DIAMOND DA4 XLS The Diamond DA40 Diamond Star is an Austrian four-seat, single engine, light aircraft constructed from composite materials. Built in both Austria and Canada, it was developed as a four-seat version of the earlier DA20 by Diamond Aircraft Industries. It has a fixed nose-wheel landing gear and a T-tail. The Rotax 914 powered prototype DA40-V1, registered OE-VPC, first flew on the 5 November 1997 and was followed by a second prototype DA40-V2 (registered OE-VPE) which was powered by a Continental IO-240. In 1998 a third prototype DA40-V3 flew powered by a Lycoming IO-360 engine. Four more test aircraft were produced followed with the first production aircraft in 2000. JAR23 certification of the IO-360 production variant was obtained in October 2000. In 2002 the production of the Lycoming engined variant was moved to Canada and the Austrian factory concentrated on diesel-engined variants. The DA40 was initially marketed as the DA40-180, powered by a fuel injected Textron Lycoming IO-360 M1A engine. In late 2006, the XL and FP models replaced the DA40-180. The FP replaced the fixed-pitch propeller version of the 180 and the XL replaced the constant-speed propeller version. The major difference between the new models and the 180 is the higher maximum cruise speeds. The DA40-XL is approximately four knots faster than the preceding DA40-180/G1000 with the two-blade Hartzell propeller and the "Speed Gear" option. The XL's speed increase is mostly due to the Powerflow exhaust system. The DA40-XL has a constant-speed propeller and is powered by a 180 hp (130 kW) Lycoming IO-360-M1A fuel injected engine. It has a maximum cruise speed of 147 knots, burning 9.2 gallons of Avgas per hour. Its maximum takeoff weight is 2,535 lb (1,150 kg). The DA40-TDI uses a Thielert "Centurion" 135 hp (101 kW) diesel engine and burns diesel or jet fuel. It has a constant speed propeller and FADEC (single lever) engine control. The first flight of the DA40D was made on Nov. 28, 2002. This model is not certified in the US. Efforts to increase the DA40's cruising speed centered on the propeller and wheel spats. The wheel fairing streamlining was improved, a three- blade scimitar-type constant-speed propeller was incorporated and the Powerflow exhaust system from the XL was retained. The canopy contour was
Transcript
DIAMOND DA4 XLS
The Diamond DA40 Diamond Star is an Austrian four-seat, single engine, light aircraft constructed from composite materials. Built in both Austria and Canada, it was developed as a four-seat version of the earlier DA20 by Diamond Aircraft Industries.
It has a fixed nose-wheel landing gear and a T-tail. The Rotax 914 powered prototype DA40-V1, registered OE-VPC, first flew on the 5 November 1997 and was followed by a second prototype DA40-V2 (registered OE-VPE) which was powered by a Continental IO-240. In 1998 a third prototype DA40-V3 flew powered by a Lycoming IO-360 engine. Four more test aircraft were produced followed with the first production aircraft in 2000. JAR23 certification of the IO-360 production variant was obtained in October 2000. In 2002 the production of the Lycoming engined variant was moved to Canada and the Austrian factory concentrated on diesel-engined variants.
The DA40 was initially marketed as the DA40-180, powered by a fuel injected Textron Lycoming IO-360 M1A engine.
In late 2006, the XL and FP models replaced the DA40-180. The FP replaced the fixed-pitch propeller version of the 180 and the XL replaced the constant-speed propeller version. The major difference between the new models and the 180 is the higher maximum cruise speeds. The DA40-XL is approximately four knots faster than the preceding DA40-180/G1000 with the two-blade Hartzell propeller and the "Speed Gear" option. The XL's speed increase is mostly due to the Powerflow exhaust system.
The DA40-XL has a constant-speed propeller and is powered by a 180 hp (130 kW) Lycoming IO-360-M1A fuel injected engine. It has a maximum cruise speed of 147 knots, burning 9.2 gallons of Avgas per hour. Its maximum takeoff weight is 2,535 lb (1,150 kg).
The DA40-TDI uses a Thielert "Centurion" 135 hp (101 kW) diesel engine and burns diesel or jet fuel. It has a constant speed propeller and FADEC (single lever) engine control. The first flight of the DA40D was made on Nov. 28, 2002. This model is not certified in the US.
Efforts to increase the DA40's cruising speed centered on the propeller and wheel spats. The wheel fairing streamlining was improved, a three-blade scimitar-type constant-speed propeller was incorporated and the Powerflow exhaust system from the XL was retained. The canopy contour was also revised, with the sides being more vertical before curving into the roof, which provides more shoulder and head room.
