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) The solenoid moves the starter pinion to engage with starter gear on the engine flywheel.
) The solenoid closes the contacts for the motor and the motor turns the engine.
) The starter power-on lights comes on.
When the engine turns faster than the starter motor, the starter motor gear disengages from the engine
gear. The starter can turn until you turn the ignition key to one of the other positions.
AIRCRAFT
DA 40 Series
AMM
Starting
Doc # 6.02.01
Rev. 5 80-00-00 Page 101
20 Sep 2007
Trouble-Shooting
1. General
The table below lists the defects you could have with the starting 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.
WARNING: DO NOT ALLOW PERSONS TO ENTER THE DANGER AREA OF THE
PROPELLER. THE PROPELLER MAY TURN AND CAUSE INJURY TO
PERSONS.
WARNING: DISCONNECT AND ISOLATE THE STARTER POWER CABLE BEFORE
DOING TESTS IN THIS SECTION. THE ENGINE MAY START AND
CAUSE INJURY TO PERSONS.
Trouble Possible Cause Repair
The starter does not operate
when the ignition key is set to
START with the ALT/BAT
switch set to ON.
The battery is discharged.
The ignition switch is defective.
The starter relay is defective.
Defective cable.
Replace/Recharge the battery.
Replace the ignition switch.
Replace the starter relay.
Do a test of the electrical
cables. Refer to Chapter 92 for
the wiring diagrams.
Repair/Replace the defective
cable.
The starter does not operate
when the ignition key is set to
START with the ALT/BAT
switch set to ON.
Starter defective.
Cable defective.
Replace the starter.
Do a test of the electrical
cables. Refer to Chapter 92 for
the wiring diagrams.
Repair/Replace the defective
cable.
The starter Power-On light
stays on after the ignition key
is released from the START
position.
The starter relay is defective.
Cable defective.
Replace the starter relay.
Do a test of the electrical
cables. Refer to Chapter 92 for
the wiring diagrams.
Repair/Replace the defective
cable.
AIRCRAFT
Starting DA 40 Series
AMM
Page 102
20 Sep 2007 80-00-00 Doc # 6.02.01
Rev. 5
Intentionally left blank
AIRCRAFT
DA 40 Series
AMM
Starting
Doc # 6.02.01
Rev. 5 80-00-00 Page 201
20 Sep 2007
Maintenance Practices
1. General
This Section tells you how to remove/install the starter relay and how to remove/install the starter
motor. Refer to Section 74-00 for data on how to remove/install the ignition switch.
For more data on the starter motor refer to the Lycoming Operators Manual.
2. Remove/Install the Starter Relay
A. Remove the Starter Relay
Detail Steps/Work Items Key Items/References
WARNING: MAKE THE ENGINE SAFE BEFORE YOU DO ANY WORK ON THE
STARTER SYSTEM. IF THE ENGINE STARTS THE PROPELLER CAN
CAUSE INJURY OR DEATH.
(1) Make sure that the engine is safe:
S Set the ignition switch to OFF.
S Set the ALT/BAT switch to OFF.
S Set the throttle to IDLE.
S Set the mixture control to LEAN CUT-OFF.
(2) Remove the engine top cowling. Refer to Section 71-10.
(3) Disconnect the airplane battery. Refer to Section 24-31.
(4) Remove the cover from the relay box:
S Remove the 2 bolts which attach the relay
box cover.
S Remove the relay cover.
AIRCRAFT
Starting DA 40 Series
AMM
Page 202
20 Sep 2007 80-00-00 Doc # 6.02.01
Rev. 5
Starter Relay
Power Cable to Starter
Relay Attaching
Bolt
Washer
Nut
Nut
Washer
Washer
Bus Bar
Washer
Nut
Power Cable
from Battery
Firewall
Battery Relay
EPU Relay
Figure 2: Starter Relay Installation, Original Design
AIRCRAFT
DA 40 Series
AMM
Starting
Doc # 6.02.01
Rev. 5 80-00-00 Page 203
20 Sep 2007
Detail Steps/Work Items Key Items/References
(5) Disconnect the cables from the starter relay.
Original design:
S Remove the 2 control cables and the 1
indicator cable.
S Remove the 2 power cables.
Modified design (MÄM 40-057):
S Remove the 1 ring terminal with the diode
suppression cable and the control cable.
S Remove the 1 power cable.
S Remove the 1 nut and 1 washer of the bus
bar connection.
Make a note of the position of the
cables.
Refer to Figure 2.
Refer to Figure 3.
(6) Remove the starter relay.
Original design:
　
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