VIDEO GND 10
CONFIG MODULE CLOCK 60 2 CLK S
B POWER 2 1 P3443 J3443 P3442 J3442 B

POWER 3
AVIONIC
POWER, HEATER 12 1 34452A22WH 1 34450A22 2A
BUS
POWER GND 2 2 2 34452A22BL 2 34451A22N
POWER GND 4 3 3
POWER GND, HEATER 13
GS IP-7

Aircraft
Industries GmbH
Confidential
8 7 6 5 4 3 2 1
F F
GTX33
NO. 1 GIA63 MODE S XPDR
INTEGRATED AVIONICS OPTIONAL
2P612 P3302
XPDR ANTENNA
NO. 2 GIA63 COM ANTENNA 23290A400 34590A142
COUPLER
INTEGRATED AVIONICS
1P611
2P606
GPS ANTENNA 34690B142
34410A142
OPTIONAL REF 9900BX TAS
1P603 P3301
BECKER
AC 3504-(1)
MAIN RS 232 IN 5 53 34502A24WH 34502A24WH 23 RS 232 OUT 1
RMI CONVERTER
REF D60-9234-50-01 MAIN RS 232 OUT 5 55 34502A24BL 34502A24BL 22 RS 232 IN 1
P1
SIGNAL GROUND 54 34502A24OR 34502A24OR 51 SIGNAL GROUND
ADF X / COS 10 34202A22 17 ADF COS
S P2414 J2414 S
ADF Y / COS 11 34203A22 16 ADF SIN
ADF Z (GROUND) 12 CAN BUS 1 HI 20 77401E22WH 12 77401C22WH
REF D64-9277-40-02
S CAN BUS 1 LO 22 77401E22BL 13 77401C22BL
HONEYWELL 14
S
E KN 63 P2413 J2413 DME E
P1 DME P1 AVIONICS
MAIN KING SERIAL DME DATA 59 34306A24 6 DATA BUS A/C POWER 2 34302B22 13 34302A22 BUS 77408A22WH
3A
A/C POWER 3 77408A22BL
MAIN KING SERIAL DME CLK 60 34307A24 F CLOCK BUS A/C GROUND 1 34303B22N 14 34303A22N CAN BUS 2 TERMINATION S
39
A/C GROUND A CAN BUS 2 LO 30 77409A22BL
MAIN KING SERIAL DME REQ 62 34305A24 D DME REQUEST GS IP-14
CAN BUS 2 HI 32 77409A22WH
S REF GTX 33 XPDR 12 GROUND
1P604 S
34512A22 K SUPPRESSION
DISCRETE IN* 12 24 21005A22 REF D64-9221-20-01
P632
11 DME ON 1P613
ANTENNA 34390A142
NAV ANTENNA 34090A400
1P614 31 SUPPRESSION
REF KN 63 DME 34512A22
OPTIONAL G/S ANTENNA 34091A400
34424A22
BECKER
REF 9900BX TAS
RA 3502-(01)
2P603
ADF RECEIVER NO. 2 GIA63
P1 2P614
REF D60-9234-50-01 INTEGRATED AVIONICS
RS 485/422 OUT A 36 34200A24WH 13 RX-A 34191A400
34200A24BL 14 RX-B G/S ANTENNA
RS 485/422 OUT B 37
2P613
D S D
27 GROUND 34190A400
NAV ANTENNA
RS 485/422 IN A 27 34201A24WH 12 TX-A 2P603

XPDR J2413 P2413
RS 485/422 IN B 28 34201A24BL 31 TX-B CAN BUS 1 TERMINATION 34 LH MAIN
BUS 21 AIRCRAFT POWER 1
S CAN BUS 1 LO 22 77408A22BL 5A 34500B22 34 34500A22
CAN BUS 1 HI 20 77408A22WH 34501B22N 35 34501A22N 27 POWER GROUND
OPTIONAL
S
AVIDYNE TAS GS IP-14
P2403 J2403
P1 9900BX P1 AVIONICS 77409A22WH
22 AWG 22 RS-232 RX 3 TAS +28 VDC POWER 1 34420B22 2 34420A22 3A BUS 77409A22BL
N/C 20 RS-232 TX 3 +28 VDC POWER 2 S P2413 J2413
21 RS-232 GROUND 3 POWER GROUND 14 34421B22N 10 34421A22N
POWER GROUND 15 CAN BUS 2 HI 32 77405E22WH 25 77405C22WH REF D64-9277-40-03
N/C 25 RS-232 RX 4 POWER SWITCH 16 GS IP-1 CAN BUS 2 LO 30 77405E22BL 24 77405C22BL
N/C 23 RS-232 TX 4 48
SIGNAL GROUND 42 34422A24OR 24 RS-232 GROUND 4 J1
MAIN ARINC 429 IN 4 A 10 34422A24WH 8 429 TX+ NO RYAN DISPLAY 15 MAIN RS 232 IN 5 53 34503A24WH 25 RS 232 OUT 2
34503A24WH
MAIN ARINC 429 IN 4 B 11 34422A24BL 9 429 TX- GEAR POSITION 11 34427A22 REF D64-9232-00-01 MAIN RS 232 OUT 5 55 34503A24BL 34503A24BL 24 RS 232 IN 2
S WEIGHT ON WHEELS 14 34428A22 REF D64-9230-30-01 SIGNAL GROUND 54 34503A24OR 58 SIGNAL GROUND
34503A24OR
TOP ANTENNA S S
34423A24OR
J1 34411A142 2P612
C MAIN ARINC 429 OUT 1 A 71 34423A24WH 10 429 RX 1+ C
MAIN ARINC 429 OUT 1 B 70 34423A24BL 11 429 RX 1- COM ANTENNA 23390A400
J3 34413A142
S 2.2k , 0.25W BOTTOM ANTENNA 1P611
34424A22 7 SUPPRESSION J2 34412A142 GPS ANTENNA 34691B142
2P604 REF KN 63 DME OPTIONAL
J4 34414A142 J2403 P2403 GOODRICH WX-500
ANNUNCIATE* 15 38 5 REMOTE MUTE Wx 500
34425A22 J1 STORMSCOPE
34410A142 REF GTX 33 XPDR (COUPLER) AVIONICS
COUPLER 3A 34400B20WH 31 34400A20WH 1 AIRCRAFT POWER
22 AWG 19 RS-232 RX 2 BUS J3441
34400B20BL 32 34400A20BL 5 AIRCRAFT GROUND J2
N/C 17 RS-232 TX 2
34402A20N 33
18 RS-232 GROUND 2 X LOOP 3 ORANGE C
NO. 1 GIA63 GS IP-4
34426A22
INTEGRATED AVIONICS 1P604 +12V 16 RED D
2P603 J3 SENSE 17 BROWN B
ANNUNCIATE* 15 38 ANT REF 2 BLACK J
MAIN RS 232 IN 3 47 34404A24WH 20 RS 232 TX
MAIN RS 232 OUT 3 49 34404A24BL 8 RS 232 RX -12V 15 YELLOW F
SIGNAL GROUND 48 34404A24OR 3 TOP ANT. Y LOOP 4 GREEN G
ANT TEST 14 BLUE H
S
ANT COM 1 DRAIN A
J2
2P604
6 CONFIG. GROUND
DISCRETE IN* 12 24 21008A22 REF D64-9221-20-01 5 RS 232 GROUND
B GIA SYS ID PROGRAM 1 22 REF. SHEET 3 22 INHIBIT B

Aircraft
Industries GmbH
Confidential
8 7 6 5 4 3 2 1
REVISION
MÄM 42-587
- ALL ALL 15.11.11 SEE TB
FIRST RELEASE
F F
NOTES:
1. SYMBOL DESIGNATIONS
E E
SHIELD TERMINATED TO GROUND
SHIELD FLOATS

SHIELD FLOATS
SHIELD FLOATS
AIRCRAFT GROUND
D D
TWISTED SHIELDED 3 CONDUCTOR GARMIN (SHIELD BLOCK) GROUND
S
SHIELD TERMINATED TO GROUND REFER TO DOC. 190-00313-09
WIRE SPLICE CONNECTION
TWISTED SHIELDED 3 CONDUCTOR

SHIELD FLOATS COAXIAL CABLE
N/C = NO CONNECTION
2. USE DOUBLE-SHIELDED WIRING: BOTH SHIELDS SHOULD BE GROUNDED ON THE RECEIVING SIDE;
C ON THE TRANSMITTING SIDE, ONLY THE OUTER SHIELD SHOULD BE GROUNDED, WHILE THE INNER C
SHIELD SHOULD FLOAT.
FLAG NOTES
1 OPTIONAL INSTALLATION IN REAR FUSELAGE, IF OÄM 42-203 IS INSTALLED
B B
Industries GmbH
A3
N ON E CHECKED:
Schematic, G1000
2 DECIMAL u0,25
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D64-9 2 3 1 -6 0 -0 1_01 "-"
ANGLE u1° MICRO-
710197 NTS 01 06
Confidential
8 7 6 5 4 3 2 1
GMA1347 P3471
AUDIO PANEL TO P3471, PIN 39, REF SHEET 3 NO. 2 GIA63
2
J2414 P2414 2P604 INTEGRATED AVIONICS
F F
47
S
S 48 S
NO. 1 GIA63
2
1P604 INTEGRATED AVIONICS
56
S AUDIO
S 57 S
23010A22 5A
23018A22 23017A22 AVIONICS

BUS J2413 P2413
100 10W 1P601
+28 V ANR TIP POWER
ON SIDE COM MIC AUDIO OUT HI 26 23202B24WH 6 23202A24WH 7 COM MIC AUDIO IN HI
ON SIDE COM MIC 27 23202B24BL 7 23202A24BL 4 COM MIC KEY
8
S
E E
ON SIDE COM AUDIO IN HI 7 23203B24WH 44 23203A24WH 9 COM AUDIO OUT HI
ON SIDE COM AUDIO LO 8 23203B24BL 45 23203A24BL 10 COM AUDIO OUT LO
46 8 COM MIC AUDIO IN LO
S COM 1
LH MAIN
BUS 5A 23200A20 26 23200B20 17 AIRCRAFT POWER 1
P3472
19 AIRCRAFT POWER 1
POWER 53 31 POWER GROUND
GS IP-4
ON SIDE COM MIC DIGI AUDIO OUT 8 23210B24WH 52 23210A24WH 14 COM MIC DIGITAL AUDIO IN
ON SIDE COM DIGI AUDIO IN 9 23210B24BL 53 23210A24BL 13 COM DIGITAL AUDIO OUT
54
S S
GPS/NAV 1 0.499 20W 1P605
LH MAIN 37
5A 34000A22 34000B22 34000E22 29 AIRCRAFT POWER 1
BUS
GS IP-4 3.2
GS AVB 1P602
53V
ON SIDE NAV DIGI AUDIO IN 28 34002B24WH 15 34002A24WH 59 VOR/LOC DIGI AUDIO OUT
D AIRCRAFT GROUND 71 34002B24BL 16 34002A24BL 61 SIGNAL GROUND
D
17
S S
POWER GROUND 14 23011A22N

