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There is 14 VDC on the ECU bus but not on the main bus with the essential bus switch set to OFF.  Power relay defective. 5 A power relay fuse failed. A failure of the cables which connect the ECU bus to the power relay and main bus. A failure of the cables which connect the power relay coil to the essential bus switch. Essential bus switch defective.  Replace the power relay. Replace the power relay fuse. Do a continuity test of the cables. Refer to Chapter 92 for the wiring diagrams. Repair/replace defective cables. Do a continuity test of the cables. Refer to Chapter 92 for the wiring diagrams. Repair/replace defective cables. Replace the essential bus switch. 

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Page 102 Doc # 6.02.01 09 Jan 2003 Rev. 4
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Electrical Power
AMM

% Maintenance Practices % 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.
% 2. Electrical Safety
% The DA 40 has a low voltage DC electrical system. When correctly maintained it is safe to work on. % The battery can supply heavy current through low resistance circuits (for example, if you ground the % positive output 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 BATTERY BEFORE DOING MAINTENANCE 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 12 VOLT POWER % SUPPLY THAT HAS OVER-CURRENT PROTECTION. DO THIS % BEFORE CONNECTING THE BATTERY
% CAUTION: USE ONLY DA 40 SPARE PARTS APPROVED BY THE % MANUFACTURER.
% % 3. Remove/Install the Avionics Master Relay or Essential Avionics Relay
% A. Remove the Avionics Master Relay or Essential Avionics Relay % %

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Detail Steps/Work Items  Key Items/References 
(1)  Remove the top engine cowling.  Refer to Section 71-11. 
(2)  Disconnect the battery: S Disconnect the negative cable from the battery. S Disconnect the positive cable from the battery. 
(3)  Remove the instrument panel cover.  Refer to Section 25-10. 

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Detail Steps/Work Items  Key Items/References 
(4)  Disconnect the electrical cables from the relay. 
(5)  Remove the bolts which attach the relay to the instrument panel floor. 
(6)  Move the relay clear of the airplane. 
% B. Install the Avionic Master Relay or Essential Avionics Relay % %

 

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Detail Steps/Work Items  Key Items/References 
(1)  Put the relay in position on the instrument floor. 
(2)  Install the bolts which attach the relay to the instrument panel floor. 
(3)  Connect the cables to the relay.  Refer to Chapter 92 for the Wiring Diagrams. 
(4)  Install the instrument panel cover.  Refer to Section 25-10. 
(5)  Connect the battery.  Refer to Section 24-34. Connect the positive cable first. 
(6)  Install the top engine cowling.  Refer to Section 71-11. 
(7)  Do a test of the relay: S Set the ELECTRIC MASTER key switch to ON. S Set the AVIONICS MASTER switch to ON. S Set the COM 2 radio ON, if installed. (Avionics master relay only). S Set the COM 1 radio to ON. (Essential avionics relay only). S Set the AVIONIC MASTER switch to OFF. S Set the ELECTRIC MASTER key switch to OFF.  The radio must operate. The radio must operate. 
　
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