G1000 System Maintenance Manual

Diamond DA40 NG · Maintenance Manual

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Overview

The G1000 System Maintenance Manual provides comprehensive instructions for the continued airworthiness of the Garmin G1000 integrated avionics and GFC700 Automatic Flight Control System (AFCS) installed in the Diamond DA 40 and DA 40 F aircraft. This manual is essential for maintenance personnel and operators to ensure compliance with FAA regulations and to maintain the operational integrity of the avionics systems. It includes detailed procedures for maintenance, troubleshooting, and equipment replacement, as well as safety precautions and guidelines for handling the avionics systems. The manual is structured to facilitate easy navigation through various sections, covering system descriptions, operational instructions, and maintenance intervals, ensuring that all necessary information is readily accessible for effective aircraft management.

The manual provides Instructions for Continued Airworthiness (ICA) for the G1000 and GFC700 systems in the Diamond DA 40 and DA 40 F.
Maintenance intervals and visual inspection procedures are critical for ensuring the airworthiness of the aircraft.
Troubleshooting procedures are included for common issues related to the G1000 alerting system and specific aircraft alerts.
Equipment removal and replacement procedures are detailed to assist maintenance personnel in managing avionics components safely.
The manual includes safety precautions for handling live circuits and sensitive equipment.

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Document details

Type: Maintenance Manual
Year: 2009
Pages: 223
File size: 4.1 MB
Publisher: diamondaviators.net

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In this document

Introduction

This section outlines the content, scope, and purpose of the manual, emphasizing its role in providing Instructions for Continued Airworthiness (ICA) for the G1000 and GFC700 systems in the DA 40 and DA 40 F. It specifies the applicability of the document to all aircraft equipped with these systems under the relevant Supplemental Type Certificate (STC).

System Description

This section provides an overview of the G1000 system, including equipment descriptions, electrical power distribution, and lightning strike protection. It details the various components and their functions within the integrated avionics system, ensuring that maintenance personnel understand the system's architecture.

Instructions for Continued Airworthiness

This section outlines the airworthiness limitations, servicing information, and maintenance intervals necessary for the continued operation of the G1000 and GFC700 systems. It includes visual inspection procedures and specific checks required for maintaining system integrity.

Troubleshooting

This section offers guidance on troubleshooting the G1000 alerting system, system annunciations, and specific alerts related to the DA 40 and DA 40 F. It provides detailed procedures for diagnosing and resolving common issues that may arise during operation.

Equipment Removal & Replacement

This section details the procedures for the removal and replacement of various G1000 components, including the MFD, PFD, audio panel, and integrated avionics units. It ensures that maintenance personnel can safely and effectively manage equipment changes.

System Return to Service Procedure

This section outlines the necessary steps for verifying software and testing backup systems before returning the aircraft to service. It emphasizes the importance of thorough checks to ensure operational readiness.

Safety notes

Keep away from live circuits; turn off system power before making electrical connections.
Components retaining a charge should be discharged carefully to avoid equipment damage.
Use caution with GDU 104X lenses; ammonia-based cleaners can harm the anti-reflective coating.

Full document text

190-00545-01 May 2009 Revision E G1000 System Maintenance Manual Diamond DA 40 & DA 40 F With GFC 700 or KAP 140 AFCS Contains FAA-Accepted Instructions For Continued Airworthiness For STC SA01444WI-D Page A G1000 System Maintenance Manual – DA 40/40F Revision E 190-00545-01 © Copyright 2008 Garmin Ltd. or its subsidiaries All Rights Reserved Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted, disseminated, downloaded or stored in any storage medium, for any purpose without the express prior written consent of Garmin. Garmin hereby grants permission to download a single copy of this manual and of any revision to this manual onto a hard drive or other electronic storage medium to be viewed and to print one copy of this manual or of any revision hereto, provided that such electronic or printed copy of this manual or revision must contain the complete text of this copyright notice and provided further that any unauthorized commercial distribution of this manual or any revision hereto is strictly prohibited. Garmin International, Inc. 1200 E. 151 st Street Olathe, KS 66062 USA Telephone: 913-397-8200 www.garmin.com Garmin (Europe) Ltd. Liberty House Bulls Copse Road Hounsdown Business Park Southampton, SO40 9RB, UK Phone: +44 (0) 23 8052 4000 Fax: +44 (0) 23 8052 4004 RECORD OF REVISIONS Revision Revision Date Description ECO # A 6/19/2007 Initial release for STC. ------ B 1/03/2008 Update for Phase 7: Add KAP 140 alignment & update FAR 91.411 & Appendix E testing. General updates throughout where noted. 51022 C 3/28/2008 Update for minor change to STC 52069 D 4/8/2008 Update for minor change to STC to add software 0321.19. 52347 E 5/04/09 Update for major change to STC to add software 0321.22 58693 DOCUMENT PAGINATION Section Pagination Table of Contents i – vi Section 1 1-1 – 1-8 Section 2 2-1 – 2-12 Section 3 3-1 – 3-34 Section 4 4-1 – 4-28 Section 5 5-1 – 5-76 Section 6 6-1 – 6-12 Section 7 7-1 – 7-28 Section 8 8-1 – 8-16 G1000 System Maintenance Manual – Diamond DA40/40F Page i 190-00545-01 Revision E The following are General Safety Precautions that are not related to any specific procedure and therefore do not appear elsewhere in this maintenance manual. These are recommended precautions that personnel should understand and apply during the many phases of maintenance and repair. KEEP AWAY FROM LIVE CIRCUITS. Maintenance personnel shall observe all safety regulations at all times. Turn off system power before making or breaking electrical connections. Regard any exposed connector, terminal board, or circuit board as a possible shock hazard. Components which retain a charge shall be discharged only when such grounding does not result in equipment damage. If a test connection to energized equipment is required, make the test equipment ground connection before probing the voltage or signal to be tested. INFORMATION SUBJECT TO EXPORT CONTROL LAWS This document may contain information which is subject to the Export Administration Regulations ("EAR") issued by the United States Department of Commerce (15 CFR, Chapter VII, Subchapter C) and which may not be exported, released, or disclosed to foreign nationals inside or outside of the United States without first obtaining an export license. A violation of the EAR may be subject to a penalty of up to 10 years imprisonment and a fine of up to $1,000,000 under Section 2410 of the Export Administration Act of 1979. Include this notice with any reproduced portion of this document. WARNING! This product, its packaging, and its components contain chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. This Notice is being provided in accordance with California's Proposition 65. If you have any questions or would like additional information, please refer to our web site at www.garmin.com/prop65. WARNING! The GDU 104X lamps contain mercury and must be recycled or disposed of according to local, state, or federal laws. If you have any questions or would like additional information, please refer to our web site at www.garmin.com/aboutGarmin/environment/disposal.jsp. CAUTION The GDU 1040s use a lens coated with a special anti-reflective coating that is very sensitive to skin oils, waxes and abrasive cleaners. CLEANERS CONTAINING AMMONIA WILL HARM THE ANTI- REFLECTIVE COATING. It is very important to clean the lens using a clean, lint-free cloth and an eyeglass lens cleaner that is specified as safe for anti-reflective coatings. NOTE All G1000 screen shots used in this document are current at the time of publication. Screen shots are intended to provide visual reference only. All information depicted in screen shots, including software file names, versions and part numbers, is subject to change and may not be up to date. NOTE The LRU serial numbers displayed on the screen are for convenience only and should be disregarded in determining the LRU software revision. For compliance activities requiring LRU serial number determination, the unit serial number used must be that on the physical LRU label, not the one displayed on the SYSTEM STATUS page. Page ii G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 NOTE All references to Diamond DA 40 aircraft made in this manual equally apply to Diamond DA 40 F aircraft, unless otherwise noted. NOTE All references to GIA 63 LRUs made in this manual equally apply to GIA 63W LRUs unless otherwise noted. G1000 System Maintenance Manual – Diamond DA40/40F Page iii 190-00545-01 Revision E TABLE OF CONTENTS PARAGRAPH PAGE 1 INTRODUCTION 1-1 1.1 CONTENT , S COPE , P URPOSE ..........................................................................................................1-1 1.2 ORGANIZATION .............................................................................................................................1-3