1P603
GS IP-10
20
S S
J3481 P3481 P3482 J3482
MKR ANTENNA HI 78 MARKER

34890A400 34890B400
ANTENNA
MKR ANTENNA LO 59
J2404 P2404
P2301 J2301
SPKR AUDIO OUT HI 42 23008A24WH 23008A24WH 43 23008B24WH 1
SPEAKER
SPKR AUDIO OUT LO 41 23008A24BL 23008A24BL 44 23008B24BL 2
45
S
2P601 NO. 2 GIA63
J2414 P2414 INTEGRATED AVIONICS
C CROSS SIDE COM MIC DIGI AUD OUT 47 23302B24WH 6 23302A24WH 14 COM MIC DIGITAL AUDIO IN C
CROSS SIDE COM DIGI AUDIO IN 48 23302B24BL 7 23302A24BL 13 COM DIGITAL AUDIO OUT
COM 2 8
S S
AVIONICS 15 17 AIRCRAFT POWER 1
5A 23300A20 23300B20
BUS
19 AIRCRAFT POWER 1
31 POWER GROUND
GS IP-15
2P602
CROSS SIDE NAV DIGI AUDIO IN 68 34102B24WH 9 34102A24WH 59 VOR/LOC DIGI AUDIO OUT
AIRCRAFT GROUND 69 34102B24BL 10 34102A24BL 61 SIGNAL GROUND
11
S S
2P603

19
S S
GPS/NAV 2 0.499 20W 2P605
B AVIONICS 23 29 AIRCRAFT POWER 1
B
5A 34100A22 34100B22 34100E22
BUS
GS IP-19 3.2
GS AVB 53V
28V LIGHTING HI 52 33004B22 REF D64-9233-10-07

Aircraft
Industries GmbH
Schematic, G1000 DAI A D64-9 2 3 1 -6 0 -0 1_01 "-"
Diamond Aircraft Industries A-2700 Wiener Neustadt CODE 710197 SCALE NTS SH 02 OF 06
Confidential
8 7 6 5 4 3 2 1
J2403 P2403
OPTIONAL
CR 900 P2 GOODRICH
34413A22
34411B22 51 34411A22 22 INHIBIT WX-500
34412A22 STORMSCOPE
+28 V ANR TIP POWER
23026A24WH PILOT
F 23026A24BL HAND F
23026A24OR MIC
GMA1347 P3471
S
AUDIO PANEL J2405 P2405
PILOT MIC AUDIO IN HI 28 23000A24WH 1 23000B24WH PILOT

PILOT MIC AUDIO IN LO 30 23000A24BL 2 23000B24BL MIC
23000A24OR 3 23000B24OR
PILOT MIC KEY IN 29 S 4 PILOT PTT
23014A24WH 55 23014B24WH 1
23014A24BL 56 23014B24BL 2
57
PILOT PHONE AUDIO LT HI OUT 9 23001A24WH 5 23001B24WH
PILOT
PILOT PHONE AUDIO RT HI OUT 10 23001A24OR 49 23001B24OR
PHONE
PILOT PHONE AUDIO LO OUT 11 23001A24BL 6 23001B24BL
S 7
S 17

S 23
E PASS PHONE L OUT HI 67 23005A24WH 18 23005B24WH E
PASS #1
PASS PHONE R OUT HI 68 23005A24OR 50 23005B24OR
PHONE
PASS PHONE AUDIO LO OUT 48 23005A24BL 19 23005B24BL
S 20
23007A24WH 24 23007B24WH
PASS #2
23007A24OR 51 23007B24OR
PHONE
+28 V ANR 23007A24BL 25 23007B24BL
S 33
COPILOT MIC AUDIO IN HI 49 23002A24WH 13 23002B24WH CO-PILOT
COPILOT MIC AUDIO IN LO 51 23002A24BL 12 23002B24BL MIC
23002A24OR 11 23002B24OR
S 14 CO-PILOT PTT
COPILOT MIC KEY IN 50 23015A24WH 53 23015B24WH 1

23015A24BL 54 23015B24BL 2
48
COPILOT PHONE AUDIO LT OUT HI 69 23003A24WH 8 23003B24WH

CO-PILOT
COPILOT PHONE AUDIO RT OUT HI 70 23003A24OR 40 23003B24OR
PHONE
COPILOT PHONE AUDIO OUT LO 71 23003A24BL 9 23003B24BL
S 10
MUSIC IN 2 LEFT 56 23025A24WH 27 23025B24WH

D MUSIC IN 2 RIGHT 57 23025A24OR 26 23025B24OR D
MUSIC IN 2 LO 76 23025A24BL 28 23025B24BL OPTIONAL
29 P692
S GDL 69
VHF - 6T ANTENNA
(AAE) DATA LINK
J2403 P2403
P691
MUSIC IN 1 LO 37 23025A24BL 23016A24WH 45 23016B24WH 19 AUDIO LEFT
MUSIC IN 1 RIGHT 18 23025A24OR 23016A24OR 47 23016B24OR 18 AUDIO RIGHT
MUSIC IN 1 LEFT 17 23025A24WH 23016A24BL 46 23016B24BL 17 AUDIO OUT LO
S 48
DATA LINK
AVIONICS
5A 23400A22 1 23400B22 35 AIRCRAFT POWER
BUS

MUSIC IN 2 LEFT 56
MUSIC IN 2 RIGHT 57 GS IP-6
J2414 P2414
MUSIC IN 2 LO 76
VOLUME
1 23022A22 73 VOLUME INCREMENT
J2405 P2405
2
36 3 23023A22 74 VOLUME DECREMENT
23016A24BL 23024A24BL
23016A24OR 37 23024A24OR
23016A24WH 35 23024A24WH
1 23020A22 71 CHANNEL INCREMENT
38
C 2 23024A22N 75 SIGNAL GROUND C
27 23025B24WH 3 23021A22 72 CHANNEL DECREMENT
23025A24WH
CHANNEL
23025A24OR 26 23025B24OR
23025A24BL 28 23025B24BL
29 OPTIONAL
BECKER
RA 3502-(01)
J2413 P2413 ADF RECEIVER
P2
REF D64-9234-50-01
ADF AUDIO IN HI 35 34206A24WH 23 34206B24WH 2 AUDIO OUT HI
ADF AUDIO IN LO 36 34206A24BL 29 34206B24BL 3 AUDIO OUT LO
30
S
OPTIONAL
P631 HONEYWELL
KN 63
DME AUDIO IN HI 15 34300A24WH 36 34300B24WH C AUDIO HI DME
DME AUDIO IN LO 16 34300A24BL 47 34300B24BL N AUDIO LO
51
S
J2414 P2414
OPTIONAL
P1 AVIDYNE
9900BX
UNSWITCHED AUDIO IN 1 HI 19 34430A24WH 42 34430B24WH 3 AUDIO TAS
B UNSWITCHED AUDIO IN LO 39 34430A24BL 43 34430B24BL 4 AUDIO GROUND
B
44
S
REF SHEET 2

Aircraft
Industries GmbH
Confidential
8 7 6 5 4 3 2 1
GEA71 J2402 P2402 J2421 P2421 J2400 P2400
GEA71 P701 ENGINE / AIRFRAME P702
J2402 P2402 J2421 P2421 J2419 P2419 LH START INITIATE
ENGINE/AIRFRAME 28V (STARTER POWERED) ANALOG IN 1A HI 52 31300A22WH 37 31300B22WH 37 31300C22WH 23 31300D22WH LEFT FUEL
ANALOG IN 1 HI 22 74000A22 50 74000B22 50 74000C22 6 74000D22 ANALOG IN 1A LO 53 31300A22BL 38 31300B22BL 38 31300C22BL 24 31300D22BL TEMP SENSOR
STARTER NOT POWERED SIGNAL GROUND 38 39 39 25
S
MAIN FUEL LEVEL LEFT

RH START INITIATE J3101
J2404 P2404 J2422 P2422 J2420 P2420 OK
28V (STARTER POWERED)
ANALOG IN 2 HI 24 74002A22 DISCRETE IN 1 A 60 31018A22 11 31018B22 11 31018C22 9 31018D22 1 LOW
32 74002B22 32 74002C22 6 74002D22
STARTER NOT POWERED
F SIGNAL GND 31 31019A22N 12 31019B22N 12 31019C22N 10 31019D22N 2 F
ENG INST LH MAIN CURR MON IN 3 A HI 48 31005A22 REF D64-9277-40-02
BUS
AIRCRAFT POWER 1 35 77015A22 5A CURR MON IN 3 A LO 49 31008A22N
GS IP-xx AUX FUEL LEVEL LEFT
POWER GROUND 20 77016A22N GS IP-19 J2419 P2419 J3109 LOW
DISCRETE IN 5 A 64 31032A22 32 31032B22 32 31032C22 5 28012B22 2 OK
J2413 P2413 1P603 NO. 1 GIA63 28012C22 TO AUX FUEL
INTEGRATED AVIONICS SIGNAL GND 35 31033A22N 28010A20 1
REF D64-9228-10-01 RELAY
RS 485 1 A 5 77010A24WH 11 77010C24WH 23 GEA RS 485 1 A REF D64-9228-10-01
GS IP-10
3A
LH AUX FUEL XFER (MOTOR)
RS 485 1 B 6 77010A24BL 12 77010C24BL 24 GEA RS 485 1 B
4.7k 28V
S 28 DISCRETE IN 7 A 66 25 25
31036A22 31036B22 31036C22 10 31036D22
2P603 NO. 2 GIA63
INTEGRATED AVIONICS 3.3k
RS 485 2 A 7 77011A24WH 55 77011C24WH 23 GEA RS 485 1 A LH ALT WARNING

S OK
RS 485 2 B 8 77011A24BL 56 77011C24BL 24 GEA RS 485 1 B 28V
S 57 ANALOG IN 3 A HI 56 31004A22 20 31004B22 20 31004C22
FAIL
P702
DISCRETE IN 19A 42 LH START REQUEST