In the last half of 2007 the company updated the DA40 line by introducing the XLS and CS versions and eliminated the FP model. The XLS is the deluxe version, with the integration of some options into the standard offering including a Powerflow tuned exhaust, WAAS-capable G1000, GDL69 datalink, and TAS traffic alert system. The CS is the budget version, with fewer standard features.
Both CS and XLS versions of the DA40 use the Lycoming IO-360-M1A fuel injected engine. The major difference is the choice of propeller, with the CS using a Hartzell two-blade aluminum constant speed prop and the XLS using an MT composite three-blade unit.
DA40s are produced at Diamond's aircraft factories in Wiener Neustadt, Austria and in London, Ontario, Canada. A joint venture has also been set up in China with Shandong Bin Ao Aircraft Industries for production of the DA40 in Shandong Province. Capacity is available for up to 1,000 aircraft a year to be produced with certification by the European Aviation Safety Agency in 2008.
Past DA40 models were available with either traditional mechanical instruments or an optional Garmin G1000 glass cockpit suite. Current production DA40s are built only with the Garmin G1000 as standard equipment. In April 2008, Diamond introduced the optional availability of Garmin Synthetic Vision Technology on the DA40 XLS.
The DA40 has accumulated a very low accident record, particularly with regard to stall and spin accidents. Its overall and fatal accident rates are one eighth that of the general aviation fleet and include no stall-related accidents. The level of safe operation is attributed to its high aspect ratio wing, low wing loading and benign flight characteristics. The aircraft can be trimmed full nose up, engine set to idle and it will descend at 600-1200 feet per minute at 48 km (89 km/h) hands-off, a lower rate of decent than the competitive Cirrus SR22 can achieve with its airframe ballistic parachute deployed.
In a 2011 analysis by Aviation Consumer magazine, the DA40 was shown to have a fatal accident rate of 0.35/100,000 hours, the lowest in US general aviation and considerably better that the Cirrus SR20 and SR22 with a combined fatal accident rate of 1.6/100,000 hours, despite its full aircraft parachute system.
SPECIFICATIONS DIAMOND DA 40 XLS
AIRCARFT ITEM IFORMATION
Engine Lycoming IO-360-M1AHorsepower 180 hp
Propeller MT 3-blade composite constant-speedAir worthiness category Normal and utility
Length 26 ft 5 inHeight 6 ft 5 in
Wing Spam 39 ft 6 inMaximum take-off weight 2,645 lbs
Maximum operate altitude 16,400 ftMaximum speed 157 ktas
Cruise speed at 75% 150 ktas/ 10 gal/ hrStall speed, full flaps 49 kias
Maximum demonstrated cross wind 20 ktsRange, at 75% 45 minutes reserve 720 nmRange, at 55% 45 minutes reserve 785 nm
GENERAL DESCRIPTION OF THE AIRPLANE
1. General
Diamond Aircraft Industries GmbH, N. A. Otto-Straße 5, A-2700 Wiener Neustadt, Austria, make the DA 40 airplane.
2. Description
The DA 40 is a single-engine, four seat, low-wing monoplane. It has a cantilever wing and a ‘T’ tail...The airplane structure is fiber-reinforced plastic composite. This gives a very strong but light structure. .The semi-monocoque fuselage is a glass-fiber reinforced-plastic (GFRP) shell with GFRP bulkheads and stiffeners. Uni-directional carbon fiber bands give extra strength and stiffness in many areas. Leftand right half-shells bond together with a center section to make the fuselage.
The center section makes the bottom of the cockpit. It has the main bulkheads which connect to the spars in each wing. The vertical stabilizer has two GFRP half-shells that are part of the fuselage shells.
The cantilever wing is a semi-monocoque structure. Each wing has two I-shaped spars with webs made form GFRP/rigid foam sandwich and caps made from CFRP bands. Each wing has top and bottom shells made of CFRP/GFRP/rigid foam sandwich which bond to the spars. GFRP ribs and webs bond to the spars and shells to complete the structure.
The wings attach to the fuselage center section. Each wing has two stump-spars. Four large bolts attach each wing to the fuselage main bulkheads. Standard ailerons and electrically operated flaps attach to the trailing edge of the wing.
The horizontal stabilizer is a semi-monocoque structure. It has top and bottom shells made of GFRP. .The shells bond to GFRP spars and ribs. The trailing edge has a conventional elevator and a trim tab.The one-piece canopy has a large quantity of wrap-around glazing. This gives a good all-round view from the cockpit. A glazed rear passenger door gives access to the rear seats from the left side of the airplane.