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1.3 DEFINITIONS/ABBREVIATIONS ......................................................................................................1-4 1.4 P UBLICATIONS ..............................................................................................................................1-6 1.5 DISTRIBUTION ...............................................................................................................................1-7 2 SYSTEM DESCRIPTION 2-1 2.1 STC REQUIREMENTS OVERVIEW ..................................................................................................2-1 2.2 E QUIPMENT DESCRIPTIONS ...........................................................................................................2-2 2.3 GDL 69A (OPTIONAL ) ..................................................................................................................2-4 2.4 REMOTE AVIONICS E NCLOSURE ...................................................................................................2-4 2.5 G1000 OPTIONAL I NTERFACES .....................................................................................................2-4 2.6 GFC 700 AFCS S YSTEM DESCRIPTION ........................................................................................2-5 2.7 E LECTRICAL P OWER DISTRIBUTION .............................................................................................2-9 2.8 L IGHTNING S TRIKE P ROTECTION ................................................................................................2-10 2.9 S HIELD BLOCK GROUNDS ...........................................................................................................2-11 2.10 S ENSOR I NSTALLATIONS .............................................................................................................2-11 2.11 BLOCK DIAGRAMS ......................................................................................................................2-11 3 G1000 CONTROL & OPERATION 3-1 3.2 G1000 NORMAL M ODE .................................................................................................................3-3 3.3 REVERSIONARY M ODE ..................................................................................................................3-4 3.4 CONFIGURATION M ODE OVERVIEW .............................................................................................3-5 3.5 G1000 / GFC 700 S OFTWARE I NFORMATION ..............................................................................3-12 3.6 G1000 S OFTWARE /CONFIGURATION P ROCEDURE ......................................................................3-19 4 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 4-1 4.1 AIRWORTHINESS L IMITATIONS .....................................................................................................4-1 4.2 S ERVICING I NFORMATION .............................................................................................................4-2 4.3 M AINTENANCE I NTERVALS ...........................................................................................................4-4 4.4 VISUAL I NSPECTION ......................................................................................................................4-8 4.5 E LECTRICAL BONDING T EST .......................................................................................................4-10 4.6 F UEL T ANK PROBE RE -CALIBRATION ........................................................................................4-11 4.7 GRS 77 E ARTH M AGNETIC F IELD UPDATES ...............................................................................4-16 4.8 GSA 81 GREASING P ROCEDURE .................................................................................................4-16 4.9 (SW V0321.19 OR EARLIER) F LAP P OSITION DISCRETE I NPUT CHECK.......................................4-17 4.10 (SW V0321.22) F LAP P OSITION DISCRETE I NPUT CHECK ..........................................................4-18 4.11 S LIP CLUTCH T ORQUE CHECK P ROCEDURE ...............................................................................4-19 4.12 (SW V0321.19 OR EARLIER) PFD/MFD P OWER I NTERRUPT F UNCTION CHECK ........................4-20 4.13 (SW V0321.22) PFD/MFD P OWER I NTERRUPT F UNCTION CHECK ............................................4-21 4.14 L IGHTNING P ROTECTION FUSE REPLACEMENT ..........................................................................4-25 5 TROUBLESHOOTING 5-1 5.1 G1000 ALERTING S YSTEM ............................................................................................................5-2 5.2 S YSTEM ANNUNCIATIONS .............................................................................................................5-5 5.3 DA 40/DA 40 F S PECIFIC ALERTS ..............................................................................................5-12 5.4 TAWS T ROUBLESHOOTING ........................................................................................................5-13 5.5 GFC 700 AFCS T ROUBLESHOOTING ..........................................................................................5-14 5.6 BACKUP COMMUNICATIONS P ATH CHECKS ...............................................................................5-27 5.7 GDU 104X T ROUBLESHOOTING .................................................................................................5-51 Page iv G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 5.8 GDU 104X ALERTS ....................................................................................................................5-53 5.9 GIA 63 T ROUBLESHOOTING ........................................................................................................5-59 5.10 GIA ALERT M ESSAGES ...............................................................................................................5-60 5.11 GEA T ROUBLESHOOTING ...........................................................................................................5-65 5.12 GTX T ROUBLESHOOTING ...........................................................................................................5-66 5.13 GRS 77/GMU 44 T ROUBLESHOOTING ........................................................................................5-67 5.14 GDC 74A T ROUBLESHOOTING ...................................................................................................5-73 5.15 GDL 69A T ROUBLESHOOTING ....................................................................................................5-74 6 G1000 EQUIPMENT REMOVAL & REPLACEMENT 6-1 6.1 GDU 104X MFD & PFD...............................................................................................................6-3 6.2 GMA 1347 AUDIO P ANEL .............................................................................................................6-3 6.3 GIA 63 (W) INTEGRATED AVIONICS UNITS ..................................................................................6-3 6.4 GEA 71 E NGINE /AIRFRAME UNIT ................................................................................................6-4 6.5 GTX 33 T RANSPONDER ................................................................................................................6-4 6.6 GDC 74A AIR DATA COMPUTER ..................................................................................................6-5 6.7 GTP 59 OAT P ROBE .....................................................................................................................6-5 6.8 GRS 77 AHRS ..............................................................................................................................6-5 6.9 GMU 44 M AGNETOMETER ...........................................................................................................6-6 6.10 GDL 69A.......................................................................................................................................6-6 6.11 GSA 81 S ERVOS ............................................................................................................................6-7 6.12 GSM 85 SERVO M OUNTS ..............................................................................................................6-7 6.13 CONFIGURATION M ODULE REMOVAL & REPLACEMENT .............................................................6-8 6.14 GEA 71 BACKSHELL T HERMOCOUPLE REMOVAL & REPLACEMENT .........................................6-10 6.15 GA35 GPS/WAAS ANTENNAS ...................................................................................................6-11 7 G1000 EQUIPMENT CONFIGURATION & TESTING 7-1 7.1 GDU 104X MFD & PFD...............................................................................................................7-1 7.2 GMA 1347 AUDIO P ANEL .............................................................................................................7-3 7.3 GIA 63 I NTEGRATED AVIONICS UNIT ...........................................................................................7-4 7.4 GEA 71 E NGINE /AIRFRAME UNIT ..............................................................................................7-10 7.5 GTX 33 T RANSPONDER ..............................................................................................................7-12 7.6 GDC 74A AIR DATA COMPUTER ................................................................................................7-14 7.7 GRS 77 AHRS / GMU 44 M AGNETOMETER ...............................................................................7-17 7.8 GDL 69 XM DATA L INK .............................................................................................................7-28 8 SYSTEM RETURN TO SERVICE PROCEDURE 8-1 8.1 S OFTWARE V ERIFICATION ............................................................................................................8-1 8.2 BACKUP P ATH S YSTEM T ESTING ..................................................................................................8-3 8.3 GFC 700 GROUND CHECKOUT ....................................................................................................8-13 8.4 M AINTENANCE RECORDS ...........................................................................................................8-16 G1000 System Maintenance Manual – Diamond DA40/40F Page v 190-00545-01 Revision E LIST OF ILLUSTRATIONS FIGURE PAGE Figure 2-1. AFCS System Block Diagram................................................................................................2-6 Figure 2-2. GSA 81 & GSM 85 ................................................................................................................2-8 Figure 2-3. G1000/DA40 Electrical Distribution......................................................................................2-9 Figure 2-4. G1000/KAP 140 Block Diagram (no WAAS) .....................................................................2-11 Figure 2-5. G1000/GFC 700 Block Diagram (WAAS shown)...............................................................2-12 Figure 3-1. GDU 104X Control Interface (GDU 1042 shown) ................................................................3-1 Figure 3-2. AFCS Controls (GDU 1044 shown) ......................................................................................3-1 Figure 3-3. GMA 1347 Controls...............................................................................................................3-2 Figure 3-4. G1000 Softkeys ......................................................................................................................3-2 Figure 3-5. Normal Mode .........................................................................................................................3-3 Figure 3-6. MFD Failure Mode.................................................................................................................3-4 Figure 3-7. PFD Failure Mode..................................................................................................................3-4 Figure 3-8. SET>ACTV Diagram.............................................................................................................3-7 Figure 3-9. Loss of Communication .........................................................................................................3-8 Figure 3-10. Configuration Status.............................................................................................................3-8 Figure 3-11. Data Transmission Indicators...............................................................................................3-8 Figure 3-12. Data Transmission Indicators...............................................................................................3-9 Figure 3-13. G1000 LRU Configuration File Storage ............................................................................3-17 Figure 3-14. GRS/GDC Configuration Settings Storage ........................................................................3-18 Figure 3-15. Software/Configuration Overview .....................................................................................3-19 Figure 4-1. Total Time In Service.............................................................................................................4-3 Figure 4-2. (SW v0321.19 or earlier) GIA I/O Page...............................................................................4-17 Figure 4-3. (SW v0321.22) GIA I/O Page ..............................................................................................4-18 Figure 4-4. GDU TEST Page..................................................................................................................4-20 Figure 4-5. Backup Capacitor Test Selection .........................................................................................4-22 Figure 4-6. Upload Complete Window...................................................................................................4-23 Figure 4-7. BKUP CAPS Checkbox on GDU TEST Page .....................................................................4-24 Figure 4-8. Aircraft Fuselage Fuse Locations.........................................................................................4-25 Figure 4-9. Instrument Panel Detail A ....................................................................................................4-26 Figure 4-10. Instrument Panel Detail B ..................................................................................................4-26 Figure 4-11. Remote Avionics Enclosure Detail C.................................................................................4-27 Figure 4-12. Remote Avionics Enclosure Detail D ................................................................................4-28 Figure 5-1. AUX – System Status Page....................................................................................................5-1 Figure 5-2. Alerts & Annunciations..........................................................................................................5-2 Figure 5-3. WARNING Softkey Annunciation ........................................................................................5-3 Figure 5-4. CAUTION Softkey Annunciation..........................................................................................5-3 Figure 5-5. ADVISORY Softkey Annunciation .......................................................................................5-3 Figure 5-6. System Annunciations............................................................................................................5-5 Figure 5-7. AFCS Annunciation Field....................................................................................................5-14 Figure 5-8. GMA 1347 Data Paths .........................................................................................................5-27 Figure 5-9. GEA 71 Data Paths ..............................................................................................................5-28 Figure 5-10. GTX 33 Data Paths ............................................................................................................5-29 Figure 5-11. GDC 74A Data Paths .........................................................................................................5-30 Figure 5-12. GRS 77 Data Paths.............................................................................................................5-31 Figure 5-13. (SW v0321.19 or earlier) Magnetometer Interference Test ...............................................5-69 Figure 5-14. (SW v0321.22) Magnetometer Interference Test...............................................................5-70 Figure 5-15. GDL 69A Data Paths..........................................................................................................5-75 Figure 6-1. (SW v0321.19 or earlier) System Status Page (Configuration Mode) ..................................6-1 Figure 6-2. (SW v0321.22) System Status Page (Configuration Mode)..................................................6-1 Figure 6-3. Configuration Module Installation .........................................................................................6-8 Page vi G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 Figure 6-4. GEA Backshell Thermocouple.............................................................................................6-10 Figure 7-1. G1000 Normal Mode Check ..................................................................................................7-1 Figure 7-2. G1000 Reversionary Mode Check .........................................................................................7-2 Figure 7-3. Marker Beacon Symbology....................................................................................................7-3 Figure 7-4. AUX – GPS STATUS Page (MFD).......................................................................................7-5 Figure 7-5. Normal Mode AHRS Check ................................................................................................7-26 