REF D64-9231-00-01 J2402 P2402 J2421 P2421 J2400 P2400 J2419 P2419
SIGNAL GROUND 37 J2801 28V (POWERED)
FUEL LEVEL LEFT
28001A22BL 15 15 28001C22BL 3 DISCRETE IN 13 A 27 31002A22 5 31002B22 5 31002C22 9 31002D22
TRANSDUCER PWR OUT LO 11 28001B22BL 6 28001D22BL GROUND RELAY NOT POWERED
E +12V TRANSDUCER POWER 16 28001A22OR 16 28001B22OR 16 28001C22OR 7 28001D22OR 2 EXCITATION
E
DIGITAL IN 1A 74 28001A22WH 14 28001B22WH 14 28001C22WH 5 28001D22WH 1 OUT HI
FUEL LEVEL LEFT LH ENGINE FIRE
S 17 17 8 J2803 J2805
LONG RANGE OK
28003A22BL 27 28003B22BL 27 28003C22BL 35 28003D22BL 3 28003E22BL 3 GROUND
DISCRETE IN 15 A 29 26100A22 43 26100B22 43 26100C22 26 26100D22 FIRE
28003A22OR 28 28003B22OR 28 28003C22OR 36 28003D22OR 1 28003E22OR 2 EXCITATION
26102A22 52 26102B22 4 26102C22 4 26102D22
DIGITAL IN 2A 75 28003A22WH 26 28003B22WH 26 28003C22WH 34 28003D22WH 2 28003E22WH 1 OUT HI TEST
2 1
DIGITAL IN 4A 77 S 29 29 37 4 26104A22N
REF RH 4 5 LH ENGINE WATER
DIGITAL IN 3A 76 REF D64-9232-00-01 32033A22N OK
J2404 P2404 J2422 P2422 J2401 P2401 J2802 DISCRETE IN 17 A 40 77403A22 51 51 8 77403D22
77403B22 77403C22 LOW
FUEL LEVEL RIGHT
28002A22BL 15 28002B22BL 15 28002C22BL 26 28002D22BL 3 GROUND
28002A22OR 16 28002B22OR 16 28002C22OR 27 28002D22OR 2 EXCITATION
28002A22WH 14 28002B22WH 14 28002C22WH 25 28002D22WH 1 OUT HI J2404 P2404 J2422 P2422 J2401 P2401
S 17 17 28 J2804 J2806 FUEL LEVEL RIGHT
LONG RANGE ANALOG IN 2A HI 54 31200A22WH 37 31200B22WH 37 31200C22WH 11 31200D22WH RIGHT FUEL
28004A22BL 29 28004B22BL 29 28004C22BL 35 28004D22BL 3 28004E22BL 3 GROUND ANALOG IN 2A LO 55 31200A22BL 38 31200B22BL 38 31200C22BL 12 31200D22BL TEMP SENSOR
28004A22OR 30 28004B22OR 30 28004C22OR 36 28004D22OR 1 28004E22OR 2 EXCITATION SIGNAL GROUND 39 S 39 39 13
28004A22WH 28 28004B22WH 28 28004C22WH 34 28004D22WH 2 28004E22WH 1 OUT HI

MAIN FUEL LEVEL RIGHT
4 J3102
S 31 31 37 OK
DISCRETE IN 2 A 61 31016A22 5 31016B22 5 31016C22 9 31016D22 1 LOW
P701 SIGNAL GND 32 31017A22N 6 31017B22N 6 31017C22N 10 31017D22N 2
D ANALOG IN 8 HI 66 30011A22
CURR MON IN 4 A HI 50 31007A22 REF D64-9277-40-03
D
3A
CURR MON IN 4 A LO 51 31009A22N
PITOT HEAT AMPS REF D64-9230-30-01 GS IP-xx
SENSOR
28V
AUX FUEL LEVEL RIGHT
ENGINE TEMP ANALOG IN 7 LO 49 31015A22BL HEATER J2420 P2420
J3110 LOW
S GS IP-18 DISCRETE IN 6 A 65 31034A22 40 31034B22 40 31034C22 5 28015B22 2 OK
SIGNAL GND 36 31035A22N 28015C22 TO AUX FUEL

28011A20 1
REF D64-9228-11-01 RELAY
GS IP-11 REF D64-9228-11-01
3A
RH AUX FUEL XFER (MOTOR)

4.7k 28V
STALL WARNING HEATER DISCRETE IN 8 A 71 31037A22 24 31037B22 24 31037C22 10 31037D22
AMPS SENSOR
28V
ENGINE TEMP ANALOG IN 8 HI 50 31014A22WH 3.3k
ENGINE TEMP ANALOG IN 8 LO 51 31014A22BL HEATER
RH ALT WARNING
S OK
S GS IP-18 REF D64-9230-30-01 28V
ANALOG IN 4 A HI 58 31006A22 25 31006B22 25 31006C22
ANALOG IN 9 HI 72 30012A22 3A FAIL
RH START REQUEST
J2420 P2420
28V (POWERED)
LH BUS VOLTS DISCRETE IN 14 A 28 31022A22 33 31022B22 33 31022C22 9 31022D22 RELAY NOT POWERED
C ANALOG IN 5 HI 46 31030A22WH 3A HI C
ANALOG IN 5 LO 47 31030A22BL
S RH ENGINE FIRE
GS IP-1
GS IP-1 OK
RH BUS VOLTS DISCRETE IN 16 A 30 26101A22 22 26101B22 22 26101C22 26 26101D22 FIRE
ANALOG IN 6 HI 62 31031A22WH 3A HI
26103A22 10 26103B22 4 26103C22 4 26103D22
ANALOG IN 6 LO 63 31031A22BL TEST
2 1
S GS IP-1 26104A22N
GS IP-1 REF LH 4 5
REF D64-9232-00-01 32033A22N RH ENGINE WATER
J2415 P2415 LH ALT AMPS SENSOR OK
P7750 DISCRETE IN 18 A 41 77404A22 77404B22 77404C22 8 77404D22
RED V+ 41 41 LOW
+10V TRANSDUCER POWER 14 24331A24OR 32 24331B24OR 1
LH FUEL XFR SWITCH
ANALOG IN 3 LO 43 24331A24BL 31 24331B24BL 3 BLK OUT LO
J2415 P2415 P2810 OFF
TRANSDUCER LO (GND) 11 S 33
DISCRETE IN 3 A 62 31038A22 40 31038B22 2 31038C22
RH ALT AMPS SENSOR ON REF D64-9228-10-01
P7751 SIGNAL GROUND 33 31025A22N 42 31025B22N 1 31025C22N
24332A24OR 37 24332B24OR 1 RED V+
P2811 OFF
DISCRETE IN 4 A 63 31026A22 41 31026B22 2 31026C22
ANALOG IN 4 LO 45 24332A24BL 36 24332B24BL 3 BLK OUT LO ON REF D64-9228-11-01
SIGNAL GROUND 34 31027A22N 43 31027B22N 1 31027C22N
TRANSDUCER LO (GND) 12 S 38 RH FUEL XFR SWITCH
DISCRETE IN *1 70 30110A22
B SIGNAL GROUND 4 30111A22N B
REF D64-9231-00-02
1
J2402 P2402 P3025 DE-ICE FLUID LEVEL
30120A22WH 34 30120B22WH 1
35 1,5 - 192 OHMS
30120A22BL 30120B22BL 2
S 36
P702 P2418 J2418 P3024 DE-ICE FLUID LEVEL

ANALOG/CURR MON IN 2 A HI 46 30117A22WH f 30117B22WH 1
1,5 - 192 OHMS
ANALOG/CURR MON IN 2 A LO 47 30117A22BL g 30117B22BL 2
TRANSDUCER POWER OUT LO 13 S h
DISCRETE IN* 20 43 31270A22 DE- ICE POWER

REF D64-9227-30-01
SIGNAL GROUND 78 27307A22N 28V (POWERED)
ANALOG / CURR MON IN 1A HI 44 30422A20
NOT POWERED
DISCRETE IN* 11A 25 31320A22 REF D64-9232-00-01

Aircraft
Industries GmbH
Confidential
8 7 6 5 4 3 2 1
F F
GRS77 CONFIG MODULE
P771
012-00605-00
AHRS
CONFIG MODULE GROUND 1 BLK 1 GND
CONFIG MODULE DATA 16 YEL 3 DATA SAFE 128 1P10001 NO. 1 GDU1040 PFD
CONFIG MODULE CLOCK 31 WHT 2 CLK PFD FAN
FAN FAIL 2 21007A22 21007A22 14 FAN MONITOR VALID
P2403 J2403 AHRS

0.499 20W LH MAIN
AIRCRAFT POWER 1 18 27 BUS GMA1347 P3472
34902E22 34902B22 34902A22 5A AUDIO PANEL
POWER GROUND 22 34903A22N 28 34903B22N REVERSIONARY MODE 1 36 31101A24WH 31101A24WH 58 REVERSIONARY MODE SEL 1
GS IP-5 REV MOD COMMON 1 37 31101A24BL 31101A24BL 38 AIRCRAFT GROUND
3.2
S S
53V GS AVB J2416 P2416 J2428 P2428 J2401 P2401
J441 P441 GMU44
MAGNETOMETER NO. 1 GIA63 1P603 P2413 J2413
RS 485 IN A 25 34701E24WH 7 34701D24WH 8 34701C24WH 8 34701B24WH 15 34701A24WH 4 RS 485 OUT A INTEGRATED AVIONICS
RS 485 IN B 39 34701E24BL 8 34701D24BL 9 34701C24BL 9 34701B24BL 21 34701A24BL 2 RS 485 OUT B ETHERNET IN B 77 31100A24WH 2 31100B24WH 3 ETHERNET OUT 1 B
9 RS 485 OUT B ETHERNET IN A 76 31100A24OR 1 31100B24OR 2 ETHERNET OUT 1 A
S 12 12 22 1
ETHERNET OUT B 3 31100A24GR 4 31100B24GR 5 ETHERNET IN 1 B
RS 232 OUT 2 10 34700E24WH 11 34700D24WH 4 34700C24WH 4 34700B24WH 5 34700A24WH 8 RS 232 IN 3
ETHERNET OUT A 2 31100A24BL 31100B24BL 4 ETHERNET IN 1 A
MAGNETOMETER POWER OUT 9 34700E24OR 13 34700D24OR 6 34700C24OR 6 34700B24OR 23 34700A24OR 9 +12VDC POWER
S 5 S
MAGNETOMETER GROUND 40 34700E24BL 12 34700D24BL 3 34700C24BL 3 34700B24BL 17 34700A24BL 6 POWER GROUND
S 14 7 7 16 3 LH MAIN PFD
E 0,5 , 25W
BUS E
5A 31105A22 31105B22 35 AIRCRAFT POWER 1
GS IP-11 CONFIG MODULE

