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DA40 D (TDI) — Your Guide Before the Test

Built entirely from the official AFM · Doc. # 6.01.05-E

Before you dive into the questions…

This isn't the AFM reformatted, and it isn't a shallow summary either. The point is to actually understand the aircraft — why a number is what it is, and what happens if you cross it — before you go test yourself against 260 questions. Every figure here is copied verbatim from the official Diamond DA 40 D Airplane Flight Manual (Thielert TAE 125 diesel engine), with a note right next to it saying exactly where it came from — same as the questions.

TAE 125-01 vs TAE 125-02-99 260 linked questions 10 systems Doc. # 6.01.05-E · Rev 6/7

01 Limitations Limitations

This section is "the law" — the numbers you don't negotiate with. Everything here comes from Chapter 2 of the AFM, and it's an EASA approved chapter, meaning none of it is judgment call, it's just execution.

The speeds that matter (V-Speeds) AFM 2.2

Four speeds you should know cold. Notice that vA (maneuvering speed) isn't a fixed number — it changes with the aircraft's mass, because it's built on how much maneuvering load the airframe can take at a given weight.

SpeedValueCondition
vA — maneuvering speed108 KIASAbove 980 kg and up to 1150 kg
vA — maneuvering speed94 KIASFrom 780 to 980 kg
vFE — max speed with T/O flaps108 KIAS—
vFE — max speed with LDG flaps91 KIAS—
vNO — max structural cruising speed129 KIASAbove it, smooth air only, and with caution
vNE — never exceed speed178 KIASUnder any circumstances
0 49 91 108 129 178 White Green (normal) Yellow (caution) vNE
The colored arcs on the airspeed indicator — in knots (KIAS); 178 is the red line

Engine limits AFM 2.4

Pay close attention here: the manual covers two different engines — TAE 125-01 and TAE 125-02-99 (fitted if modification MÄM 40-256 has been carried out). Some figures change between the two, and this is exactly the point where you need to know which engine your actual airplane has.

Direct comparison between the two engines — note the difference in RPM and altitude
ItemTAE 125-01TAE 125-02-99
Max RPM (continuous)2500 RPM2300 RPM
Max overspeed— (not defined)2500 RPM for a maximum of 20 seconds
Max altitude for engine restart6500 ft (6000 ft for R5 version)8000 ft
Coolant typeDAI-G30-MIXDAI-G48-MIX
Max fuel temperature (Jet Fuel)+65°C+75°C

The figures that don't change between the two engines — and these are just as worth memorizing:

ItemValue
Max take-off/continuous power99 kW (135 DIN-hp) at 2300 RPM
Oil pressure — min / max1.2 bar / 6.5 bar
Oil quantity — min / max4.5 liters / 6.0 liters
Max oil consumption0.1 liters/hr
Oil temperature — min / max-32°C / +140°C
Max gearbox temperature120°C
Max coolant temperature+105°C
Propeller diameter187 cm (6 ft 2 in)
Propeller blade angle (0.75R)12° to 28°
Warning Exceeding any of these limits means overstressing the engine or the airframe — not a "theoretical warning." The manual is clear that it must not happen.

Engine instrument markings AFM 2.5

Worth a pause: on the TAE 125-02-99 engine (with the new AED/CED), the RPM gauge has no yellow range at all — it goes straight from green (0 to 2300 RPM) to red above 2300. The TAE 125-01 engine, on the other hand, has a yellow band from 2400 to 2500 RPM before red. If you're asked "where's the yellow band on the -02-99?" — the answer is: there isn't one.

GaugeYellow (caution)Red (prohibited)
Ammeter85 to 90 AAbove 90 A
Voltmeter11.0–12.6 V and 15.0–15.5 VBelow 11 V or above 15.5 V
Note The full annunciator panel (WARNING/CAUTION/STATUS) is covered in the Electrical System section — here's just a quick summary: red lights = WARNING/START/TRIM FAIL/ECU BACKUP UNSAFE, amber = CAUTION/LOW VOLTS/ALTERNATOR/PITOT/LOW FUEL/ENGINE/ECU A/ECU B, white = FUEL TRANS/GLOW.