A polyurethane paint finish protects the outside skin from ultraviolet rays and humidity. The fixed tricycle landing gear has fairings attached to each leg. The main legs attach to the fuselage center-section. The nose leg attaches to the forward fuselage. Each main wheel has a disc brake on the inside. Hydraulic pressure operates each disc brake.
The flight control system uses conventional ailerons, elevator and rudder. The DA 40 has 2 control sticks and 2 rudder pedal assemblies to operate the primary flight-controls. Push-pull rods operate the ailerons and elevator. Cables operate the rudder.
An electric motor operates the wing flaps. A handwheelp cable operate the elevator trim.
The DA 40 is powered by one of the following engines:
Lycoming IO360 - a four cylinder, direct drive, horizontally-opposed engine. The engine has a fuel Iinjection system and a conventional wet-sump oil system.
The DA 40 has a hydraulic constant-speed propeller with 3 blades.
The airplane has an aluminum fuel tank in each wing. Each tank consists of several chambers. The fuel tanks are inboard between the spars. The tank assemblies have fuel fillers at or near the outboard end. Flexible hoses connect the tanks to a fuel selector and shut-off valve under the cockpit floor. An electrical boost pump (Lycoming version only) and an engine driven pump supply fuel to the engine. The tanks have fuel quantity probes which operate the cockpit indicating systems.
The airplane has two sources of electrical power. A 28 Volt (Lycoming version) battery supplies power when the engine is not running. An alternator provides power when the engine is running. Switches and circuit breakers control all electrical devices. A starter key controls the engine starter motor. It also controls the magnetos (Lycoming version)).
The DA 40 has a full range of flight instruments. These include Pitot/static instruments to show airspeed and altitude, as well as electrically driven instruments and vacuum driven instruments version only) to show attitude. The airplane has all the usual engine instruments, except that the The airplane also has radio and navigation aids installed.
OPERATORS
This is an aircraft which is used in a few countries like a civil aircraft or like a military aircraft.
Civil
The aircraft is popular with flying schools and is operated by private individuals and companies.
Military
It’s used in the following countries
Bolivian Air Force - 9 for basic flight training Ecuadorian Air Force
Academy “Cosme Rennella Barbatto” Jamaican Defence Forces Singapore Youth Flying Club United States Air Force Academy
57-10 RIGHT WING STRUCTURE FROM ILLUSTRATED PARTS CATALOG
Pos. Part No. Description Quant. Remarks S/N 1 from
02-1 Right Wing Structure RF
010 Wing Top Shell RF D4.001
020 Wing Bottom Shell RF D4.001
030 DA4-5717-00-00 Rear Spar 1 D4.001
040 DA4-5715-00-00 Front Spar 1 D4.001
060 DA4-5712-40-00 Front Root Rib 1 D4.001
070 DA4-5712-41-00 Middle Root Rib 1 D4.001
080 DA4-5712-42-00 Rear Root Rib 1 D4.001
090 DA4-5712-44-00 Main Fuel Tank Inner Rib 1 D4.001
100 DA4-5712-45-00 Main Fuel Tank Outer Rib 1 D4.001
110 DA4-5712-47-00 Flap Control Rib 1 D4.001
120 DA4-5712-46-00 Aileron Control Rib 1 D4.001
130 DA4-5711-49-00 End Rib 1 D4.001
140 DA4-5732-00-00 Wing Tip 1 D4.001
150 DA4-5711-49-00 End Rib 1 D4.001
155 DA4-5712-51-00 Rear Web 2 1 D4.001
160 DS-NS1-200-145-B Anchor-Nut Plate 6 D4.001
170 DS-NS1-175-145-B Anchor-Nut Plate 2 D4.001
180 DIN7337 POP Rivet, Pan Head 16 D4.001
200 DA4-5710-00-51 Hinge Link, Flaps 2 D4.001
210 DA4-5710-00-52 Bracket, Flaps 2 D4.001
220 DIN912-M5x16-8,8 Screw, Internal Hex. Head 8 D4.001
230 DIN125A-M5 Washer 8 D4.001
240 DIN9021B-M5 Washer 8 D4.001
250 DIN985-M5 Nut 8 D4.001
300 DA4-5710-00-52 Bracket, Flaps 1 D4.001
310 DA4-5710-00-53 Bracket, Ailerons 1 D4.001
320 DIN912-M5x16-8,8 Screw, Internal Hex. Head 4 D4.001