012-00605-00 BLK
1P603 NO. 1 GIA63 GND 1 1 CONFIG MODULE GROUND
INTEGRATED AVIONICS VCC 4 RED 23 CONFIG MODULE POWER
ARINC 429 OUT 1 A 14 34904A24WH 14 MAIN ARINC 429 IN 6 A 3 YEL 22 CONFIG MODULE DATA
DATA
ARINC 429 OUT 1 B 29 34904A24BL 15 MAIN ARINC 429 IN 6 B 2 WHT 43 CONFIG MODULE CLOCK
CLK
S
GDC74 P741
RS 232 OUT 1 26 34905A24WH 56 MAIN RS 232 IN 6 AIR DATA
SIGNAL GROUND 41 34905A24BL 57 SIGNAL GROUND ARINC 429 OUT 3 A 32 31103A24WH 31103A24WH 16 ARINC 429 IN 2 A
RS 232 IN 1 11 34905A24OR 58 MAIN RS 232 OUT 6 ARINC 429 OUT 3 B 33 31103A24BL 31103A24BL 17 ARINC 429 IN 2 B
S S S
ARINC 429 OUT 2 A 13 34906A24WH ARINC 429 OUT 3 A 47 31151A24WH 31102A24BL 6 ETHERNET OUT 2 A
ARINC 429 OUT 2 B 28 34906A24BL ARINC 429 OUT 3 B 48 31151A24BL 31102A24GR 7 ETHERNET OUT 2 B
S S 31102A24OR 8 ETHERNET IN 2 A
RS 232 OUT 4 21 34907A24OR 31102A24WH 9 ETHERNET IN 2 B
SIGNAL GROUND 35 34907A24BL GRS77 P771 S
P2403 J2403
RS 232 IN 4 6 AHRS
34907A24WH
P2403 J2403 ARINC 429 OUT 3 A 12 31104A24WH 55 31104B24WH 18 ARINC 429 IN 1 A
S
ARINC 429 IN 1 A 15 34908A24WH 4
S 57 S
ARINC 429 IN 1 B 30 34908A24BL 5
D S 6
D
41 MAIN RS 232 IN 1 P2414 J2414
42 SIGNAL GROUND 2P10001 NO. 2 GDU1043/1045 MFD
43 MAIN RS 232 OUT 1 ARINC 429 OUT 3 A 33 31152A24WH 20 31152B24WH 18 ARINC 429 IN 1 A
GDC74 P741 22
S S
AIR DATA
ARINC 429 OUT 1 B 42 34908B24BL 31102A24WH 7 ETHERNET OUT 2 B
ARINC 429 OUT 1 A 41 34908B24WH 31102A24OR 6 ETHERNET OUT 2 A
J2413 P2413 31102A24GR 9 ETHERNET IN 2 B
S
31102A24BL 8 ETHERNET IN 2 A
ARINC 429 OUT 1 A 26 34909B24WH 31 34909A24WH 12 MAIN ARINC 429 IN 5 A
ARINC 429 OUT 1 B 27 34909B24BL 32 34909A24BL 13 MAIN ARINC 429 IN 5 B S
S 33 31151A24WH 16 ARINC 429 IN 2 A

GMA1347 P3472 31151A24BL 17 ARINC 429 IN 2 B
J2404 P2404 AUDIO PANEL
J3122 P3122 GTP 59 S
OAT PROBE REVERSIONARY MODE 2 56 31153A24WH 31153A24WH 58 REVERSIONARY MODE SEL 1
TEMP PROBE POWER OUT 2 31203C24WH 48 31203B24WH 1 31203A24WH POWER
REV MOD COMMON 2 57 31153A24BL 31153A24BL 38 AIRCRAFT GROUND
TEMP PROBE IN HI 3 31203C24BL 49 31203B24BL 2 31203A24BL SENSE
S S
TEMP PROBE IN LO 4 31203C24OR 50 31203B24OR 3 31203A24OR LOW
S 51 4
2P603 NO. 2 GIA63 57 CDU ID PROG 3

INTEGRATED AVIONICS NO. 2 GIA63 2P603 P2414 J2414
ADC 14 MAIN ARINC 429 IN 6 A INTEGRATED AVIONICS
0,5 , 25W
LH MAIN 15 MAIN ARINC 429 IN 6 B ETHERNET OUT A 2 31150A24WH 2 31150B24WH 4 ETHERNET IN 1 A
AIRCRAFT POWER 1 55 34900B22 34900A22 5A
C BUS ETHERNET OUT B 3 31150A24OR 1 31150B24OR 5 ETHERNET IN 1 B C
POWER GROUND 17 34901A22N ETHERNET IN A 76 4
31150A24GR 31150B24GR 2 ETHERNET OUT 1 A
GS IP-5 56 MAIN RS 232 IN 6 ETHERNET IN B 77 31150A24BL 3 31150B24BL 3 ETHERNET OUT 1 B
57 SIGNAL GROUND S 5 S
J2403 P2403 58 MAIN RS 232 OUT 6
ARINC 429 OUT 2 A 29 18 12 MAIN ARINC 429 IN 5 A MFD GS IP-13
34910B24WH 34910A24WH
19 0,5 , 25W
ARINC 429 OUT 2 B 30 34910B24BL 34910A24BL 13 MAIN ARINC 429 IN 5 B RH MAIN
BUS 5A 31155A22 31155B22 35 AIRCRAFT POWER 1
S 20
RS 232 OUT 1 11 34911B24OR 23 34911A24OR

AIRCRAFT GROUND 12 SAFE 128
34911B24BL 22 34911A24BL MFD FAN
RS 232 IN 1 10 34911B24WH 21 34911A24WH FAN FAIL 2 21006A22 21006A22 14 FAN MONITOR VALID
S 24
CONFIG MODULE OPTIONAL

BLK 012-00605-00
CONFIG MODULE GROUND 1 1 GND FLIR EVS3 P3445 J3445 P3444 J3444
YEL VIDEO 9 34453B179 34453A179 28 COMP VIDEO IN 1 HI
CONFIG MODULE DATA 40 3 DATA
WHT VIDEO GND 10
CONFIG MODULE CLOCK 60 2 CLK S
B POWER 2 1 P3443 J3443 P3442 J3442 B

POWER 3
AVIONIC
POWER, HEATER 12 1 34452A22WH 1 34450A22 2A
BUS
POWER GND 2 2 2 34452A22BL 2 34451A22N
POWER GND 4 3 3
POWER GND, HEATER 13
GS IP-7

Aircraft
Industries GmbH
Confidential
8 7 6 5 4 3 2 1
F F
GTX33
NO. 1 GIA63 MODE S XPDR
INTEGRATED AVIONICS OPTIONAL
2P612 P3302
XPDR ANTENNA
NO. 2 GIA63 COM ANTENNA 23290A400 34590A142
COUPLER
INTEGRATED AVIONICS
1P611
2P606
GPS ANTENNA 34690B142
34410A142
OPTIONAL REF 9900BX TAS
1P603 P3301
BECKER
AC 3504-(1)
MAIN RS 232 IN 5 53 34502A24WH 34502A24WH 23 RS 232 OUT 1
RMI CONVERTER
REF D60-9234-50-01 MAIN RS 232 OUT 5 55 34502A24BL 34502A24BL 22 RS 232 IN 1
P1
SIGNAL GROUND 54 34502A24OR 34502A24OR 51 SIGNAL GROUND
ADF X / COS 10 34202A22 17 ADF COS
S P2414 J2414 S
ADF Y / COS 11 34203A22 16 ADF SIN
ADF Z (GROUND) 12 CAN BUS 1 HI 20 77401E22WH 12 77401C22WH
REF D64-9277-40-02
S CAN BUS 1 LO 22 77401E22BL 13 77401C22BL
HONEYWELL 14
S
E KN 63 P2413 J2413 DME E
P1 DME P1 AVIONICS
MAIN KING SERIAL DME DATA 59 34306A24 6 DATA BUS A/C POWER 2 34302B22 13 34302A22 BUS 77408A22WH
3A
A/C POWER 3 77408A22BL
MAIN KING SERIAL DME CLK 60 34307A24 F CLOCK BUS A/C GROUND 1 34303B22N 14 34303A22N CAN BUS 2 TERMINATION S
39
A/C GROUND A CAN BUS 2 LO 30 77409A22BL
MAIN KING SERIAL DME REQ 62 34305A24 D DME REQUEST GS IP-14
CAN BUS 2 HI 32 77409A22WH
S REF GTX 33 XPDR 12 GROUND
1P604 S
34512A22 K SUPPRESSION
DISCRETE IN* 12 24 21005A22 REF D64-9221-20-01
P632
11 DME ON 1P613
ANTENNA 34390A142
NAV ANTENNA 34090A400
1P614 31 SUPPRESSION
REF KN 63 DME 34512A22
OPTIONAL G/S ANTENNA 34091A400
34424A22
BECKER
REF 9900BX TAS
RA 3502-(01)
2P603
ADF RECEIVER NO. 2 GIA63
P1 2P614
REF D60-9234-50-01 INTEGRATED AVIONICS
RS 485/422 OUT A 36 34200A24WH 13 RX-A 34191A400
34200A24BL 14 RX-B G/S ANTENNA
RS 485/422 OUT B 37
2P613
D S D
27 GROUND 34190A400
NAV ANTENNA
RS 485/422 IN A 27 34201A24WH 12 TX-A 2P603