Figure 7-6. Reversionary Mode AHRS Information...............................................................................7-27 Figure 8-1. (SW v0321.19 or earlier) System Status Page (Configuration Mode) ..................................8-1 Figure 8-2. (SW v0321.22) System Status Page (Configuration Mode)...................................................8-1 Figure 8-3. Pre-Flight Test......................................................................................................................8-13 LIST OF TABLES TABLE PAGE Table 1-1. MDL Configurations Summary...............................................................................................1-1 Table 1-2. Required Documents ...............................................................................................................1-6 Table 1-3. Previously Approved Type Design..........................................................................................1-6 Table 1-4. Reference Publications ............................................................................................................1-7 Table 3-1. LRU to Configuration File Relationship Summary...............................................................3-16 Table 4-1. Maintenance Intervals..............................................................................................................4-4 Table 4-2. Visual Inspection Procedure....................................................................................................4-8 Table 4-3. Power Interrupt Category A (200mS) Mod Status ................................................................4-20 Table 4-4. Power Interrupt Category A (200mS) Mod Status ................................................................4-21 Table 4-5. Lightning Protection Fuse Part Numbers ..............................................................................4-25 Table 5-1. AFCS Annunciation Troubleshooting ...................................................................................5-15 Table 5-2. AFCS General Troubleshooting ............................................................................................5-16 Table 5-3. PFT Faults (Monitor Processor) ............................................................................................5-24 Table 5-4. Normal Mode Faults (Monitor Processor).............................................................................5-24 Table 5-5. PFT Faults (Control Processor) .............................................................................................5-25 Table 5-6. Normal Mode Faults (Control Processor)..............................................................................5-25 Table 5-7. Magnetometer Interference Test Sequence (Example)..........................................................5-71 Table 6-1. Configuration Module Kit – 011-00979-00.............................................................................6-8 Table 6-2. Thermocouple Kit (011-00981-00) .......................................................................................6-10 Table 7-1: Engine/Airframe Instrument Checks .....................................................................................7-11 G1000 System Maintenance Manual – Diamond DA40/40F Page 1-1 190-00545-01 Revision E 1 INTRODUCTION 1.1 Content, Scope, Purpose This document provides Instructions for Continued Airworthiness (ICA) for the Garmin G1000 integrated avionics and GFC700 Automatic Flight Control System (AFCS) as installed in the Diamond Model DA 40 and DA 40 F. This document satisfies the requirements for continued airworthiness as defined by 14 CFR Part 23.1529 and Appendix G. Information in this document is required to maintain the continued airworthiness of the G1000 and GFC700. 1.1.1 Applicability This document applies to all Diamond Aircraft Industries, Inc., Model DA 40 and DA 40 F aircraft equipped with the G1000 and optional GFC700 AFCS system under this STC. Modification of an aircraft by this Supplemental Type Certificate (STC) obligates the aircraft operator to include the maintenance information provided by this document in the operator’s Aircraft Maintenance Manual and the operator’s Aircraft Scheduled Maintenance Program. This System Maintenance manual and the contained Instructions for Continued Airworthiness supersedes all previous system maintenance manuals and ICAs, including the following Garmin documents: • 190-00303-03 • 190-00492-01 • 190-00492-03 • 190-00545-00 NOTE Differences in software versions that affect the maintenance manual content will be indicated with in the procedures as needed. If no indication of software version is provided for the procedure or step then it is understood to apply to all software versions. 1.1.2 Identifying an MDL Configuration There are six approved configurations within this STC, each defined as a subset of the Master Drawing List (MDL). Each configuration differs in both hardware and software installation requirements. Refer to the MDL, Garmin document 005-00400-01 for each configuration type design definition. Table 1-1. MDL Configurations Summary MDL Configuration Aircraft System Upgrades Available G1000 System Software Version -1 Configuration Software Upgrade WAAS Upgrade Coupled VNAV (optional) 0369.13, 0321.17, 0321.18, 0321.19 or 0321.22 -2 Configuration G1000 & GFC 700 Software Upgrade Coupled VNAV (optional) 0369.13, 0321.17, 0321.19 or 0321.22 -3 Configuration Software Upgrade WAAS Upgrade 0369.13, 0321.17, 0321.18, 0321.19 or 0321.22 -4 Configuration G1000 & No AP Software Upgrade 0369.13, 0321.17, 0321.19 or 0321.22 -5 Configuration Software Upgrade WAAS Upgrade 0321.17, 0321.18, 0321.19 or 0321.22 -6 Configuration G1000 & Honeywell KAP 140 Software Upgrade 0321.17, 0321.19 or 0321.22 Page 1-2 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 IMPORTANT! If the technician is unsure of the G1000 MDL configuration, perform the following steps: Check System Software Version 1. Power on the G1000 system by turning on the BAT master switch, then the AVIONICS MASTER switch. 2. On the MFD power-up page, the G1000 system software version is displayed in the upper right corner in the following format: Diamond DA40 System XXXX.XX -or- Diamond DA40F System XXXX.XX The system software version is also displayed at the AUX – SYSTEM STATUS page in the upper right corner. 3. This system software version is the primary identifier of which G1000/GFC700 configuration is installed. Refer to Table 1-1. NOTE The approved G1000 system software versions for this STC are listed in Table 1-1. If the system software version differs from that shown in Table 1-1, investigate further to determine which G1000 configuration is installed. Refer to the appropriate G1000/GFC700 System Maintenance manual (see list of superseded manuals which may apply in Section 1.1.1). Check for GFC 700 AFCS Installation To verify whether the GFC 700 AFCS is installed, do the following; 1. Check the G1000 MFD for a dedicated AFCS mode control keypad (see Figure 3-2). 2. Check the aircraft throttle lever for installation of a ‘Go Around’ (GA) button. 3. If the aircraft has these features installed, it is equipped with the Garmin GFC 700 autopilot. 4. The aircraft is either a -1 or a -2 MDL Configuration. Check for WAAS Installation To verify whether WAAS is installed, do the following: 1. On the MFD, go to the AUX – GPS STATUS page. 2. Check to see whether a softkey labeled SBAS is displayed. The SBAS softkey only appears if the G1000 is equipped with GIA 63Ws. 3. If the SBAS softkey is present, the aircraft is a -1, -3, or a -5 MDL Configuration. G1000 System Maintenance Manual – Diamond DA40/40F Page 1-3 190-00545-01 Revision E 1.2 Organization The following outline briefly describes the organization of this manual: Section 2: System Description Provides a complete description of the type design change associated with installing the G1000 integrated cockpit system in the Diamond DA 40. An overview of the G1000 and GFC 700 system interface is also provided. Section 3: G1000 Control & Operation Presents basic control and operation information specifically tailored to maintenance practices. Basic G1000 Configuration Mode operation is also described. Section 4: G1000 Instructions for Continued Airworthiness FAA-Approved Instructions for Continued Airworthiness provides airworthiness limitations and scheduled maintenance requirements for the G1000 and GFC 700 systems. Section 5: Troubleshooting Provides troubleshooting information to aid in diagnosing and resolving potential problems with the G1000 and GFC 700 systems. Section 6: G1000 Equipment Removal & Replacement Gives instructions for the removal and replacement of G1000 and GFC700 equipment. Section 7: G1000 Equipment Configuration & Testing Gives instructions for loading software, configuring, and testing of G1000 equipment. Section 8: System Return to Service Procedure Specifies return-to-service procedures to be performed upon completion of maintenance of the G1000 system. Page 