Mass and center of gravity AFM 2.7, 2.8

ItemValue
Max take-off mass — Normal Category1150 kg (2535 lb)
Max take-off mass — Utility Category980 kg (2161 lb)
Max landing mass (with 18 mm struts / MÄM 40-123)1150 kg
Max landing mass (without them)1092 kg (2407 lb)
Max baggage compartment load30 kg (66 lb)

Center of gravity isn't one fixed number — it's an allowed "zone" that moves with mass. A simple chart is clearer than a paragraph of text:

780 980 1150 2.40 2.46 2.55 2.59 Mass (kg) Center of gravity — meters aft of the Datum Plane Allowed zone (standard tank) Aft limit — Long Range Tank
The green zone = allowed (standard tank). The dashed line = the aft limit if you have the Long Range Tank installed (slightly tighter)
ConditionValue
Most forward limit — from 780 to 980 kg2.40 m aft of DP
Most forward limit — at 1150 kg2.46 m aft of DP (linear variation between them)
Most rearward limit — standard tank2.59 m aft of DP
Most rearward limit — Long Range Tank2.55 m aft of DP

Approved maneuvers and load factors AFM 2.9, 2.10

CategoryMax bank angle
Normal Category60°
Utility Category90°
Caution Aerobatics and spinning are prohibited in both categories. And: avoid extended negative g — it causes propeller control problems and engine surging.
Being honest about this one The numeric load factor table in the AFM (section 2.10) is printed in the original document without a clear decimal point — we confirmed this by rendering the actual page image, not just extracting the text. So no question or exact figure was built on that particular table; what actually matters in practice is avoiding extended negative g, and that's stated explicitly.

Altitude and crew AFM 2.11, 2.12

ItemValue
Max demonstrated operating altitude16400 ft (5000 m)
Minimum crewOne person
Max occupants — Normal Category4 people
Max occupants — Utility Category2 people, both must be in the front seats

Kinds of operation and fuel AFM 2.13, 2.14

Approved: VFR, Night VFR, and IFR. Absolutely prohibited: flight into known or forecast icing conditions, and flight into known thunderstorms.

TankTotal capacityUsable
Standard (per side)15.0 US gal (56.8 liters)14.0 US gal (53.0 liters)
Long Range (per side)20.5 US gal (77.6 liters)19.5 US gal (73.8 liters)

Max permitted quantity difference between the two tanks (Long Range): 9 US gal (~34 liters). And watch out: the quantity gauge "freezes" at 15 gal even if there's actually 19.5 in there — you have to use the alternate measuring device or assume 15 for planning purposes only.

Other limits worth memorizing AFM 2.16

ItemValue
Airplane operating temperature range-20°C to +54°C (below -20°C, external pre-heat is mandatory)
Min fuel temperature to start (Diesel/uncertain blend)-5°C
Min fuel temperature for take-off (Diesel/uncertain blend)+5°C
  • The canopy and passenger door must never be locked with the key during operation — they must stay openable from outside at any moment.
  • Smoking on the airplane is prohibited entirely.
  • If the seal on the EMERGENCY switch is broken, or the ECU BACKUP UNSAFE light comes on, IFR flights are prohibited.

And if the KAP 140 autopilot system is installed: max operating speed 165 KIAS, min speed 70 KIAS, min operating altitude 800 ft AGL (cruise/climb/descent/maneuvering) or 200 ft AGL on final approach only. It must be switched off during take-off and landing.

02 Emergency Procedures Emergency Procedures

The golden rule is written word-for-word at the top of the chapter: "fly the aircraft first." Before you try to solve any problem, take control of the flight attitude and think about a place to make an emergency landing. The manual also asks you to think ahead — before the flight — about where you'd land if something happened at each phase of flight, so you're never shocked and can act calmly and decisively.

Basic emergency speeds AFM 3.1.2

This is the table that keeps coming back in almost every emergency scenario — just memorize it at max mass (1150 kg):

Event850 kg1000 kg1150 kg
Engine failure after take-off (T/O flaps)596672
Best glide angle (flaps UP)606873
Emergency landing — flaps UP606873
Emergency landing — T/O flaps596672
Emergency landing — LDG flaps586371

Engine problems AFM 3.2

On the ground: if oil pressure is in the red range — shut down the engine immediately, no debate.

During take-off: if there's enough distance to stop — power lever to IDLE and land straight ahead. If you can no longer stop and haven't reached a safe height yet —

Warning Do not attempt to turn back to the airfield. Land straight ahead. Turning back can be fatal — that's the manual's own wording, not me exaggerating.

In flight (engine running roughly or lost power): Power lever MAX, open Alternate Air if there's icing, check MAIN tank quantity, turn on the transfer pump, confirm the emergency fuel valve is on NORMAL, and switch to ECU B. If that doesn't fix it, switch back to AUTOMATIC. If the power loss continues — do an ECU reset by cycling ENGINE MASTER OFF then ON.

Restarting the engine in flight AFM 3.2.4, 3.2.5

ItemValue
Max airspeed for windmilling the propeller110 KIAS
Windmilling restart airspeed range73 – 110 KIAS
Airspeed the propeller starts windmilling on its own — TAE 125-01~105 KIAS
Same, TAE 125-02-99 (without the dual-mass flywheel mod)~110 KIAS
Expected altitude loss during a restart attemptAt least 1000 ft (300 m)
Caution On a TAE 125-02-99 engine with the dual-mass flywheel modification (MÄM 40-701): if the engine fails and the propeller keeps windmilling — that's normal. But if the propeller has stopped completely, that indicates a major mechanical failure, and a restart with a stationary propeller should not be attempted at all.