XPDR J2413 P2413
RS 485/422 IN B 28 34201A24BL 31 TX-B CAN BUS 1 TERMINATION 34 LH MAIN
BUS 21 AIRCRAFT POWER 1
S CAN BUS 1 LO 22 77408A22BL 5A 34500B22 34 34500A22
CAN BUS 1 HI 20 77408A22WH 34501B22N 35 34501A22N 27 POWER GROUND
OPTIONAL
S
AVIDYNE TAS GS IP-14
P2403 J2403
P1 9900BX P1 AVIONICS 77409A22WH
22 AWG 22 RS-232 RX 3 TAS +28 VDC POWER 1 34420B22 2 34420A22 3A BUS 77409A22BL
N/C 20 RS-232 TX 3 +28 VDC POWER 2 S P2413 J2413
21 RS-232 GROUND 3 POWER GROUND 14 34421B22N 10 34421A22N
POWER GROUND 15 CAN BUS 2 HI 32 77405E22WH 25 77405C22WH REF D64-9277-40-03
N/C 25 RS-232 RX 4 POWER SWITCH 16 GS IP-1 CAN BUS 2 LO 30 77405E22BL 24 77405C22BL
N/C 23 RS-232 TX 4 48
SIGNAL GROUND 42 34422A24OR 24 RS-232 GROUND 4 J1
MAIN ARINC 429 IN 4 A 10 34422A24WH 8 429 TX+ NO RYAN DISPLAY 15 MAIN RS 232 IN 5 53 34503A24WH 25 RS 232 OUT 2
34503A24WH
MAIN ARINC 429 IN 4 B 11 34422A24BL 9 429 TX- GEAR POSITION 11 34427A22 REF D64-9232-00-01 MAIN RS 232 OUT 5 55 34503A24BL 34503A24BL 24 RS 232 IN 2
S WEIGHT ON WHEELS 14 34428A22 REF D64-9230-30-01 SIGNAL GROUND 54 34503A24OR 58 SIGNAL GROUND
34503A24OR
TOP ANTENNA S S
34423A24OR
J1 34411A142 2P612
C MAIN ARINC 429 OUT 1 A 71 34423A24WH 10 429 RX 1+ C
MAIN ARINC 429 OUT 1 B 70 34423A24BL 11 429 RX 1- COM ANTENNA 23390A400
J3 34413A142
S 2.2k , 0.25W BOTTOM ANTENNA 1P611
34424A22 7 SUPPRESSION J2 34412A142 GPS ANTENNA 34691B142
2P604 REF KN 63 DME OPTIONAL
J4 34414A142 J2403 P2403 GOODRICH WX-500
ANNUNCIATE* 15 38 5 REMOTE MUTE Wx 500
34425A22 J1 STORMSCOPE
34410A142 REF GTX 33 XPDR (COUPLER) AVIONICS
COUPLER 3A 34400B20WH 31 34400A20WH 1 AIRCRAFT POWER
22 AWG 19 RS-232 RX 2 BUS J3441
34400B20BL 32 34400A20BL 5 AIRCRAFT GROUND J2
N/C 17 RS-232 TX 2
34402A20N 33
18 RS-232 GROUND 2 X LOOP 3 ORANGE C
NO. 1 GIA63 GS IP-4
34426A22
INTEGRATED AVIONICS 1P604 +12V 16 RED D
2P603 J3 SENSE 17 BROWN B
ANNUNCIATE* 15 38 ANT REF 2 BLACK J
MAIN RS 232 IN 3 47 34404A24WH 20 RS 232 TX
MAIN RS 232 OUT 3 49 34404A24BL 8 RS 232 RX -12V 15 YELLOW F
SIGNAL GROUND 48 34404A24OR 3 TOP ANT. Y LOOP 4 GREEN G
ANT TEST 14 BLUE H
S
ANT COM 1 DRAIN A
J2
2P604
6 CONFIG. GROUND
DISCRETE IN* 12 24 21008A22 REF D64-9221-20-01 5 RS 232 GROUND
B GIA SYS ID PROGRAM 1 22 REF. SHEET 3 22 INHIBIT B

Aircraft
Industries GmbH
Confidential
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
RELAY REVISIONS
87A
30
87 new drawing
"-" all
86 85
32014A22 32041A22 REF D64-9227-50-01
F GEAR
+ - WARNING
P2415
32039A22
32035A22 32036A22 5
31320A22 REF D64-9231-60-01 P3202
32033B22N
J2414 32036B22 2 32036C22
GEAR WRN 23028B22 41 REF D64-9231-60-01 32037A22N 1 32037C22N S9
4 5 NC
ELEV LIMIT 32033A22N GS-IP-12
32014A22 L1 D1 C
2 1 NO
NOSE LDG GEAR DOWN THROTTLE
5A 27300A22 26104A22N 26102A22
REF D64-9231-60-01 SWITCHES
REF D64-9227-30-01 TEST 26103A22 32038A22 S1 S12 S10 NC
NOSE GS-IP-7 NC NC
32023A22 17 32023B22
C C C
32015A22 32015A22 16 32015B22 NO
NO NO
32016A22N 32016A22N 15 32016B22N
L2 D2
GS-IP-13 LH LDG GEAR DOWN
33032A22 S3
P2415 P2412
E REF D64-9233-10-07 LH NC
32023A22 47 32024B22 21 32024C22
C
32017A22 32017A22 48 32017B22 28 32017C22
NO
32018A22N 32018A22N 49 32018B22N 22 32018C22N
L
H L3 D3
GS-IP-5
M RH LDG GEAR DOWN
A S5
I RH NC
32023A22 50 32025B22 25 32025C22
N C
32019A22 32019A22 51 32019B22 26 32019C22
NO
B 32020A20N 32020A20N 52 32020B22N 20 32020C22N
U 34427A22
S GS-IP-6 REF D64-9231-60-01
D4 NOSE LDG GEAR UP
RELAY S2 NO
L4 87A C
32026A22 25 32026B22
NC
30 32027A22N 24 32027B22N
32021A22 32022A22
D 87
LH LDG GEAR UP
UNSAFE GS-IP-6
P2412 S4 NO
86 85
C
32026A22 53 32028B22 24 32028C22
NC
GEAR 32029A22N 54 32029B22N 23 32029C22N
UP
2 1
RH LDG GEAR UP
5A 32005A22 GS-IP-5
S6 NO
32006A22 C
32026A22 55 32030B22 19 32030C22
DOWN 3 NC
32007A22N 32031A22N 56 32031B22N 27 32031C22N
GS-IP-5
GS-IP-7
SQUAT SWITCH LH
32004A22
S7 NC
C
32008A20 32008A20 57 32008B20 15 32008C20
NO
6 32010B20 16 32010A20
C P2402 P3203
32010C20 6 32010D20 1
Pos. 18
(bottom)
RL5
HYDRAULIC
RELAY
PUMP 1
EMERGENCY
RELEASE SWITCH A1 A2
REF D64-9224-30-01 32000A10 32001A10 32010E20 32009A20N
P2402 P3203 S11 NC
M
1 32011A20
C
32004A22 40 32004B22 3 32004C22 32004D22 3 X1 X2
NO
32002A22 32003A22N GS-HP
32004A22N
2
GS-HP Pos. 17
GS-HP (top)
GS-HP
B NOSE LDG GEAR UP 32011A20 32012D20

S8 NC P2415 P2402 P3203
C
32012A20 44 32012B20 21 32012C20 2 32012D20
NO
32013A20N 45 32013B20N
GS-IP-5
I S O 2768
1. WIRING SHOWN WITH LANDING GEARS DOWN AND LOCKED, THROTTLE ON IDLE AND NOT POWERED.
Date Name Date Name
NTS
2. S1, S3, S5, S12 CLOSED WHEN LANDING GEARS DOWN AND LOCKED, S7 OPENED WHEN AIRPLANE ON GROUND, Next Higher Assembly :
S2, S4, S6 OPENED WHEN LANDING GEARS UP AND LOCKED, S7 CLOSED WHEN AIRPLANE AIRBORN.
Title :
D64-9200-00-00
S8 OPENED WHEN NOSE LANDING GEAR DOWN, S8 CLOSED WHEN NOSE LANDING GEAR UP. Schematic, Landing Gear
S9 AND S10 CLOSED WHEN BOTH POWER LEVERS ARE IN IDLE POSITION.
A Diamond
AIRCRAFT
Industries GmbH
3. TEST SWITCH WIRED NORMALLY OPEN.
DA42 NG

D64-9232-00-01.dft
8 7 6 5 4 3 2 1
REVISIONS
"-" all new drawing
LH MAIN BUS
EMERGENCY FLOOD
FLOOD SWITCH OFF
E OXY
33204B22 DIMMING
ON
5A 33204A22 CONTROL
J3305 P3305
33207A22 1 RED SWITCHED D.C. IN
5kΩ
33208A22N 2 BLK GROUND
REF. D64-9225-60-01
GS-IP-13
33211A22 5 YL ADJ
33212A22 6 YL ADJ
D 33210A22 4 WH LAMP
33209A22 3 WH LAMP
J3307
1 2
P3307
ELECTROLUMINESCENCE
LAMP

I S O 2768
Date Name Date Name
NTS
Title :
D64-9200-00-00
Schematic, Flood Light
A Diamond
AIRCRAFT
Industries GmbH

DA42 NG

D64-9233-10-01.dft
REVISION
VÄM 42-004
- 01 ALL 14.07.08 SEE TB
FIRST RELEASE
F OÄM 42-171 F
18.05.09 SEE TB
A 01 E-2 corrected J3308 in J3337
E-3 changed REF to D64-9231-60-0x
TERMINAL BLOCK
33050A22 1
33004B22
V IN
V OUT 2 33011A22
REGULATOR REF D64-9231-60-0x

LM 138K 33000B22
3 EMERGENCY
300 33002B22 J3337 P3337 COMPASS
E E
4 33001A22 1 BLK LIGHTING
33003A22N 2 BLK LIGHTING
INSTRUMENT V ADJ 5
RH MAIN BUS GS-IP 3 OXYGEN PESSURE
OFF
J3309 P3309 GAUGE
33051A22 6 33026A22 REF D64-9227-50-02
33005A22 1 WH
INST LT ON 33032A22 REF D64-9232-00-01
33006A22N 2 BLK
NAV LT
OPTIONAL
3A 33048A22 33049A22
5k DE-ICE BACKUP CIRCUIT SWITCH RH SWITCH TOP
PANEL INSTR. BREAKER
D DIMMING LIGHT D
R5 CONTROL
LOCAL J3306 P3306 J3333 J3330 J3332 J3336
1 2 J3338 2 1 2 1 1 2 2 1
33047A22 1 RED SWITCHED D.C. IN
5k
33042A22N 2 BLK GROUND
GS-IP-15 33061A22 33058A22 33045A22 33044A22

33060A22 33059A22 33046A22 33043A22
33021A22 5 YL ADJ
33022A22 6 YL ADJ SWITCH LH
33057A22 4 WH LAMP
C 33056A22 3 WH LAMP J3331 C
1 2
33056A22 33055A22
33057A22 33054A22
B B
Industries GmbH
A3
N ON E CHECKED:
Schematic, Dimming
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Regulator & Plac ards
2 DECIMAL u0,25
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D64-9 2 3 3 -1 0 -0 7 A
ANGLE u1° MICRO-
710197 NTS 01 01
Confidential
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
REVISIONS
"-" all new drawing
"A" E7 corrected pinout of P2418

F
FRONT BAGGAGE COMPARTMENT INSTRUMENT PANEL RIGHT FUSELAGE
J2418 P2418
J2404 P2404
PILOT MAP LIGHT
J3320 P3320
REF D64-9224-30-01 33200A22 A 33200B22 33200B22 20 33200C22 33200C22 1
33201A22N 21 33201B22N 33201B22N 2
GS-IP-12 CO-PILOT MAP LIGHT

J3321 P3321
33202A22 18 33202B22 33202B22 1
33203A22N 11 33203B22N 33203B22N 2
GS-IP-12 PASSENGER READING LIGHT

D
33202B22 TAXI / MAP
ACL
REF D64-9233-40-01 33115A20 5
LH MAIN BUS
REF D64-9233-40-01 33113A20

I S O 2768
Date Name Date Name
NTS
Title :
D64-9200-00-00
Schematic, Map/Reading
A Diamond
AIRCRAFT
Lights
Industries GmbH