1-4 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 1.3 Definitions/Abbreviations The following are some common acronyms & definitions found throughout this manual: ADI: Attitude Display Indicator ADF: Automatic Direction Finder AFCS: Automatic Flight Control System AFMS: Airplane Flight Manual Supplement AHRS: Attitude Heading Reference System AMM: Airplane Maintenance Manual CDI: Course Deviation Indicator CDU: Control Display Unit CFR: Code of Federal Regulations DME: Distance Measuring Equipment EAU: Engine/Airframe Unit EIS: Engine Instrumentation Systems GDL: Garmin Data Link GDU: Garmin Display Unit GEA: Garmin Engine Airframe Unit GIA: Garmin Integrated Avionics GMA: Garmin Marker Beacon & Audio Panel Unit GMU: Garmin Magnetometer Unit GPS: Global Positioning System GS: Glideslope GSA: Garmin Servo Actuator GSM: Garmin Servo Mount GTX: Garmin Transponder HIRF: High Intensity Radiated Fields HSDB: High-Speed Data Bus (Ethernet) HSI: Horizontal Situation Indicator IAU: Integrated Avionics Unit ICA: Instructions for Continued Airworthiness ICS: Inter-Com System ILS: Instrument Landing System LOC: Localizer LPV: Localizer Precision with Vertical Guidance approach LRU: Line Replaceable Unit MET: Manual Electric Trim MFD: Multi-Function Flight Display OAT: Outside Air Temperature OBS: Omni-Bearing Selector PFD: Primary Flight Display G1000 System Maintenance Manual – Diamond DA40/40F Page 1-5 190-00545-01 Revision E STC: Supplemental Type Certificate SW: Software TC: Type Certificate TSO: Technical Standard Order TVS: Transient Voltage Suppressor WAAS: Wide Area Augmentation System VHF: Very High Frequency VOR: Very High Frequency Omni-directional Range 1.3.1 Units of Measure Unless otherwise stated, all units of measure are English units. Page 1-6 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 1.4 Publications The following documents are required by this maintenance manual to perform maintenance: Table 1-2. Required Documents Part Number Document 005-00400-01 STC Master Drawing List 005-00400-08 General Arrangement, G1000/KAP140, WAAS, Diamond DA40/40F (-5 MDL Configuration) 005-00400-09 General Arrangement, G1000/KAP140, no WAAS, Diamond DA40/40F (-6 MDL Configuration) 005-00400-10 General Arrangement, G1000/GFC700, WAAS, Diamond DA40/40F (-1 MDL Configuration) 005-00400-11 General Arrangement, G1000/GFC700, no WAAS, Diamond DA40/40F (-2 MDL Configuration) 005-00400-15 General Arrangement, G1000 Only, WAAS, Diamond DA40/40F (-3 MDL Configuration) 005-00400-16 General Arrangement, G1000 Only, no WAAS, Diamond DA40/40F (-4 MDL Configuration) 005-00400-12 Resistor Installation Drawing, G1000, WAAS, Diamond DA40/40F (-1 & -3 MDL Configurations) 005-00400-13 Resistor Wiring Diagram, G1000, WAAS, Diamond DA40/40F (-1 & -3 MDL Configurations) 005-00400-55 Optional Dual Audio Path Wiring For TAWS Installations in Diamond DA40 / DA40F DA4-9231-60-01 OR DA4-9231-60-05 Diamond Wiring Diagram (Diamond Part Number, -05 applies to GFC700 aircraft) 6.02.01 Diamond DA 40 Airplane Maintenance Manual (Diamond Part Number) The following design drawings are carried over from the prerequisite previously approved STCs for continued airworthiness purposes. IMPORTANT! Previous STC General Arrangement drawings, Required Equipment Lists, and hardware/software equipment lists are obsolete and are now superseded by the new General Arrangement drawings provided in Table 1-2. The following type design data still applies to previously installed equipment. Table 1-3. Previously Approved Type Design Part Number Document STC# 005-00304-00 G1000 Install, Diamond DA40/40F SA01254WI-D 005-00336-17 Pitch Servo Installation, GFC700 AFCS, Diamond DA40/40F 005-00336-18 Roll Servo Installation, GFC700 AFCS, Diamond DA40/40F 005-00336-19 Pitch Trim Servo Installation, GFC700 AFCS, Diamond DA40/40F SA01389WI G1000 System Maintenance Manual – Diamond DA40/40F Page 1-7 190-00545-01 Revision E The following publications are recommended to be available during maintenance activities. Table 1-4. Reference Publications Part Number Document 005-00304-00 G1000 Install, Diamond DA40/40F 190-00492-10 G1000/GFC 700, DA40 Airplane Flight Manual Supplement 190-00492-11 G1000, No Autopilot, DA40 Airplane Flight Manual Supplement 190-00492-12 G1000, KAP140, DA40 Airplane Flight Manual Supplement 190-00324-07, 190-00324-08, OR 190-00324-09 G1000/GFC700 DA 40 Cockpit Reference Guide* 190-00355-04 GDL 69/69A XM Satellite Radio Activation Instructions *See AFMS for correct CRG P/N required. 1.5 Distribution This document is required for maintaining the continued airworthiness of aircraft equipped with this STC. Revisions to this document will be made by Garmin and will be distributed by Garmin per standard documentation revision procedures. For the latest revision to this document, check Garmin’s web site at: www.garmin.com/ and click on ‘Dealers Only’. NOTE Only Garmin-authorized dealers and service centers are given access to the Dealer portion of the Web Site. If you do not have a Dealer Password, contact Garmin directly to obtain the latest revision of this document. Page 1-8 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 This page intentionally left blank. G1000 System Maintenance Manual – Diamond DA40/40F Page 2-1 190-00545-01 Revision E 2 SYSTEM DESCRIPTION 2.1 STC Requirements Overview The -1 and -2 STC configurations require the following STCs to be installed on the aircraft prior or concurrently to the installation of this STC: STC #SA01254WI-D Garmin G1000 in Diamond DA40 / 40F STC #SA01389WI Garmin GFC 700 in Diamond DA40 / 40F For the -3, -4, -5, and -6 configurations of this STC, only STC #SA01254WI-D is required to be installed. Certain Diamond Optional Aircraft Modifications (OAM) are part of the initial type design requirements for the above STCs. These modifications define much of the systems and electrical design for the Garmin G1000 and GFC 700 and are installed by the Diamond factory. The following OAMs may be installed on a DA40 equipped with the G1000, depending on STC configurations: DA40 & DA40F Aircraft: OAM 40-226 G1000/GFC700 Provisions OAM 40-061 KAP 140 Autopilot (Optional)* OAM 40-068 Essential Bus OAM 40-073 Slick Start System OAM 40-082 IFR Lightning Protection OAM 40-146 Remote Avionics Provisions OAM 40-071 Extended Range Fuel Tanks OAM 40-162 G1000 with Extended Range Fuel Tanks OAM 40-210 Provisions for Becker RA3502 ADF OAM 40-211 Provisions for Honeywell KN63 DME OAM 40-213 Provisions for Garmin GDL 69A DA40 Aircraft Only: OAM 40-161 G1000 Provisions with KAP 140* OAM 40-196 G1000 Provisions without KAP 140 STC #SA1840SC Hartzell Propeller DA40F Aircraft Only OAM 40-222 G1000 in DA40F Provisions *Currently only supported by the -5 and -6 STC configurations. The KAP140 Autopilot has been certified for use with G1000 System Software version 0321.17 or later by this STC. Page 2-2 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 2.2 Equipment Descriptions 2.2.1 GDU 1040 PFD & GDU 1040, 1042, or 1044 MFD Two Garmin GDU 1040 displays are installed in the Diamond instrument panel. One is configured as a PFD and the other as a MFD (Configuration is determined by wiring harness). Both displays provide control and display of nearly all functions of the G1000 integrated cockpit system. The displays are located side-by-side with the GMA 1347 Audio Panel located in the middle. For GFC 700-equipped aircraft, the MFD is either a GDU 1042 or GDU 1044. Both are distinguished by their dedicated AFCS control keypad on the lower left bezel. The GDU 1044 has an additional VNV key which allows for coupled-VNAV descents. Electrical power to the PFD is from the ‘Essential’ power bus, whereas the MFD receives power from the ‘Main’ power bus. Therefore, both displays power-up immediately when the aircraft master switch is turned on. To provide proper electrical bonding, beryllium copper ‘finger’ strips are installed on the lower lip of the display. This provides sufficient contact area to which the displays can be grounded to the airframe. Both displays are installed in the Diamond panel using built-in ¼-turn fasteners. Each display uses an existing connector per OAM 40-161 or OAM 40-226. Two cooling fans are also installed behind the panel for PFD and MFD cooling. 2.2.2 GMA 1347 Audio Panel The Garmin GMA 1347 Audio Panel is a digital audio panel with integrated marker beacon receiver. The GMA 1347 provides control of all cockpit intercom/mic systems as well as NAV/COM/ILS audio. The unit also provides display reversion mode control through a large red button. Power is received from the ‘Essential’ bus. The unit powers up when the aircraft master switch is turned on. The GMA 1347 interfaces with the existing marker beacon antenna as well as existing mic and phone jacks. 