Defective RPM regulating system AFM 3.2.6

  • Governor failure: adjust RPM manually with the power lever, and try not to exceed 2500 RPM.
  • Overspeed: reduce power to not exceed 2300 RPM. If you need a stronger climb, up to 2500 RPM is permitted for a maximum of 10 minutes only.
  • Underspeed: RPM can drop to 1400 or below — meaning no climb or go-around power. Land as soon as possible.

Fuel transfer pump failure AFM 3.2.7

The emergency fuel valve's EMERG. TRANSFER position moves fuel at an approximate rate of 18 to 21 US gal/hr (70-80 liters/hr) — much slower than the normal electric transfer pump.

Warning You must return the valve to NORMAL before the AUX tank indicator reaches zero — otherwise, the engine will stop in flight once AUX is completely empty.

Smoke and fire AFM 3.3

The general pattern across all scenarios (ground / take-off / in flight): emergency fuel valve OFF, transfer pump OFF, ENGINE MASTER OFF, ELECTRIC MASTER OFF, then open the canopy and evacuate the aircraft as soon as it stops. If it's an electrical fire specifically in flight: switch the EMERGENCY switch ON (if installed) before turning off ELECTRIC MASTER — that way the backup battery keeps feeding the attitude gyro and the flood light.

Caution With heavy smoke, you're allowed to partially open the front canopy in flight (it stays in that position until landing) to improve ventilation — the manual says flight characteristics aren't significantly affected.

Gliding AFM 3.4

Propeller stateGlide ratioHorizontal distance per 1000 ft
Windmilling8.81.45 NM (2.68 km)
Fully stopped (stationary)10.31.70 NM (3.14 km)

The better figure (10.3) is more theoretical — it may not actually be achievable while maintaining a safe airspeed.

Emergency landing AFM 3.5

  • Engine off: touch down at the lowest possible airspeed.
  • Defective tire: land at the edge of the runway on the side of the good tire, and hold that wing low — that way any swerve expected during rollout gets corrected within the runway.
  • Defective brakes: landing on grass is better — the higher rolling resistance shortens the stopping distance.

Recovering from an unintentional spin AFM 3.6

Warning — four actions, at the same instant Power lever IDLE, full rudder opposite the direction of rotation, control stick fully forward, ailerons neutral — all four together, simultaneously. Then once rotation stops: rudder neutral, ease the stick back, and don't exceed vNE = 178 KIAS as you return to normal flight attitude.

Other emergencies AFM 3.7

Icing

Pitot heat ON, cabin heat ON, air distribution lever to DEFROST, increase power (to prevent ice building up on the propeller blades), and open Alternate Air.

CautionIce build-up increases stall speed — pay attention.

If Pitot heat fails: open the Alternate Static valve and close the emergency windows.

Electrical system failures

  • Complete failure: check circuit breakers, switch ESSENTIAL BUS ON. If there's still no power, switch the EMERGENCY switch ON.
  • Starter malfunction (won't disengage): Power lever IDLE, ENGINE MASTER OFF, ELECTRIC MASTER OFF — and terminate flight preparation entirely.
  • Voltage in the red range (above 15.5V or below 11V): ESSENTIAL BUS ON, land at the nearest suitable airfield.
  • An alternator failure leaves the batteries as the last source — good for at least 30 minutes.

Suspicion of carbon monoxide contamination

Cabin heat OFF, open ventilation and emergency windows, reduce speed below 120 KIAS, and unlatch the front canopy to the "Cooling Gap" position. (120 KIAS is actually the max demonstrated speed for opening the canopy in flight at all — don't exceed it.)

DOOR light illuminated

Reduce speed immediately and visually confirm the canopy and rear door. If either one isn't locked: keep speed below 140 KIAS and land at the nearest suitable airfield.

Warning Don't try to lock the rear door in flight — the safety latch can release and the door can separate from the aircraft.

03 Normal Procedures Normal Procedures

This section walks you from the pre-flight inspection all the way to engine shutdown — every normal flight, step by step. Focus on the numbers that keep coming up in every practical lesson.

Normal operating speeds AFM 4A.2

Speed850 kg1000 kg1150 kg
vR (rotation, T/O flaps)495559
vY (best rate of climb, T/O flaps)546066
Cruise climb (flaps UP)606873
Normal landing approach (LDG flaps)586371
Min speed during Go-Around (T/O flaps)546066

Pre-flight inspection — points not to forget AFM 4A.3.1

ItemValue
Main gear tire pressure2.5 bar (36 psi)
Nose gear tire pressure2.0 bar (29 psi)
  • Fuel Cooler Baffle: remove it if ground temperature is above 20°C, install it if below 20°C.
  • Drain both tank sumps to check for water and sediment — until clean fuel comes out.