"A" VÄM 42-004 13.08.08 Kowarsch
DA 42 NG
D64-9233-20-01 from 1

D64-9233-20-01a.dft
REVISION
OÄM 42-193
- 01 ALL 14.04.11 SEE TB
FIRST RELEASE
F F
FRONT BAGGAGE COMPARTMENT INSTRUMENT PANEL RIGHT FUSELAGE
E E
J2418 P2418
J2404 P2404
PILOT MAP LIGHT
J3320 P3320
REF D64-9224-30-01_01 33200A22 A 33200B22 33200B22 20 33200C22 33200C22 1
33201A22N 21 33201B22N 33201B22N 2
GS-IP-12 PASSENGER READING LIGHT

J3321 P3321
33202A22 18 33202B22 33202B22 1
33203A22N 11 33203B22N 33203B22N 2
GS-IP-12
D D
33202B22 TAXI / MAP
ACL
REF D64-9233-40-01 33115A20 5
LH MAIN BUS
REF D64-9233-40-01 33113A20
C C
B B
Industries GmbH
A3
N ON E CHECKED:
Schematic, Map/Reading
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Light Wiring, RACC
2 DECIMAL u0,25
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D64-9 2 3 3 -2 0 -0 1 x 0 1 "-"
ANGLE u1° MICRO-
710197 NTS 01 01
Confidential
8 7 6 5 4 3 2 1
F F
NAV LIGHT ASSY L/H WING L/H NACELLE LEFT FUSELAGE INSTRUMENT PANEL RIGHT FUSELAGE
LH MAIN
BUS
SW11
GS-RP
P2400 J2400
P3312 TAXI/MAP
STROBE LIGHT 33113A20 5
P2421 J2421 STROBE
ACL
2 2
P2402 J2402 J2404 P2404
BLACK 33104D20BL 2 33104A20N
POWER
RED 1 1 33104D20WH 1 33104C20WH 55 33104B20WH 55 33104A20WH 33109A20WH 55 33109B20WH
SUPPLY
WHITE 3 3 33104D20OR 3 33104C20BL 56 33104B20BL 56 56 33109B20BL
4 57 57 GS-IP-17 57
J2419 33117A22
P2419
E P3332 J3332 39 / 15W J3330 33121D20 52 33121C22 E
DE-ICE LIGHT
1 1 33120A22 1 33120B22 53 33120C22 ICE LIGHT
2 22AWG 2 33123A22N 2 33123B22N 13 33120D20 REF D64-9230-40-01
REF D64-9230-40-01
NAV LIGHT
GS-RP
P3313 J3313 28 33100C20 SW10
INST LT. RH MAIN
RED bl 48 33100B20 48 33100A20 33114A20 5
rd 1 33100D20 33 33101C20N NAV LT. BUS
POSITION
bl 33102A20 42 33102B20
WHITE bk 2 33101D20N
GS-RP 33102A20
CENTRE FUSELAGE
SW9
P2415 J2415 TAXI/MAP LH MAIN
P3316 J3316 33115A20 5
TAXI ACL BUS
TAXI 1 33107B20 1 33107A20
2 33108B20N 2 33108A20N 33108A20N

LANDING GS-IP-17
D 1 33105B20 9 33105A20 D
SW8
2 33106B20N 10 33106A20N 33116A20 5 LDG LT. RH MAIN

LANDING START BUS
P3317 J3317
33106A20N
GS-IP-18
NAV LIGHT ASSY R/H WING R/H NACELLE
NAV LIGHT
P2401 J2401
P2422 J2422
P3315 J3315 GS-RP
WHITE bl
bk 2 33103D20N 7 33103C20N
bl
rd 1 33102D20 6 33102C20 33102C20 42 33102B20
GREEN
P2420 J2420
C P3333 J3333 39 / 15W P3331 J3331 C
DE-ICE LIGHT
1 1 33121A22 1 33121B22 53 33121C22
STROBE LIGHT P3314 GS-RP 33122B22N
2 22AWG 2 33122A22N 2
BLACK 2 2 33109D20BL 2 33109A20N GS-RP
POWER
WHITE 3 3 33109D20OR 3 33109C20BL 33109C20BL 56 33109B20BL
SUPPLY
RED 1 1 33109D20WH 1 33109C20WH 33109C20WH 55 33109B20WH
4 57
B B
Industries GmbH
REVISION
REV SH ZONE DESCRIPTION DATE APPROVAL FIRST ANGLE PROJECTION FORMAT DA 42 N G
CLASSIFICATION: - DRAWN TITLE
VÄM 42-004
- 01 ALL FIRST RELEASE 14.07.08 R. Zeillinger A3
N ON E CHECKED:
VÄM 42-004 Schematic, Exterior
A 01 ALL 12.08.08 R. Zeillinger
CORRECTED ICE-LIGHTS WIRE GAUGES UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Lighting
OÄM 42-053/j DIMENSIONS ARE IN MM
C4 REMOVED R/H DE-ICE LIGHT 3.2 THIS DRAWING WAS PRODUCED USING STRESS: N/A
B 01 E3-E2 REMOVED DE-ICE LIGHT RESISTORS 04.05.09 R. Zeillinger DIMENSION TOLERANCES
A E6-E5 ADDED RESISTOR AND CONNECTOR SOFTWARE: SOLID EDGE V18 MANUF.: N/A DWG.ORIG. DWG.NO. REV A
2 DECIMAL u0,25
J3332 FOR L/H DE-ICE LIGHT 1DECIMAL u0,5 FINISH
OÄM 42-053/o DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D64-9 2 3 3 -4 0 -0 1 C
C 01 C4 ADDED R/H DE-ICE LIGHT, RESISTOR 14.12.09 SEE TB ANGLE u1° MICRO-
AND CONNECTOR J3333 RAD u0,5 METER D64-9233-40-01C.dft APPROVED: CODE SCALE SH OF
710197 NTS 01 01
Confidential
8 7 6 5 4 3 2 1
REVISION
OÄM 42-222
- 01 ALL 14.11.13 SEE TB
FIRST RELEASE
F F
LH WING
LH LED POS/ACL
LIGHT ASSEMBLY
POS/ACL P3312 J2400
ACL PWR WH 1 33104E20WH 1 33104D20WH 1
GND BLK 2 33104E20BL 2 33104D20BL 2
E SYNC YEL 3 33104E20OR 3 33104D20OR 3 E
4
REF D64-9233-40-01_01
J3313
POS. PWR OR 4 33100E20 1 33100D20 28
2 33101D20N 33
D D
RH WING
RH LED POS/ACL
LIGHT ASSEMBLY J3315 J2401
POS/ACL 2 33103D20N 7
POS. PWR OR 4 33102E20 1 33102D20 6
P3314 REF D64-9233-40-01_01

C SYNC YEL 3 33109E20OR 3 33109D20OR 3 C
GND BLK 2 33109E20BL 2 33109D20BL 2
ACL PWR WH 1 33109E20WH 1 33109D20WH 1

4
B B
Industries GmbH
A3
N ON E CHECKED:
Schematic, LED Posit ion /
Ant i-Collision Lights
2 DECIMAL u0,25
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D64-9 2 3 3 -4 0 -0 1 x 0 1 "-"
ANGLE u1° MICRO-
710197 NTS 01 01
Confidential
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
REVISIONS
"-" all new drawing
D64-9225-60-01
REF.
RH MAIN BUS
24303B20 33204B22
33204A22
J3490
AH 34903B22 C
BACKUP
D
D 34903A22 34904A22N A
ARTIFICIAL
3A
B HORIZON
GS-IP-13

I S O 2768
Date Name Date Name
NTS
Title :
D64-9200-00-00
Schematic, Attitude
A Diamond
AIRCRAFT
Gyro
Industries GmbH

DA42 NG

D64-9234-10-01.dft
REVISION
OÄM 42-270
- 01 ALL NEW DRAWING, DOES NOT SUPERSEDE
03.07.14 SEE TB
F ANOTHER DRAWING. F
E REF. E
D64-9225-60-01
RH MAIN BUS
24303B20 33204B22
33204A22
J3490
AH 34903B22 1
34904A22N 6
3A 34903A22
GS-IP-13
STANDBY
D D
ATTITUDE
TP1 15 MODULE
CONFIG. TP2 14
MODULE TP3 10
TP4 5
C C
B B
Industries GmbH
A3
NONE CHECKED:
Schematic, MD302
2 DECIMAL u0,25
ANGLE u1° MICRO-
RAD u0,5 METER D64-9234-10-02.dft APPROVED: N/A CODE SCALE SH OF
710197 NTS 01 01
Confidential
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
REVISIONS
"-" all new drawing
R J3491
H
1A 34905A22 A
STANDBY
M C
D A 34906A22N B
DRUM
I ALTIMETER
N GS-IP
B
U
S

I S O 2768
Date Name Date Name
NTS
Title :
D64-9200-00-00
Schematic, Drum
A Diamond
AIRCRAFT
Altimeter
Industries GmbH

DA42 NG

D64-9234-20-01.dft
REVISION
OÄM 42-119
- 01 ALL 23.11.12 SEE TB
FIRST RELEASE
F F
E E
P3447 J3447
GWX 68 P400 2P10001 MFD GDU 104X
ETHERNET IN A 34 34442B24WH 4 34442A24WH 10 ETHERNET OUT 3 A

ETHERNET IN B 35 34442B24OR 5 34442A24OR 11 ETHERNET OUT 3 B
ETHERNET OUT A 36 34442B24GR 6 34442A24GR 12 ETHERNET IN 3 A
ETHERNET OUT B 37 34442B24BL 7 34442A24BL 13 ETHERNET IN 3 B
S 8 S
Wx RDR
D D
A/C POWER 1 7 34440B22 1 34440A22 5A AV BUS
A/C POWER GND 13 34441B22N 9 34441A22N

A/C POWER GND 15
REMOTE POWER OFF 44 GS-IP 7
C C
B B
Industries GmbH
A3
NONE CHECKED:
Schematic, GWX 68
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Weather Radar Wiring
2 DECIMAL u0,25
ANGLE u1° MICRO-
710197 NTS 01 01
Confidential
8 7 6 5 4 3 2 1
REVISION
OÄM 42-273
- 01 ALL 12.09.14 SEE TB
FIRST RELEASE
F F
E E
P3447 J3447
GWX 70 P751 2P10001 MFD GDU 104X
ETHERNET IN A 4 34442B24WH 4 34442A24WH 10 ETHERNET OUT 3 A

