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WARNING: WHEN YOU COMPLETE WORK ON THE CONTROLS, 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.
2. Remove/Install the Flap Actuator
Refer to Figures 1 & 3.
A. Remove the Flap Actuator
Detail Steps/Work Items Key Items/References
(1,) If possible, set the flaps to the T/O position.
(2,) Disconnect the airplane main battery. Refer to Section 24-31 (Lycoming
version) or 24-34 (TAE version).
(3,) Remove the passenger seat. Refer to Section 25-10.
(4,) Disconnect the electrical supply connector to the
flap motor.
(5,) Disconnect the control harness plug from the
switch-board.
(6,) Remove the bolt which attaches the actuator
push-rod to the idler lever.
At the rear main bulkhead.
Hold the flaps.
(7,) Lower the flaps by hand until they stop.
AIRCRAFT
Flight Controls DA 40 Series
AMM
Detail Steps/Work Items Key Items/References
Page 202
20 Sep 2007 27-50-00 Doc # 6.02.01
Rev. 5
(8,) Remove the bolt which attaches the actuator
body to the mounting bracket.
At the left rear closing rib.
(9,) Remove the actuator from the airplane.
B. Install the Flap Actuator
Detail Steps/Work Items Key Items/References
(1) Put the flap actuator in position in the fuselage.
(2) Install the bolt which attaches the actuator body to
the mounting bracket.
At the left rear closing rib.
Make sure that the bush is in position in
the actuator swivel block.
Torque: 6.4 Nm (4.7 ft.lb).
(3) Install the bolt which attaches the actuator pushrod
to the idle lever.
At the rear main bulkhead. Hold the
flaps.
Torque: 6.4 Nm (4.7 ft.lb).
(4) Connect the control harness plug for the
switch-board.
(5) Connect the electrical supply connector to the flap
motor.
(6) Connect the airplane main battery. Refer to Section 24-31 (Lycoming
version) or 24-34 (TAE version).
(7) Do the adjustment procedure. See Paragraph 4.
(8) Do an inspection of all the controls that you have
connected.
S If necessary for your airworthiness authority,
do a second inspection of the controls.
(9) Install the passenger seat. Refer to Section 25-10.
AIRCRAFT
DA 40 Series
AMM
Flight Controls
Doc # 6.02.01
Rev. 5 27-50-00 Page 203
20 Sep 2007
3. Test the Flap Control System
A. Equipment
Item Quantity Part Number
Inclinometer. 1 Commercial.
Spring balance. 1 Commercial.
B. Test the Flap Control System Procedure
Detail Steps/Work Items Key Items/References
(1) Make a copy of the Control Surfaces Adjustment
Report.
Refer to Section 06-00.
Use it to record the measurements.
(2) Make sure that the flaps are fully UP:
S Set the ALT/BAT switch (Lycoming version) or
ELECTRIC MASTER key switch (TAE
version) to ON.
S Set the flaps to T/O.
S When the flaps stop moving, set the flaps to
UP.
S When the flaps stop moving, set the ALT/BAT
switch (Lycoming version) or ELECTRIC
MASTER key switch (TAE version) to OFF.
(3) Do a test for the correct pre-load in the flap UP
position:
S Put a loop of adhesive tape on the trailing
edge of the left flap opposite the up-stop.
S Pull down on the loop of tape with the spring
balance until the flap just moves from the upstop.
S Record the value in the Control Surfaces
Adjustment Report. The value must be as shown in the
Control Surfaces Adjustment Report.
(4) If the pre-load is not correct, adjust the control rod
between the bellcrank in the wing and the flap
horn. Do items 3 & 4 again as necessary.
Refer to Section 27-00.
AIRCRAFT
Flight Controls DA 40 Series
AMM
Detail Steps/Work Items Key Items/References
Page 204
20 Sep 2007 27-50-00 Doc # 6.02.01
Rev. 5
(5) Do items 3 & 4 for the right flap.
(6) Zero the inclinometer to the left flap:
S Put the inclinometer on the left flap close to
the flap horn.
S Zero the inclinometer.
S Remove the inclinometer.
(7) Set the flaps to T/O:
S Set the ALT/BAT switch (Lycoming version) or
ELECTRIC MASTER key switch (TAE
version) to ON.
S Set the flaps to T/O.
S When the flaps stop moving, set the ALT/BAT
switch (Lycoming version) or ELECTRIC
MASTER key switch (TAE version) to OFF.
(8) Measure the angle of the left flap.
S Record the value in the Control Surfaces
Adjustment Report.
Use the inclinometer.
The value must be as shown in the
Control Surfaces Adjustment Report.
　
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