Starting and warm-up AFM 4A.3.3

ItemValue
Max continuous starter operation10 seconds
Starter cooling period between attempts20 seconds
After 6 failed attemptsCool down a full half hour
Time for oil pressure to leave the red range after start3 seconds
Normal oil pressure on a cold engine (up to 20 seconds)Can reach 6.5 bar
Warm-up — IDLE2 minutes
Warm-up — then until temperatures are green1400 RPM

Before taxi and before take-off AFM 4A.3.4, 4A.3.6

ItemValue
Idle RPM890 ± 20 RPM
Power lever at MAX (before take-off check)10 seconds
Expected RPM at MAX2240 – 2300 RPM
Expected LOAD at MAX90 – 100%

The ECU TEST is a mandatory part of the before take-off check — it automatically switches between ECU A and ECU B, and you watch the caution lights blink then go out. Any fault during the test = stop flight preparation, even if the engine runs fine afterward.

Climb AFM 4A.3.8

Caution If oil or coolant temperature reaches the yellow range during climb: increase airspeed by 5 kts and reduce power by 10% — a slower climb for better cooling.

The engine manufacturer's recommended cruise power setting: 70%.

Fuel transfer and landing AFM 4A.3.10 – 4A.3.13

  • The normal (electric) transfer pump moves fuel at an approximate rate of 60 US gal/hr, much faster than the emergency valve.
  • On approach: slow to 108 KIAS before selecting T/O flaps, and to 91 KIAS before selecting LDG flaps.
  • During descent: below 5000 ft, power as required; above 5000 ft, don't go below 30% — to avoid an unrecognized flame-out below -10°C OAT.

Engine shutdown AFM 4A.3.15

Warning The engine must run at idle for at least 2 minutes before shutdown — to avoid heat damage to the turbocharger.

After landing, check the ELT by listening on 121.5 MHz. And before refueling, the aircraft must be connected to an electrical ground point at the unpainted areas on the steps.

04 Abnormal Procedures Abnormal Procedures

The difference from the Emergency section: things here are "lighter" — a gauge out of the green, a caution light on — not necessarily "land right now," but you still need to know exactly what the correct step is.

Indications outside the green range AFM 4B.2

IndicationConditionAction
High RPM—Reduce power. A short time in the yellow range is allowed (e.g. for a go-around).
High coolant temperatureWATER LEVEL light off, during climbReduce power 10%, increase airspeed 10 kts. If it's not back in the green within 60 seconds, reduce power further.
High/low coolant temperatureWATER LEVEL light onExpect coolant loss — prepare for an emergency landing with engine off.
High oil temperatureOil pressure lowExpect oil loss and engine failure — prepare for an emergency landing.
High oil temperatureOil pressure greenReduce power, increase airspeed, monitor the temperature.
Low oil temperature—Increase power, reduce airspeed, monitor.
High oil pressureTemperatures greenMost likely a faulty indication — keep monitoring temperatures.
High oil pressureTemperatures not greenReduce power — expect engine failure, prepare for an emergency landing.
High gearbox temperature—Reduce power and increase airspeed.
High fuel temperature—Reduce power, increase airspeed. You can transfer fuel from AUX to reduce the temperature.
Note If RPM is below 1500 with the power lever at IDLE, oil pressure has to actually drop into the red range before the caution light comes on — that's normal, not a gauge fault.

Electrical faults on the annunciator panel AFM 4B.3

  • LOW VOLTS: normal voltage is 14V, and the caution activates below 12.6V. Possible causes: a fault in the supply, or RPM too low.
  • ECU A / ECU B: press the ECU TEST button for more than two seconds to reset. If it returns or won't reset — land at the nearest suitable airfield, and the engine has to be inspected afterward either way.
  • PITOT: if it happens after prolonged ground operation — normal, this is a thermal switch protecting against overheating, and it re-activates on its own after a cooling period.
  • LOW FUEL: comes on when usable fuel in MAIN drops below approximately 3 US gal (+2/-1).

Faults on the AED 125 display AFM 4B.4

  • GENERATOR (high electrical load): most likely a wiring or equipment fault — turn off anything non-essential.
  • High VOLT: land at the nearest suitable airfield. (And the ENGINE light might come on during ground warm-up due to a normal higher voltage reading on a cold engine — not a real fault.)

Take-off from a short grass strip AFM 4B.5

Brakes applied, T/O flaps, Power lever MAX, control stick fully back, then release the brakes. Ease the stick forward gradually after the nose wheel lifts.