ETHERNET IN B 3 34442B24OR 5 34442A24OR 11 ETHERNET OUT 3 B
ETHERNET OUT A 23 34442B24GR 6 34442A24GR 12 ETHERNET IN 3 A
ETHERNET OUT B 22 34442B24BL 7 34442A24BL 13 ETHERNET IN 3 B
S 8 S
Wx RDR
D A/C POWER 1 18
D
A/C POWER 1 20 34440B22 1 34440A22 5A AV BUS
Wiring
A/C POWER GND 8 34441B22N 9 34441A22N
REMOTE POWER OFF 56
GS-IP 7
Weather Radar
Schematic, GWX 68
C C
B B
Industries GmbH
A3
NONE CHECKED:
Schematic, GWX 70
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A Weather Radar Wiring
2 DECIMAL u0,25
ANGLE u1° MICRO-
710197 NTS 01 01
Confidential
8 7 6 5 4 3 2 1
REVISION
VÄM 42-004
- 01 ALL 14.07.08 SEE REV. "-"
FIRST RELEASE
F MÄM 42-373, CORRECTED CO-AX F
A 01 ALL 11.08.09 SEE TB
WIRE NUMBER, NEW STANDARD.
BECKER
RA 3502-(01)
ADF RECEIVER P2 P2413 J2413 ADF
AVIONICS
SUPP. VOLT. +28VDC 18 34204B22 21 34204A22 2A BUS
SUPP. VOLT. +28VDC 36 34205B22N 22 34205A22N
GROUND 4
GS IP-8
AUDIO OUT HI 2 34206B24WH
AUDIO OUT LO 3 34206B24BL
RX-A 13 34200A24WH
REF D64-9231-60-01
RX-B 14 34200A24BL
TX-A 12 34201A24WH
E BECKER E
TX-B 31 34201A24BL
AN 3500
P1 ADF ANTENNA
GROUND 27
ON 11 G OP. VOLT. +18VDC
OP. VOLT. +18VDC 1 34207A22 34207A22 H OP. VOLT. +18VDC
GROUND 23 34208A22 34208A22 K GROUND
+ADF 16 34209A22 34209A22 C +ADF
+18V 20 34210A22
C-CONTROL 34 34211A22
SUPP. VOLT. +28VDC SWITCHED 37 34212A22
/AUDIO NAV 32 34213A24WH 34215A24WH A 50 HZ

AUDIO NAV 33 34213A24BL 34215A24BL B 100 HZ
J MOD GROUND
GROUND 29 34214A22N
J9
ANTENNA 34290A400 34290A400 E RF HI
D F RF GND D
BECKER
AC 3504-(1)
RMI CONVERTER P1
SUPP. VOLT. +28VDC 11 34204C22
SUPP. VOLT. +28VDC 24
GROUND 21 34214A22N
AUDIO NAV 3 34213A24BL

/AUDIO NAV 4 34213A24WH
SUPP. VOLT. +28VDC SWITCHED 12 34212A22

C-CONTROL 10 34211A22
+18V 6 34210A22
+ADF 5 34209B22
C C
/50 HZ 8 34215A24WH
100 HZ 9 34215A24BL
GROUND 20
ADF SIN 16 34203A22

REF D64-9231-60-01
ADF COS 17 34202A22
B B
Industries GmbH
A3
N ON E CHECKED:
Schematic, ADF
2 DECIMAL u0,25
DECIMAL u1 IN FILENAME SYSTEM: N/A DAI A D64-9 2 3 4 -5 0 -0 1 "A"
ANGLE u1° MICRO-
RAD u0,5 METER D64-9234-50-01a.dft APPROVED: CODE SCALE SH OF
710197 NTS 01 01
Confidential
8 7 6 5 4 3 2 1
REVISION
MÄM 42-366
- 01 ALL 15.06.09 SEE TB
FIRST RELEASE
F F
INSTRUMENT PANEL LH ENGINE NACELLE LH ENGINE COMPARTMENT

TB
J6123
ECU A 1 2A 39Ω / 25W FEATHER
61211A22 1 61211B22 61213A22 RELAY LH
ECU B 2 2A
87A P6123 CPC 2
30
61215A22 3 61215B22 1 1
87 GOVERNOR LH
E 61217A22 61217A22 2 E
J6123
47000µF / 40V 85
86
2 61207D22 61209A22N
FUSELAGE LH 61219A22N
ENGINE MASTER LH GS-RP

GS-RP
OFF J2402 J2421
2A 61207A22 J2419
7 61207B22 7 61207C22
ON
24360A20 2A 61201A22 4 61201B22 45 61201C22 61201C22 18 61201D22 J6121
10 61202B22 46 61202C22 61202C22 19 61202D22 1 UNFEATHERING
61203B22N 61203B22N 24 61203A22N 2 VALVE LH
REF D64-9277-40-02
OFF
2A
GS-RP
D ON D
24363A20 2A 61202A22
RH ENGINE NACELLE RH ENGINE COMPARTMENT

TB
J6124
ECU A 1 2A 39Ω / 25W FEATHER
61212A22 1 61212B22 61214A22 RELAY RH
ECU B 2 2A
87A P6124 CPC 2
30
61216A22 3 61216B22 1 1
87 GOVERNOR RH
61218A22 61218A22 2
J6124
47000µF / 40V 85
86
2 61208D22 61210A22N
FUSELAGE RH 61220A22N
C ENGINE MASTER RH GS-RP
C
GS-RP
OFF J2404 J2422
2A 61208A22 J2420
7 61208B22 7 61208C22
ON
24370A20 2A 61204A22 46 61204B22 46 61204C22 61204C22 18 61204D22 J6122
47 61205B22 47 61205C22 61205C22 19 61205D22 1 UNFEATHERING
61206B22N 61206B22N 24 61206A22N 2 VALVE RH
REF D64-9277-40-03
OFF
2A
GS-RP
ON
24373A20 2A 61205A22
B B
Industries GmbH
CLASSIFICATION: - DRAWN Kowarsch 15.06.09 TITLE
A3
NONE CHECKED: Kowarsch Schematic, Feathering
UNLESS OTHERWISE SPECIFIED INTERCHANGEABLE PART NO QA: N/A System
2 DECIMAL u0,25
ANGLE u1° MICRO-
RAD u0,5 METER D64-9261-20-01_01.dft APPROVED: Zeillinger CODE 710197 SCALE SH 01 OF 01
NTS
Confidential
8 7 6 5 4 3 2 1
REVISION
01 MÄM 42-388
"-" 02 ALL 07.09.09 SEE TB
FIRST RELEASE
F F
INSTRUMENT PANEL FUSELAGE ENGINE NACELLE EMI FILTER ENGINE HARNESS

J2423 (OPTIONAL WITH ADF)
CPC 1 CPC 1
1 77402B22OR 1 77402A22OR 1 1 Sensor Supply
POWER 4 77402B22WH 4 77402A22WH 5 5 Sensor Signal
LEVER 2 77402B22BL 2 77402A22BL 6 6 Sensor GND
SENSOR 6 77420B22OR 6 77420A22OR 2 2 Sensor Supply
ECU A 3 77420B22WH 3 77420A22WH 4 4 Sensor Signal
5 77420B22BL 5 77420A22BL 3 3 Sensor GND
E E
22 AWG
J3205
VOTER LH
32050A22 1 32050B22 20 20 A/C on Ground
9
8
REF D64-9230-30-01
30 30 A/C on Ground
7
ECU 12
TEST LH 11 J2417 J2427
22 AWG 24321A22WH 6 24321B22WH 6 24321C22WH 13 13 Selftest Signal
10
24321A22BL 7 24321B22BL 7 24321C22BL 14 14 Selftest GND
8 8
ENGINE MASTER LH OFF REF D64-9261-20-01
ECU A
2A
ON
7.5 24360A20 24361A22 10 24361B22 10 24361C22 11 11 Engine Master
L
H 24362A22 12 24362B22 12 24362C22 12 12 Engine Master
74010A22 14 74010B22 14 74010C22 31 31 Glow Enable
D E REF SHEET 2 2A
D
C
REF D64-9261-20-01 24327A20 17 17 ECU A Power Supply
U
5 24300B14 5 24300C14 1 24328A20 18 18 ECU A Power Supply
ECU A
B 24329A20 19 19 ECU A Power Supply
U 20 24300A14
S REF D64-9231-60-01 31005A22 2 31005B22 2 31005C22 29 29 GPC Annun. Lamp
74015A22N
4.7k
24342A20N 21 21 ECU A GND

GS-RP 24343A20N 22 22 ECU A GND
24344A20N 23 23 ECU A GND
GS-RP
74011A16 25 25 GPC Power Supply

C REF D64-9224-30-01 24004B4 50A 74012A16 26 26 GPC Power Supply
C
J2402 J2421
77401C22BL 2 77401B22BL 2 77401A22BL 7 7 CAN Low
REF D64-9231-60-01
77401C22WH 1 77401B22WH 1 77401A22WH 8 8 CAN High
3 3 4.7k
DIAGNOSTIC
74016A22N 32 32 GPC Caution Lamp
2 77401CC22BL
7 77401CC22WH GS-RP
B B
Industries GmbH
A3
N ON E CHECKED: K owarsch Schematic, LH ECU
2 DECIMAL u0,25
ANGLE u1° MICRO-
710197 NTS 01 02
Confidential
8 7 6 5 4 3 2 1
F INSTRUMENT PANEL FUSELAGE ENGINE NACELLE EMI FILTER ENGINE HARNESS F

CPC 2 CPC 2
ECU B 3 77421B22WH 10 77421A22WH 10 10 Sensor Signal
22 AWG
3
2 J2417 J2427
E 23 23 E
1
24325A22BL 24 24325B22BL 24 24325C22BL 15 15 ECU A
6
5 24325A22WH 25 24325B22WH 25 24325C22WH 16 16 ECU B
24322A22WH 29 24322B22WH 29 24322C22WH 13 13 Voter
4
24322A22BL 30 24322B22BL 30 24322C22BL 14 14 Signal Input
VOTER LH
31 31
GS-IP 5A 51802A20
OFF REF D64-9261-20-01
ECU B ENGINE MASTER LH 2A
ON
24365A22 17 24365B22 17 24365C22 18 18 Engine Master
2A
REF SHEET 1 REF D64-9261-20-01
24333A20 23 23 ECU B Power Supply
L 9 24301B14 9 24301C14 2 24334A20 24 24 ECU B Power Supply
D H 51801A10 24335A20 25 25 ECU B Power Supply D
E
C
U 24346A20N 27 27 ECU B GND
ECU B
24347A20N 28 28 ECU B GND
B 20 24301A14 24348A20N 29 29 ECU B GND
U 24349A20N 30 30 ECU B GND
GS-RP
S
GS-RP 28039A22 3 3 Fuel Pump Output B

28038A22 2 2 Fuel Pump Output A
FUEL PUMP A
FUEL RELAY LH LH FUEL
PUMP A 87A PUMP A
J2805
30
7.5 28030A20 21 28030B20 21 28030C20 28031A20 1 28031B20
87
22 22
28034A20N 2 28034B20N
GS-IP-17 86 85
C C
GS-RP
FUEL PUMP B
FUEL RELAY LH LH FUEL
PUMP B 87A PUMP B
J2806
30
7.5 28032A20 27 28032B20 27 28032C20 28033A20 1 28033B20
87
28 28
28035A20N 2 28035B20N
GS-IP-22 86 85
GS-RP
B OFF B
ON
28036A22N 28037A22 4 28037B22 4 28037C22
FUEL PUMPS LH
GS-IP-3