2.2.3 GIA 63 or GIA 63W Integrated Avionics Unit (2) Two Garmin GIA 63 IAUs provide VHF COM, NAV, GS, and GPS navigation functions to the G1000. GIA 63W models include a GPS/WAAS engine. GIAs also serve as a communication interface to all other G1000 LRUs in the system. Both GIAs are located remotely beneath the baggage compartment in a sheetmetal enclosure. The #1 GIA is powered through the ‘Essential’ power bus and immediately powers up when the aircraft master switch is turned on. The #2 GIA receives power through the ‘Main Avionics’ bus and powers up when the avionics master switch is turned on. Both GIA 63s interface to the following equipment: • Existing VOR/LOC/Glideslope Antenna System • Existing VHF COM 1 & 2 Antennas • Existing Garmin GA56 GPS1 & 2 Antennas (GIA 63 only) • GA35 GPS/WAAS Antennas (GIA 63W only) G1000 System Maintenance Manual – Diamond DA40/40F Page 2-3 190-00545-01 Revision E 2.2.4 GEA 71 Engine/Airframe Unit The Garmin GEA 71 Engine/Airframe Unit provides engine/airframe data to the G1000 system. Data received from transducers/sensors is processed, then sent to GIA 63, and subsequently to the GDU 1040 MFD. In display reversionary mode, engine instrumentation is displayed on the PFD as well. The GEA is located behind the instrument panel and is mounted in a vertical orientation. Power is received from the ‘Essential’ power bus. The GEA interfaces to the following: • Manifold Pressure Sensor (MAP, DA 40 aircraft only) • Oil Pressure Sensor • Fuel Pressure Sensor • Tachometer Sensor • Oil Temperature Sensor • Fuel Flow Sensor • 4 Cylinder Head Temperature (CHT) Sensors • 4 Exhaust Gas Temperature (EGT) Sensors • Alternator Current Sensor • Existing Fuel Probes • Existing Pitot Heat System • Existing Open Door Detection Switches • Existing Starter Engage System NOTE STC SA01254WI-D provisions engine/airframe sensors for the Diamond DA 40 aircraft only. For DA 40 F aircraft with fixed-pitch propellers, all engine sensors are provisioned and installed per Diamond OAM 40-222. 2.2.5 GTX 33 Mode S Transponder The Garmin GTX 33 provides Mode A, C, and S altitude and position reporting information to the G1000 system. The unit is mounted in the remote avionics enclosure below the baggage compartment. Power is received from the ‘Essential’ bus. The GTX 33 interfaces with the existing transponder antenna. 2.2.6 GDC 74A Digital Air Data Computer The Garmin GDC 74A provides digital air data computations to the G1000 system. The unit is mounted horizontally behind the instrument panel and is fastened to a rack. Power is received from the ‘Essential’ bus. The GDC 74A connects to existing pitot/static ports. 2.2.7 OAT Probe The Garmin GTP 59 OAT Probe provides the GDC 74A with air temperature data. The OAT probe is mounted to the bottom starboard side of the DA 40 fuselage. Page 2-4 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 2.2.8 GRS 77 Attitude & Heading Reference System The Garmin GRS 77 AHRS provides attitude and heading information to the G1000 system. The unit is mounted remotely in the baggage compartment, to the starboard side of the remote avionics enclosure. Power is received from the ‘Essential’ bus. The GRS 77 interfaces with and provides power to the GMU 44 Magnetometer. The GRS 77 supplies attitude and heading information directly to the PFD, MFD, and to both GIAs. 2.2.9 GMU 44 Magnetometer The GMU 44 provides horizontal and vertical magnetic field information to the GRS 77 AHRS. This allows heading to be calculated and provides assistance during AHRS alignment. The GMU 44 is mounted beneath the starboard wing. 2.3 GDL 69A (Optional) The GDL 69A provides optional XM Radio weather and music entertainment through means of a dedicated satellite data link. The GDL 69A is mounted in the remote avionics enclosure. Power to the GDL 69A is received from the ‘Main Avionics’ bus. The GDL 69A sends weather data through the HSDB bus to the MFD, where the data link interface is controlled. Digital audio is sent directly to the GMA 1347. 2.4 Remote Avionics Enclosure Refer to 005-00304-00, Sheets 2 & 8: A remote avionics enclosure allows LRUs to be inserted vertically, from above. The enclosure is also cooled with an avionics fan and duct assembly. The assembly is grounded to an existing grounding station using a field-fabricated aluminum ground strap. Two braided grounding straps are also attached to the GRS 77 rack from the enclosure. A Comant diplexer is installed on the enclosure as shown. A field- fabricated component bracket with resistors, voltage suppressors and attached wiring is fastened to the forward portion of the enclosure. 2.5 G1000 Optional Interfaces Installation of all other optional equipment that interfaces to the G1000, including ADF, DME, and GDL 69A is documented by Diamond OAM factory drawings. 2.5.1 KAP 140 AFCS The Phase 7 amendment to STC SA01444WI-D adds two new installation configurations to the MDL (See Table 1-1), both of which allow for G1000 systems with GDU 8.20 and greater to interface with existing DA40 aircraft equipped with the Honeywell KAP 140 AFCS. The G1000 interfaces to the KAP 140 by providing the following from the #2 GIA 63: -Output of Lateral & Vertical Navigation Signals -Output of Course Datum -Output of Heading Datum -Output of Encoded Altitude -ILS Energize Discrete -GPS Select Discrete Additionally, the G1000 receives the following from the KAP 140: -Pitch Trim Fail Discrete Input -Pitch Trim Fail Aural Input The G1000 – KAP 140 interface was included as part of the original G1000 certification under STC SA01254WI. In order to be compatible with WAAS, GDU software changes were made as part of System Software Version 0321.17 or later, which were certified as a follow-on amendment to STC SA01444WI-D. G1000 System Maintenance Manual – Diamond DA40/40F Page 2-5 190-00545-01 Revision E 2.6 GFC 700 AFCS System Description The GFC 700 is a two-axis fail-safe digital flight control system that is integrated within the G1000 system. The only distinguishing hardware from a standard G1000 installation is the MFD and the GSA 81 Servos and GSM 85 Servo Mounts. The following functions are provided by the GFC 700 in this installation: • Flight Director • Autopilot • Manual Electric Trim Flight Director: The Flight Director operates within the #1 GIA 63 and uses data from the G1000 system, including air data, attitude, and navigation data, to calculate commands for display to the pilot and for the Autopilot. Flight Director command bars and mode annunciations are sent to the PFD through a high-speed Ethernet connection for display to the pilot. The Flight Director operates independently of the Autopilot, and allows the pilot to hand-fly the command bars, if desired. Autopilot: The Autopilot operates within the three GSA 81 servos. Flight Director data is processed within the three servos and turned into aircraft flight control surface commands. The Autopilot cannot operate unless the Flight Director is engaged. Manual Electric Trim: Independent of the Flight Director and Autopilot, Manual Electric Trim (MET) allows the pilot to control the elevator trim tab by the MET switch located on the pilot control stick. Engaging both sides of the switch in the same direction causes the autopilot to disengage (if engaged) and drives the pitch trim servo in the desired direction. The ARM side of the MET switch may also be used to disconnect the autopilot and cancel the resulting AP DISC alerts. Page 2-6 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 Figure 2-1. AFCS System Block Diagram G1000 System Maintenance Manual – Diamond DA40/40F Page 2-7 190-00545-01 Revision E 2.6.1 GFC 700 Electrical Aspects The wiring and switches used by the GFC 700 are provisioned by Diamond under OAM 40-226, and are not included in the Garmin GFC 700 STC design. In general, the pitch and pitch trim servos are wired in parallel to both GIA 63s and use the RS-485 serial protocol to communicate while the pitch servo has its own line to both GIAs. See the Diamond wiring diagrams listed in Table 1-2 for more details on wiring. The Diamond provisions also include the following switches: AP DISC Switch There are two large red AP DISC switches located on the pilot and copilot control sticks. When normally closed, +28 VDC is allowed to pass through to the SERVO ENABLE pins of each servo, allowing the Autpilot and servos to operate. When pushed, the switches break the +28VDC source and the Autopilot disconnects and takes the servos offline. CWS Switch A control wheel steering switch is located on the pilot’s control stick. When pressed, this switch activates CWS mode. The Autopilot, if engaged, is temporarily disengaged, and the Flight Director command bars immediately synchronize to the current aircraft pitch and roll attitude. When released, the Autopilot will re-engage (if previously engaged) and the Flight Director will orient itself to the last known pitch and roll reference established during CWS mode. This allows the pilot to hand fly the aircraft when desired and also allows the pilot to reestablish a desired aircraft flight attitude for the Autopilot to maintain. MET Switch See previous functional description of MET. GA Switch A Go-Around switch is installed within the engine throttle knob and activates the GA Flight Director mode. During this mode, the Autopilot disengages (if engaged) and the Flight