Flap system failures AFM 4B.6

If only UP or only T/O is available: fly a flat approach, and control speed and rate of descent with the power lever. If only LDG is available: perform a normal landing.

Landing at a high landing mass AFM 4B.7

For aircraft whose max landing mass is 1092 kg — landing between 1092 and 1150 kg counts as an abnormal procedure, at an approach speed of 71 KIAS.

05 Powerplant Powerplant

This isn't a regular carbureted gasoline engine — it's a real diesel, four-stroke, common-rail direct injection, liquid-cooled, with a turbo and an intercooler. And the most important part: it has two electronic control units (ECU A and ECU B) that handle everything for you — you just move the power lever, and they take care of the rest.

Engine overview AFM 7.9.1

ItemValue
TypeDiesel, four-stroke, liquid-cooled, wet sump lubrication
Propeller gearbox reduction ratio1 : 1.69
Displacement — TAE 125-011689 cm³ (103 in³)
Displacement — TAE 125-02-991991 cm³ (121.5 in³)
Note Even if you disconnect the battery from the distribution system with the ELECTRIC MASTER switch, the ECU still gets direct power from the battery — because it's the most important thing on the aircraft.

Controls AFM 7.9.2

  • Power lever: doesn't directly control fuel or manifold pressure — it just sets the requested power percentage (LOAD %), and the ECU translates that into manifold pressure, injection quantity and propeller speed.
  • ELECTRIC MASTER: three positions — OFF / ON / START.
  • ENGINE MASTER: must be ON for you to crank the engine at all.
  • ECU SWAP: normally set to AUTOMATIC — the engine is controlled by ECU A, and it switches to ECU B automatically on a failure.
  • ALTERNATE AIR: normally closed (lever forward). Pull it back if the air filter is blocked or icing occurs — it draws air from the engine compartment instead.
Caution — governor oil pressure loss The propeller governor has its own oil circuit, completely separate from the engine's own oil. If that circuit loses pressure, the blades automatically go to the finest pitch angle possible — meaning maximum RPM, not minimum.

ECU TEST button — two jobs in one AFM 7.9.2

What happens when you press it depends on the power lever position:

  • Power lever at IDLE and RPM below ~900: starts the full ECU self-test — it switches from A to B and back while the propeller cycles, and you watch the lights blink then go out.
  • Power lever above IDLE: it becomes just a "reset" button for an ECU A or ECU B caution — once only, and only for minor faults.
  • IFR aircraft: the same button also tests the ECU Backup Battery — if its charge is below 70% of rated capacity, the ECU BACKUP UNSAFE light stays on continuously.

Engine instruments (CED / AED) AFM 7.9.4

InstrumentShows
CED 125RPM, oil pressure (OP), oil temperature (OT), coolant temperature (CT), gearbox temperature (GT), LOAD
AED 125MAIN/AUX fuel quantity, coolant level (WATER LEVEL), left/right fuel temperature, ammeter (GENERATOR), voltmeter (VOLT), fuel flow rate (FUEL FLOW)

Cooling and turbo AFM 7.9.6, 7.9.7

The cooling system has a radiator and a bypass — the bypass operates while the engine is cold (speeds up warm-up), and once temperature reaches roughly 80°C, a thermostat valve activates the radiator. There's also a separate heat exchanger for cabin heating, which operates regardless of coolant temperature, plus an expansion tank with an overpressure relief valve.

The turbo: exhaust spins the turbine, and any excess bypasses it through the waste gate valve, controlled by the ECU based on a pressure sensor reading behind the compressor — this prevents excess manifold pressure at low altitudes. Compressed air is cooled in the intercooler before entering the engine — colder air is denser, which means more power.

Two oil systems, not one AFM 7.9.8

  • Engine and turbo lubrication: a standard wet sump system, with a separate cooler under the engine. Checked with a dipstick through an opening in the upper cowling.
  • Gearbox and propeller governor: a completely separate oil circuit, checked through an inspection glass at the front lower cowling.

ECU A and ECU B — how the dual redundancy works AFM 7.10.2

The ECU monitors everything about the engine — oil temperature and pressure, coolant and gearbox temperature, camshaft and crankshaft speed (each sensor doubled for safety), common rail fuel pressure, manifold pressure and temperature, and even power lever position (also doubled). Based on all that it controls the starter, the propeller governor valve, the rail pressure valve, the four injection nozzles, the glow plugs, and the waste gate valve.

ECU A Controls the engine normally ECU B Ready backup Internal fault / lost sensor → automatic switchover If the cause was a lost sensor and it returns — switches back automatically ECU TEST button: manual swap / self-test / IFR battery check
ECU B isn't just a "manual backup" — it's a fully automatic switchover system, and it becomes the one actually running the engine during a fault
Warning After an ECU A/B FAIL message appears, the engine must be inspected by maintenance — even if you were able to clear the message in flight.