Aircraft
Industries GmbH
Schematic, LH ECU DAI A D64-9 2 7 7 -4 0 -0 2_01 "-"
Diamond Aircraft Industries A-2700 Wiener Neustadt CODE 710197 SCALE 1:1 SH 02 OF 02
Confidential
8 7 6 5 4 3 2 1
REVISION
01 MÄM 42-388
"-" 02 ALL 07.09.09 SEE TB
FIRST RELEASE
F F

P2425 (OPTIONAL WITH ADF)
CPC 1 CPC 1
E 22 AWG
E
J3206
VOTER RH
32051A22 1 32051B22 20 20 A/C on Ground
9
8
REF D64-9230-30-01
30 30 A/C on Ground
7
ECU 12
TEST RH 11 J2416 J2428
10
36 36
ENGINE MASTER RH OFF REF D64-9261-20-01
ECU A
2A
ON
R
74020A22 33 74020B22 33 74020C22 31 31 Glow Enable
E REF SHEET 2 2A
D C
17 17
D
REF D64-9261-20-01 24336A20 ECU A Power Supply
U
1 24302B14 1 24302C14 1 24337A20 18 18 ECU A Power Supply
ECU A
B 24338A20 19 19 ECU A Power Supply
U 20 24302A14
S REF D64-9231-60-01 31007A22 2 31007B22 2 31007C22 29 29 GPC Annun. Lamp
74025A22N
24350A20N 21 21 ECU A GND

24352A20N 23 23 ECU A GND
GS-RP

C REF D64-9224-30-01 24004B4 50A 74022A16 26 26 GPC Power Supply C
J2404 J2422
REF D64-9231-60-01
3 3 4.7k
DIAGNOSTIC
2 77405CC22BL
7 77405CC22WH GS-RP
B B
Industries GmbH
A3
N ON E CHECKED: K owarsch Schematic, RH ECU
2 DECIMAL u0,25
ANGLE u1° MICRO-
710197 1:1 01 02
Confidential
8 7 6 5 4 3 2 1

P2425 (OPTIONAL WITH ADF)
F CPC 2 CPC 2
F
22 AWG
3
2 J2416 J2428
23 23
1
24326A22BL 24 24326B22BL 24 24326C22BL 15 15 ECU A
6
5 24326A22WH 25 24326B22WH 25 24326C22WH 16 16 ECU B
E E
24324A22WH 29 24324B22WH 29 24324C22WH 13 13 Voter
4
VOTER RH
31 31
GS-IP 5A 51804A20
OFF REF D64-9261-20-01
ECU B ENGINE MASTER RH 2A
ON
2A
REF SHEET 1 REF D64-9261-20-01
24339A20 23 23 ECU B Power Supply
R 14 24303B14 14 24303C14 2 24340A20 24 24 ECU B Power Supply
H 51803A10 24341A20 25 25 ECU B Power Supply
E
D C D
U 24354A20N 27 27 ECU B GND
ECU B
24355A20N 28 28 ECU B GND
B 20 24303A14 24356A20N 29 29 ECU B GND
U 24357A20N 30 30 ECU B GND
GS-RP
S
GS-RP 28049A22 3 3 Fuel Pump Output B

28048A22 2 2 Fuel Pump Output A
FUEL PUMP A
FUEL RELAY RH RH FUEL
PUMP A 87A PUMP A
J2807
30
7.5 28040A20 21 28040B20 21 28040C20 28041A20 1 28041B20
87
22 22
28044A20N 2 28044B20N
GS-IP-11 86 85
GS-RP
C C
FUEL PUMP B
FUEL RELAY RH RH FUEL
PUMP B 87A PUMP B
J2808
30
7.5 28042A20 27 28042B20 27 28042C20 28043A20 1 28043B20
87
28 28
28045A20N 2 28045B20N
GS-IP-22 86 85
GS-RP
OFF
ON
B 28046A22N 28047A22 20 28047B22 20 28047C22 B
FUEL PUMPS RH
GS-IP-1

Aircraft
Industries GmbH
Schematic, RH ECU DAI A D64-9 2 7 7 -4 0 -0 3_01 "-"
Diamond Aircraft Industries A-2700 Wiener Neustadt CODE 710197 SCALE 1:1 SH 02 OF 02
Confidential
8 7 6 5 4 3 2 1
REVISION
MÄM 42-403
- ALL ALL 27.11.09 SEE TB
FIRST RELEASE
F F

CPC 1 CPC 1
E E
22 AWG
J3205
VOTER LH
32050A22 1 32050B22 20 20 A/C on Ground
9
8
REF D64-9230-30-01
30 30 A/C on Ground
7
ECU 12
TEST LH 11 J2417 J2427
10
8 8
ENGINE MASTER LH OFF REF D64-9261-20-01
2A
ON
24360A20 24361A22 10 24361B22 10 24361C22 11 11 Engine Master
L
5A
74010A22 14 74010B22 14 74010C22 31 31 Glow Enable
D H 2A
D
ECU A
E REF D64-9261-20-01 24327A20 17 17 ECU A Power Supply
C 20 24300A14 5 24300B14 5 24300C14 1 24328A20 18 18 ECU A Power Supply
U 24329A20 19 19 ECU A Power Supply
A
REF D64-9231-60-0X 31005A22 2 31005B22 2 31005C22 29 29 GPC Annun. Lamp
B 74015A22N
U 4.7k
S 24342A20N 21 21 ECU A GND
24344A20N 23 23 ECU A GND
GS-RP

C REF 50A 26 26
C
24004B4 74012A16 GPC Power Supply
D64-9224-30-01_01 27 27
74013A16 GPC Power Supply
J2402 J2421
REF D64-9231-60-0X
3 3 4.7k
DIAGNOSTIC
2 77401CC22BL
7 77401CC22WH GS-RP
B B
Industries GmbH
A3
N ON E CHECKED: K owarsch Schematic, LH ECU
2 DECIMAL u0,25
ANGLE u1° MICRO-
710197 NTS 01 02
Confidential
8 7 6 5 4 3 2 1
F INSTRUMENT PANEL FUSELAGE ENGINE NACELLE EMI FILTER ENGINE HARNESS F

CPC 2 CPC 2
22 AWG
3
2 J2417 J2427
E 23 23 E
1
24325A22BL 24 24325B22BL 24 24325C22BL 15 15 ECU A
6
5 24325A22WH 25 24325B22WH 25 24325C22WH 16 16 ECU B
24322A22WH 29 24322B22WH 29 24322C22WH 13 13 Voter
4
VOTER LH
31 31
GS-IP 5A 51802A20
OFF REF D64-9261-20-01
ENGINE MASTER LH 2A
ON
L 24363A20 24364A22 16 24364B22 16 24364C22 17 17 Engine Master

DA42 NG AMM r5

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AIRCRAFT

AIRPLANE MAINTENANCE MANUAL

Copyright © by DIAMOND AIRCRAFT INDUSTRIES, Wiener Neustadt, Austria

Diamond Aircraft Industries GmbH

Doc # 7.02.15 Page i

20-00 Standard Practices

Page ii Doc # 7.02.15

Doc # 7.02.15 Page iii

Page iv Doc # 7.02.15

Revision Date Inserted Inserted Revision Date Inserted Inserted

Original 18 Feb 2009

Doc # 7.02.15 Page v

2. Record of Incorporated Temporary Revisions

Temporary Revision Number Description of Temporary Revision

AMM-TR-OÄM-42-142 Sun Visors for Tall Canopy

AMM-TR-MÄM-42-353 Removal of Check Valves in Nacelle

AMM-TR-MÄM-42-357 Limitation Placard

AMM-TR-MÄM-42-364 Gear Up Landing Check

AMM-TR-MÄM-42-366 Change of the Resistor for the Feathering System

AMM-TR-MÄM-42-388 Isolationdiodes for ECU

Temporary Revision Number Description of Temporary Revision

AMM-TR-MÄM-42-319 Main Landing Gear Measurement

AMM-TR-MÄM-42-332 Inspection Intervals Rudder Trim Mechanism

AMM-TR-MÄM-42-334 Improved Maintenance Instructions

AMM-TR-MÄM-42-336 Optimized NLG Actuator

AMM-TR-MÄM-42-356/a Rudder Trim Adjustment

AMM-TR-MÄM-42-384 Alternate Air Valve FOD Screen

AMM-TR-MÄM-42-391 Turbo System Aluminium Tube

AMM-TR-MÄM-42-395 Improved Heating

AMM-TR-MÄM-42-398/a & 450 Change of Breather Line Installation

AMM-TR-MÄM-42-406 Radiator and Intercooler Protection

AMM-TR-MÄM-42-440 Flap Preload Adjustment

AMM-TR-MÄM-42-447 Replacement Instructions MLG Joints

AMM-TR-MÄM-42-448 New Governor Speed Settings

AMM-TR-MÄM-42-451 Engine Shock Mount Torques

AMM-TR-MÄM-42-454 Inspection of MLG Door Hinges

AMM-TR-MÄM-42-462 Additional Drainage in the Static System

AMM-TR-MÄM-42-471 Fuel Pulsation Damper

AMM-TR-MÄM-42-478 Extended Time Limit Oxygen Cylinder

Page vi Doc # 7.02.15

Temporary Revision Number Description of Temporary Revision

AMM-TR-MÄM-42-480 Fuel Pumps Check Valves

AMM-TR-MÄM-42-495 Alternative Hydraulic Fluids and Greases

AMM-TR-MÄM-42-515 Safety Walk Adhesive Strips

AMM-TR-MÄM-42-522 Maintenance Interval GFC 700

AMM-TR-MÄM-42-524 & 380 Maintenance Program Phase 1

AMM-TR-MÄM-42-533 Caliper Back Plate Torque Value Correction

AMM-TR-MÄM-42-534 Propeller Shipping Plug Removal

AMM-TR-MÄM-42-535 Gearbox Oil Inspection

AMM-TR-MÄM-42-538 Fuel Drain Valve Mounting Torque

AMM-TR-MÄM-42-550 Routing in Center Wing

AMM-TR-MÄM-42-551 Alternator Regulator E4A-91-200-000

AMM-TR-MÄM-42-570 Large Washer at RH FWD Engine Mounting Arm Bolt

AMM-TR-MÄM-42-594 Alternative Engine Shock Mount

AMM-TR-MÄM-42-600 Performance Enhancement

AMM-TR-MÄM-42-641 Propeller Pitch Information

AMM-TR-OÄM-42-176 & 171 Retrofit Installation of Austro Engine E4-B

AMM-TR-OÄM-42-187 Coated Safety Walk

AMM-TR-OÄM-42-191 Trim Weight