Director displays a 7° pitch up nose attitude for reference during a missed approach or go-around procedure. Page 2-8 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 2.6.2 GSA 81 Servo and GSM 85 Servo Mount Figure 2-2. GSA 81 & GSM 85 The GSA 81 is mated to the GSM 85 Servo Mount to form a single servo unit. There are three servo units in this installation: • Pitch • Pitch Trim • Roll The design of the servo assembly allows the servo actuator (GSA 81) to be removed from the servo mount (GSM 85) without the need to de-rig the aircraft control cables. The servo mount contains the capstan (cable for roll/pitch, chain for pitch trim) and the slip clutch which allows a pilot to manually overpower the Autopilot. G1000 System Maintenance Manual – Diamond DA40/40F Page 2-9 190-00545-01 Revision E 2.7 Electrical Power Distribution Distribution of power to the G1000 occurs on three buses: Essential Bus: The ‘Essential’ bus is tied directly to the aircraft battery via the master switch. When the master switch is turned on, power is immediately supplied the ‘Essential’ bus. The ‘Essential’ bus is tied via a relay switch to the ‘Main’ aircraft bus. There are two circuit breakers on either side of the relay, combined with a single diode, allowing the battery to be charged by the alternator. Only equipment deemed essential for safe flight is connected to this bus. Main Aircraft Bus: The ‘Main’ bus receives power from the aircraft battery when tied to the ‘Essential’ bus. After the aircraft engine is started, the alternator supplies power to the aircraft ‘Main’ bus, and to the rest of the system. In the event of an alternator or other power failure, the ‘Essential’ bus can be isolated with the ‘Essential Bus’ switch. This causes the ‘Essential’ bus to revert to battery power. Only the MFD receives power from the ‘Main’ bus. Main Avionics Bus: A ‘Main Avionics’ bus is tied to the ‘Main’ aircraft bus via the ‘Avionics Master’ switch and switch relay. The #2 GIA 63, the ADF, DME, GFC 700 AFCS, and the GDL 69A are connected to this bus. Figure 2-3. G1000/DA40 Electrical Distribution Page 2-10 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 2.8 Lightning Strike Protection The following modifications to the aircraft provide additional protection of G1000 equipment from the effects of lightning strike. 2.8.1 Alternator / Battery Voltage Suppressors & Fuses Refer to 005-00304-00, Sheet 5: Two Transient Voltage Suppressors (TVS) are installed behind the instrument panel near the circuit breakers. Voltage suppressors help protect the avionics/electrical equipment against the effects of lighting strike. One voltage suppressor is connected to the load side of the aircraft battery circuit breaker, and the other is connected to the line side of the alternator circuit breaker. One 3.2 Amp slow-blow fuse is wired in line with each voltage suppressor. Fuses are easily removed by twisting the fuse holder cap counter- clockwise and removing the fuse. 2.8.2 GIA / AHRS Lightning Protection Refer to 005-00304-00, Sheets 8, 10 & 11: The GRS 77 and both GIA 63s are uniquely protected from the effects of lightning. A 0.499Ω resistor, a transient voltage suppressor, and a 3.2 Amp slow-blow fuse are used for each GIA and the AHRS. These components are installed on a field-fabricated aluminum block, which is mounted to the front of the remote avionics enclosure. Power leads for the AHRS and both GIAs are routed from the aircraft harness to a 9-pin connector (P900), whose mating connector is mounted to the fabricated block (J900). Power is returned to the LRU after passing through the resistor and voltage suppressor. Refer to 005-00400-12: For WAAS-equipped aircraft, seven additional resistors are installed on a sheetmetal bracket on the side of the remote avionics box. Three resistors are inline between the #1 GIA 63W and GRS 77 RS-232 serial communications line and four are inline between the #1 GIA 63W and PFD High Speed Data Bus (HSDB) cable. 2.8.3 Lightning Strike Maintenance Proper electrical bonding of all metallic components is critical for the protection against the effects of lighting. Severe corrosion may inhibit a component’s ability to bond to the aircraft’s electrical ground plane. The following summarizes maintenance practices which are implemented to maintain adequate lightning protection for the aircraft. See Section 4, Table 4-1 for exact maintenance requirements and associated intervals: • Annual visual inspection of all G1000 equipment, including voltage suppressors, resistors, fuses, etc. • An electrical bonding check of G1000 equipment every 1000 hours or anytime a lightning strike occurs or is suspected. • Regular replacement (every 24 calendar months) of all five 3.2 Amp slow-blow fuses ensures they are in fresh condition. • Replacement of voltage suppressors, resistors, and fuses anytime a lightning strike occurs or is suspected. G1000 System Maintenance Manual – Diamond DA40/40F Page 2-11 190-00545-01 Revision E 2.9 Shield Block Grounds Most G1000 connectors employ a Shield Block grounding system to provide necessary ground reference to wire shielding and/or transducers. The shield block termination method allows multiple grounds to be terminated directly to a block mounted to the connector backshell assembly. Refer to G1000/DA40 Install Drawing, 005-00304-00 for installation details. Note that older G1000 installations may employ a slight different ‘SPIDER’ shield grounding system. 2.10 Sensor Installations Refer to 005-00304-00, Sheets 5, 9, & 12 for the engine sensor installation drawings. 2.11 Block Diagrams 2.11.1 G1000 & KAP140 Figure 2-4. G1000/KAP 140 Block Diagram (no WAAS) Page 2-12 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 2.11.2 G1000 & GFC700 Figure 2-5. G1000/GFC 700 Block Diagram (WAAS shown) G1000 System Maintenance Manual – Diamond DA40/40F Page 3-1 190-00545-01 Revision E 3 G1000 Control & Operation All control and operation of G1000 equipment as normally used in flight occurs through the PFD, MFD and GMA 1347 audio panel. Figure 3-1 identifies GDU 1040 buttons. Figure 3-3 identifies various GMA 1347 buttons. COM Frequency Toggle Key COM Frequency Selector Knob Course (Inner) /Baro (Outer) Selector Knob Map Panning/Range Joystick Navigation Systems Controls Flight Management System (FMS) Knob Multi-Function Softkeys (Numbered 1-12, left to right) NAV Frequency Toggle Key NAV Frequency Tuner Knob Heading Bug Selector NAV Volume/Ident Knob Altitude Selector Knob COM Volume/Squelch Knob GFC 700 AFCS Controls Figure 3-1. GDU 104X Control Interface (GDU 1042 shown) 3.1.1 AFCS Controls The dedicated AFCS controls located on the GDU 1042 and 1044 are discussed in detail in the G1000 CRG. The following figure is provided for reference: Heading Mode Key Approach Mode Key NOSE UP Key NOSE DN Key Autopilot Key Flight Director Key Navigation Mode Key Altitude Hold Mode Key Vertical Speed Mode Key Flight Level Change Mode Key VNAV Mode Key Figure 3-2. AFCS Controls (GDU 1044 shown) Page 3-2 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 Display Backup Reversionary Button Volume/Squelch Control ICS Isolation Digital Recording Playback Manual Squelch Navigation Radio Audio Navigation Radio Audio Marker Beacon Signal Sensitivity Marker Beacon/Mute Speaker Passenger Address Split COM Transmitters Transceiver Audio Cellular Telephone Figure 3-3. GMA 1347 Controls 3.1.2 FMS Knob The FMS knob is the primary control for the G1000 system. Operation is similar to the Garmin 400/500 Series units. • To cycle through different configuration screens: To change page groups: Rotate the large FMS knob. To change pages in a group: Rotate the small FMS knob. • To activate the cursor for a page, press the small FMS knob directly in, as one would push a regular button. • To cycle the cursor through different data fields, rotate the large FMS knob. • To change the contents of a highlighted data field, rotate the small FMS knob. This action either brings up an options menu for the particular field, or in some cases allows the operator to enter data for the field. • To confirm a selection, press the ENT key. • To cancel a selection, press the small FMS knob in again, deactivating the cursor. The CLR key may also be used to cancel a selection or deactivate the cursor. 