06 Fuel System Fuel System

First thing to unlearn There is no "Fuel Selector" on this aircraft. If you're coming from a C172 or anything with LEFT/RIGHT/BOTH — forget that idea. The engine takes fuel from the MAIN tank (left wing) only, always. The AUX tank (right wing) exists to "feed" MAIN through an electric transfer pump, not to feed the engine directly.

How the system works AFM 7.9.5

Injection is direct and high-pressure into the cylinders — one injector per cylinder, all fed from the common rail. Rail pressure is produced by a high-pressure pump, itself fed by a low-pressure pump — both mechanical, driven directly by the engine.

Fuel that isn't injected (and on a diesel engine that's a much larger quantity than what's actually burned) returns through the AUX tank back to MAIN — that way the hot fuel coming back from the rail cools down, and cold fuel in both tanks warms up a bit. Rail pressure itself is controlled by an electrical valve, using the return line's flow rate as its reference.

AUX — right wing Secondary / backup source MAIN — left wing Only source for the engine Transfer pump + emergency valve NORMAL · EMERG.TRANSFER · OFF Low → high pressure pump Common Rail — 4 injectors Engine Return line (cools via AUX)
The dashed line = surplus fuel returning from the rail, passing through AUX before it returns to MAIN — this is what "cools" the hot fuel

The tanks AFM 7.9.5

  • MAIN (left): an aluminum chamber plus a filler tube connected by a flexible hose. It has two vents: one with a check valve and capillary that lets air in and stops fuel from escaping, and a second with a pressure relief valve set at 150 mbar (2 psi) — this protects the tank against overfilling if a transfer fails.
  • AUX (right): same idea, but both vents include a capillary (one paired with a check valve, the second purely as an extra safety measure).
  • A coarse (finger) filter sits before each tank's outlet, and a drain valve sits at the lowest point of each tank — for checking water and sediment.
  • Gascolator: at the lowest point of the whole fuel system, centrally under the fuselage, roughly 30 cm ahead of the wing leading edge — with its own drain valve.
Note The fuel quantity probe's reading is non-linear — meaning you can't calculate remaining fuel or consumption by simple proportion from the number it shows.

Long Range Tank AFM 7.9.5

Adds an extra tank chamber of roughly 5 US gal (19 liters) in place of the standard filler tube. Usable capacity works out to 19.5 US gal per side, but the gauge itself can't display more than 15 US gal — above that, the reading stays "stuck" at 15 even if there's actually more in there.

Fuel temperature AFM 7.9.5

ItemValue
Full gauge range-30°C to +75°C
Lower yellow bar (general)-30°C to +4°C
Flashing (no start on Diesel/uncertain blend)-30°C to -6°C
Steady (no take-off on Diesel/uncertain blend)-5°C to +4°C

If you're running Jet Fuel only (not diesel or a blend), operating in the yellow range is perfectly permitted.

Approved fuel grades AFM 2.14

JET A-1, JET A, JP-8, JET Fuel No. 3 (China), TS-1 (only if MÄM 40-256 has been carried out), and Diesel Fuel (EN590) — and blends of any of these grades are permitted. One single exception: Indonesia and Malaysia don't allow diesel fuel at all.

Caution Cold diesel can form solid particles that clog the Gascolator filter — and it isn't heated. If you're returning to a cold environment after running on diesel, each tank must be refilled at least twice with more than 10.6 US gal (40 liters) of Jet Fuel (or 17.2 US gal/65 liters with the Long Range Tank) — or both tanks must be fully drained before refueling with Jet Fuel.

Fuel cooler AFM 7.9.5

Installed in the right wing (between the spars), drawing cooling air from an opening on the lower surface, closed off by a baffle — remove it if ground temperature is above 20°C, install it if below.

Alternate fuel quantity measuring device AFM 7.9.5

Works on the "communicating vessels" principle — you seat it against the stall strip on the wing leading edge, connect it to the tank drain, and read the quantity off the rising tube. The aircraft must be on level ground for an accurate reading, and its normal home is a bag behind the pilot seat.

07 Electrical System Electrical System

A 12-volt DC system, but with four different batteries — not just one — each with a specific job. Once you understand who feeds whom, the whole annunciator panel stops being a list you memorize and starts making sense.

Generation and storage — the four batteries AFM 7.10.1

SourceSpecRole
Alternator (Generator)90 ampsBottom left of the engine, flat-belt driven. Regulates voltage between 12 and 14V.
Main battery12V / 23AhRight side of the firewall — the primary storage source.
Excitation battery12V / 1.3AhBehind the instrument panel — energizes the alternator field if the main battery fails.
ECU Backup battery12V / 12AhUnder the rear right seat — an extra source for ECU B only, via a 30A fuse.
Emergency battery (IFR models only)Dry, non-rechargeablePowers the attitude gyro and flood light for a full hour when the EMERGENCY switch is activated.

