Doc # 6.02.01 Page 205
Rev. 4 09 Jan 2003

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AIRCRAFT AMM
Spigot 
Starter Motor 
Power Cable 
Bolt  Plain Nut, Serrated Washer, Plain Washer 
Figure 4: Remove/Install the Starter 

80-00-00
Starting
AMM

3. Remove/Install the Starter
A. Remove the Starter
Detail Steps/Work Items  Key Items/References 
WARNING: MAKE THE ENGINE IS SAFE BEFORE YOU DO ANY WORK ON THE STARTER SYSTEM. IF THE ENGINE IS TURNED, 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 cowlings.  Refer to Section 71-10. 
(3)  Disconnect the airplane battery.  Refer to Section 24-31. 
(4)  Disconnect the electrical cables from the starter: S Move the rubber boot clear of the power cable. S Remove the nut and washer that attaches the cable to the connector stud. S Remove the cables from the starter. 
(5)  Cut the lock-wire on the bolt which holds the link for the alternator. Remove the bolt. 
(6)  Release the three nuts and one bolt which attach the starter to the engine. Remove the starter from the airplane. 

Doc # 6.02.01 Page 207
Rev. 4 09 Jan 2003

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AMM

B. Install the Starter
DA 40 Series

Detail Steps/Work Items  Key Items/References 
(1)  Put the starter into position on the engine. 
(2)  Install the washers, three nuts and one bolt which attach the starter to the engine.  Torque: 23 Nm (17 ft.lb). 
(3)  Move the link for the alternator into position and install the bolt. Lock the bolt with lock-wire.  Torque: 23 Nm (17 ft.lb). 
(4)  Connect the electrical cable to the starter: S Install the power cable on the stud. S Install the shake-proof washer. S Install the nut. S Move the rubber boot into position over the connector.  Torque: 2.7 Nm (2 ft.lb). 
(5)  Connect the airplane battery.  Refer to Section 24-31. 
(6)  Install the engine cowlings.  Refer to Section 71-10. 
(7)  Do an engine run-up.  Refer to the DA 40 Airplane Flight Manual. 

Page 208 Doc # 6.02.01 09 Jan 2003 Rev. 4
80-00-00
Starting
AMM

% Section 80-01 % Starting - TAE 125 Diesel Engine % 1. General
% This Section tells you about the system that cranks the TAE 125 Diesel engine for starting.
% Refer to Section 24-33 for more data on the electrical supplies to the system Refer to Section 76-01 % for data about the engine control system.
% 2. Description and Operation
% Figure 1 shows the simplified schematic diagram of the starter system. The system operates off a 12 % VDC supply.
% The TAE 125 Diesel 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 this % bus for the starter.
% The ELECTRIC MASTER key switch (marked OFF ON START) is located on the bottom left of the % instrument panel. Turn the key clockwise against the spring to operate the starter. Release the key % when the engine starts. The spring returns the key to the ON position.
% A starter relay located on the instrument panel floor controls the current to the starter solenoid. An % ENGINE MASTER switch located on the bottom left of the instrument panel controls the ground % connection for the starter relay. This switch must be set to ON for the starter system to operate.
　
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