The alternator's output connects to the battery bus through a 100A fuse. The main battery connects directly to the hot battery bus through a 50A fuse (fixed, never disconnects), and connects to the battery bus through the "battery relay," which is controlled by the ELECTRIC MASTER switch.

Note The IFR-model emergency battery is checked at every 100-hour inspection, and its cells are replaced every two years or after any real use (when the switch's seal is broken).

Distribution — seven "buses" AFM 7.10.1

Alternator (90A) Main battery ECU Backup Hot Battery Bus (always live) Battery Bus ECU Bus Main Bus Essential Bus Avionic Bus Essential Avionic Bus 50A fuse ELECTRIC MASTER ENGINE MASTER power relay Charges ECU Backup AVIONIC MASTER essential tie relay AVIONIC MASTER Alternate path if ESSENTIAL BUS is ON
The dashed red line = the emergency path: switching ESSENTIAL BUS ON separates the Essential Bus from Main Bus and connects it directly to the Hot Battery Bus instead

The short version: Hot Battery Bus is always live, feeding just the map/reading light and the accessory socket. Battery Bus is the hub — from it, ECU Bus (the engine) and Main Bus (everything else) both get fed. If the alternator fails, you switch the ESSENTIAL BUS switch ON, which separates Main Bus and ties Essential Bus directly to the battery — guaranteeing power for the essential equipment only, for a limited time.

Gauges AFM 7.10.1

  • Voltmeter: shows ECU Bus voltage — which under normal conditions is the alternator voltage. It's normal for it to be in the upper yellow range for the first 10 minutes of engine operation; if it stays yellow for longer than a minute, the ENGINE caution light comes on (on the conventional panel).
  • Ammeter: shows the current the alternator is supplying to the system.

Annunciator panel — the thirteen lights AFM 2.6, 7.10.3

Every light has one color and one cause. Red = Warning (continuous tone + double red blink). Amber = Caution (momentary tone + double amber blink). White = Status (no sound, just information).

Red — WARNING WARNING START DOOR TRIM FAIL ECU BACKUPUNSAFE Amber — CAUTION CAUTION LOW VOLTS ALTERNATOR PITOT LOW FUEL ENGINE ECU A ECU B White — STATUS FUEL TRANS GLOW
13 lights, 3 colors, one cause per light — the full meaning table is below
LightCause
DOORThe front canopy and/or rear door isn't fully closed and locked
STARTThe starter hasn't disengaged from the engine after starting (normal during actual starter operation)
TRIM FAILA failure in the autopilot's automatic trim system
ECU BACKUP UNSAFEThe ECU Backup battery is below 70% charge
LOW VOLTSVoltage below 12.6V (returns to normal above 12.9V)
ALTERNATORAlternator failure — the battery has become the only source
PITOTPitot heat is off or has failed
LOW FUELUsable MAIN fuel is below ~3 US gal
ENGINEA reading on the engine instruments is outside the green range
ECU A / ECU BA fault in the corresponding control unit
FUEL TRANSThe transfer pump is actually running right now
GLOWThe glow plugs are active

The annunciator panel check starts automatically when you switch ELECTRIC MASTER on — every light blinks, sound is muted, and pressing the Acknowledge button turns them off and sounds a brief tone. You can also run an extra self-test by holding that same button for two seconds.

Pitot heat AFM 7.10.1

Double protection: a thermal switch keeps the temperature steady, plus an extra thermal fuse as a last line of defense. If that fuse blows, Pitot heat will never turn back on until it's serviced — the aircraft needs maintenance.

08 Propeller Propeller

A short section because the information about it is compact — but every word in it gets asked about one way or another.

ItemValue
Manufacturer and modelmt-Propeller — MTV-6-A/187-129
Type3-blade, constant speed, hydraulically regulated
Diameter187 cm (6 ft 2 in)
Blade angle (at 0.75R)12° to 28°

The blades themselves are wood-composite with a fiber-reinforced plastic coating and a stainless steel edge — near the hub there's an additional adhesive PU foil layer on the leading edge. The goal: lowest possible weight with minimal vibration.

Blade pitch isn't something the pilot controls directly — it's part of the engine control system, and the ECU adjusts it automatically based on the requested power setting.

Warning Never move the propeller by hand — not while it's running, and not even right after shutdown (there can be residual pressure in the injection line).
Caution Avoid running the engine at high RPM on the ground as much as possible — the blades can be damaged by flying gravel.

09 Flight Controls Flight Controls

The core idea: ailerons, elevator and flaps are all worked by rigid control rods — the rudder is the only one worked by cables. Remember that distinction, because it gets asked in more than one form.

Ailerons AFM 7.3

GFRP/CFRP sandwich construction, 4 hinges per aileron — each hinge pin sits in an aluminum bracket and is secured by a roll pin. Lose that roll pin, and the hinge pin itself can be lost — a real loss of flight safety, not just a maintenance note.

Flaps AFM 7.3

ItemValue
Hinges per flap6
PositionsCruise (UP) · T/O · LDG
Drive typeElectric motor, 3-position selector switch

A torsion tube in the fuselage is what connects the left flap to the right. The Cruise position is at the top of the switch. UP and LDG are additionally protected by a limit switch that prevents overrunning the end of travel.

Flap position indicator: 3 lights next to the selector switch — the upper green light = Cruise/UP, the middle white light = T/O, the lower white light = LDG. If two lights are on together, the flaps are still traveling between two positions.

Elevator and rudder AFM 7.3

SurfaceConstructionHingesOperation
ElevatorGFRP sandwich5Steel push-rods
RudderGFRP sandwichUpper hinge (1 bolt) + lower hinge (4 screws)Steel cables — the one exception

Elevator trim AFM 7.3

A black wheel on the center console, right behind the power lever, with a friction device to prevent over-rotation and a mark showing the T/O position. Turn it forward = nose down, turn it back = nose up.

Pedal adjustment AFM 7.3

Note Pedals may only be adjusted on the ground — pull the black handle behind the rear attachment to unlock them, move your feet to the position you want, and release the handle to lock.

10 Airframe Airframe

Everything "physical" about the aircraft — from the outer structure down to the Pitot-Static system — is in this section. Not one system, but a collection of parts you need to know the basic description of, and where to find them.

Basic structure AFM 7.2

PartDescription
FuselageGFRP, molded semi-monocoque construction. Firewall fire protection is fire-resistant matting, clad in stainless steel on the engine side.
WingsEach wing has two spars (front and rear) plus a top and bottom shell — a "fail-safe" concept. GFRP/CFRP sandwich construction, with an aluminum fuel tank inside each wing.
TailA "T" tail, GFRP semi-monocoque construction. The stabilizers have twin spars with no sandwich, while the rudder and elevator are sandwich construction.

Instrument panel AFM 7.4

The manual describes only two example variants — VFR and IFR — even though many instrument panel versions can actually be fitted. Front ventilation comes from adjustable nozzles in the panel itself, plus spherical nozzles in the roll bar next to the front seats and on the center console above the passengers' heads.

Landing gear and brakes AFM 7.5

Fixed (non-retractable) landing gear — sprung steel main gear struts, and a free-castering nose wheel sprung by an elastomer package. Brakes are hydraulic disk brakes, operated by independent toe pedals.

Note Flying without the wheel fairings is possible, but the manual notes a reduction in some areas of performance.

Parking brake: a lever on the small center console under the instrument panel, in the upper position when released. Pull it down until it catches — pressure is built up beforehand by pumping the toe brake pedals repeatedly.

Seats and baggage compartment AFM 7.6, 7.7

The seats are a carbon fiber/Kevlar hybrid material with GFRP, and include energy-absorbing foam elements — for improved passive safety. The baggage compartment is behind the rear seat backs, and no bag may be loaded without a baggage net fitted.

Canopy and rear door AFM 7.8

  • The front canopy has two locking positions — fully closed, or "Cooling Gap" (a ventilation gap, ground use only, prohibited for take-off).
  • The rear door has a gas pressure damper that stops it dropping suddenly (though it must be held in strong wind), plus an extra lever protecting against unintentional opening.
  • The key lock on either one must never be used before flight, so the aircraft stays openable from outside in an emergency.

Heating and ventilation: two levers on the small center console — the left one, up = heat on, down = heat off. The center one (air distribution), up = DEFROST (toward the canopy), down = FLOOR (toward the floor).

Note — if installed The emergency axe (modification OÄM 40-326) is stowed on the floor panel under the co-pilot's seat, for breaking through the canopy if it can't be opened during an emergency.

Pitot-Static system and stall warning AFM 7.11, 7.12

Total pressure is measured at the leading edge of a Pitot probe under the left wing, and static pressure from two orifices on the same probe. If it fails, the Alternate Static valve lets you use cabin static pressure as a backup source.

Stall warning is a horn, activated by suction from an orifice on the left wing leading edge (marked with a red ring) at roughly 10 down to a minimum of 5 knots above stall speed — it gets louder the closer you get to the critical speed.

Avionics AFM 7.13

A push-to-talk (PTT) button sits on each control stick, with jacks for up to 4 headsets between the front seats.