3.1.3 Softkeys Some pages have commands or selections that are activated by the GDU 1040 softkeys. If a softkey is associated with a command, that command will be displayed directly above the key. A grayed-out softkey shows a command that is unavailable. A softkey that is highlighted shows the current active selection. Figure 3-4. G1000 Softkeys G1000 System Maintenance Manual – Diamond DA40/40F Page 3-3 190-00545-01 Revision E 3.2 G1000 Normal Mode To start the G1000 system in Normal Mode: 1. Turn on the aircraft master switch. The following G1000 equipment is powered on: • PFD & MFD (MFD receives power only if ‘Essential Bus’ switch is OFF) • GRS 77 AHRS • GDC 74A Air Data Computer • No. 1 GIA 63 Integrated Avionics Unit • GEA 71 Engine/Airframe Unit • GTX 33 Mode S Transponder • GMA 1347 Digital Audio Panel 2. Turn on the DA 40 AVIONICS MASTER switch. The following G1000 equipment is powered on: • No. 2 GIA 63 Integrated Avionics Unit • GFC 700 (if equipped) • GDL 69A (if equipped) The G1000 system is now powered in the normal mode. The PFD and MFD will function as specified in the G1000/DA 40 Cockpit Reference Guide, when the system has been correctly installed and configured. Figure 3-5. Normal Mode Page 3-4 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 3.3 Reversionary Mode Should a display communication or hardware failure occur, the G1000 system automatically enters the reversionary mode. The system reversionary mode forces the remaining display into showing all information related to safe flight. A manual reversionary mode also allows the operator to force the system into reversionary mode in situations where the system does not automatically enter reversionary mode. A large red button labeled ‘DISPLAY BACKUP’ on the GMA 1347 audio panel activates the manual reversionary mode. Figure 3-6. MFD Failure Mode Should the PFD display fail, the MFD automatically enters reversionary mode. In this mode, flight- critical information from the AHRS/Air Data system is displayed on the MFD along with essential engine instrumentation. Figure 3-7. PFD Failure Mode G1000 System Maintenance Manual – Diamond DA40/40F Page 3-5 190-00545-01 Revision E 3.4 Configuration Mode Overview The Configuration Mode exists to provide the avionics technician with a means of configuring, checking, and calibrating various G1000 sub-systems. Troubleshooting and diagnostics information can also be viewed in this mode. To start the system in Configuration Mode: 1. Start the system in normal mode as described in Section 3.2. 2. Remove power to the PFD and MFD by pulling the circuit breakers labeled PFD and MFD. 3. Press and hold the ENT key on the PFD while applying power using the PFD circuit breaker. 4. Release the ENT key after ‘INITIALIZING SYSTEM’ appears in the upper left corner of the PFD. 5. Power on the MFD in the same manner. It is best to have both displays in Configuration Mode whenever performing post-installation practices. NOTE It is good practice to cycle power to the entire G1000 system, not just the displays, anytime software loading, configuration or other maintenance procedures have been performed and a system restart is necessary. CAUTION The Configuration Mode contains certain pages and settings that are critical to aircraft operation and safety. These pages are protected and cannot be modified, unless the technician is properly authorized and equipped. However, most protected pages are viewable to allow system awareness for troubleshooting. NOTE For a complete description and breakdown of each Configuration Mode page, refer to the G1000 Line Maintenance & Configuration Manual, Garmin part number 190-00303-04. Page 3-6 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 3.4.1 SET>ACTV Configuration Throughout the configuration mode pages, there are SET and ACTIVE columns for input/output settings and other parameters. SET: Refers to a setting or group of settings that reside in PFD Internal Memory and/or the Master Configuration Module. ACTIVE: Refers to an ‘active’ setting or parameter currently being used by the LRU. LRUs store the ‘active’ settings within internal memory. Data can be manually copied from one column to the other (and consequently from PFD memory to the LRU memory and vice-versa) by using the following two softkeys, when available: • SET>ACTV (read ‘Set to Active’) softkey: Allows the installer to send the information in the SET column (data stored in the master config module) to the ACTV column (data used by LRU). • ACTV>SET (read ‘Active to Set’) softkey: Causes the LRUs current settings to be copied to the master configuration module as SET items. CAUTION The ACTV>SET softkey must be used with caution! If an improperly configured unit is installed, this softkey causes the wrong configuration to replace the correct aircraft configuration. G1000 System Maintenance Manual – Diamond DA40/40F Page 3-7 190-00545-01 Revision E In the first example shown in Figure 3-8, the SET columns do not match the ACTIVE columns. The inequality between SET and ACTIVE indicates a configuration mismatch. By pressing the SET>ACTV softkey, this copies the SET column to the LRU unit’s configuration memory. The settings then become the ACTIVE settings for the LRU being configured. = = Master Configuration Module LRU Memory Master Configuration Module LRU Memory Master Configuration Module LRU Memory = Master Configuration Module LRU Memory = Configuration Mismatch SET>ACTV Softkey Configuration Correct Master Configuration Module LRU Memory Master Configuration Module LRU Memory Figure 3-8. SET>ACTV Diagram Page 3-8 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 When troubleshooting the system, technicians can look for inequalities between SET and ACTIVE columns. Certain problems can be resolved simply by pressing the SET>ACTV softkey, which reloads settings to the specific LRU from the PFD. (Note that this can also be accomplished by reloading the configuration files for the LRU, using the approved system software version. Section 7 describes this process for each LRU). A blank active column, as shown in Figure 3-9, represents loss of communication between the display and the particular unit. See Section 5 for more details on troubleshooting. Figure 3-9. Loss of Communication 3.4.2 Configuration Prompts When configuration settings are changed, the technician receives on-screen prompts and/or confirmations such as those shown in Figure 3-9. Section 7 shows other prompts encountered during the configuration process. Figure 3-10. Configuration Status 3.4.3 (SW v0321.19 or earlier) Data Transmission Indicators Several configuration screens utilize an indicator light system to show discrete (ON/OFF) data and/or hardware component status. Unless otherwise noted, the following applies to all such status indicators: • Green Light: Expected data is successfully received and is ON. A green light could also indicate that the parameter/component is working correctly. • Red Light: Expected data is not received. A red light could also indicate that a parameter/component is invalid. • No Light (Black): Expected data is successfully received and is OFF, or no data is expected. A black light could also indicate that the parameter/component is not responding. Figure 3-11. Data Transmission Indicators G1000 System Maintenance Manual – Diamond DA40/40F Page 3-9 190-00545-01 Revision E 3.4.4 (SW v0321.22) Data Transmission Indicators Several configuration screens utilize an indicator system to show discrete (ON/OFF) data and/or hardware component status. Unless otherwise noted, the following applies to all such status indicators: • Green check mark: Expected data is successfully received and is ON. A green check mark could also indicate that the parameter/component is working correctly. • Red X: Expected data is not received. A red X could also indicate that a parameter/component is invalid. • Amber ?: Indicates that the parameter/component is not responding. Figure 3-12. Data Transmission Indicators Page 3-10 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 3.4.5 (SW v0321.19 or earlier) Configuration Mode Navigation Using the FMS knob as described in Section 3.1.2, a user can navigate through different pages and page groups in the Configuration Mode. For complete description and breakdown of each page, refer to the G1000 Line Maintenance & Configuration manual, Garmin part number 190-00303-04. System Page Group 1. System Status 5. System Upload 9. System Configuration 2. Date/Time Setup 6. Diagnostics Terminal 10. System Setup 3. Main Lighting 7. Maintenance Log 11. Manifest Configuration 4. Audio Alert Configuration 8. OEM Diagnostics GDU Page Group 1. RS-232 / ARINC 429 Configuration 4. Diagnostics 7. Alert Configuration 2. GDU Status 5. Serial/Ethernet I/O 8. Airframe Configuration 3. GDU Test 6. Alert Configuration GIA Page Group 1. RS-232 / ARINC 429 Configuration 3. GIA I/O Configuration 5. GIA Status 2. CAN / RS-485 Configuration 4. COM Setup GEA Page Group 1. Engine Data 2. GEA Status 3. GEA Configuration GTX Page Group 1. RS-232 / ARINC 429 Configuration 2. Transponder Configuration GRS Page Group 1. AHRS / Air Data Input 2. GRS / GMU Calibration GDC Page Group 1. GDC Configuration GFC Page Group 1. GFC Configuration 2. GFC Status GMA Page Group 1. GMA Configuration GDL Page Group 1. GDL 69 Configuration CAL Page Group 1. Fuel Tank Calibration 2. Flaps and Trim Calibration 3. HSCM Calibration G1000 System Maintenance Manual – Diamond DA40/40F Page 3-11 190-00545-01 Revision E 3.4.6 (SW v0321.22) Configuration Mode Navigation Using the FMS knob as described in Section 3.1.2, a user can navigate through different pages and page groups in the Configuration Mode. For complete description and breakdown of each page, refer to the G1000 Line Maintenance & Configuration manual, Garmin part number 190-00303-04. System Page Group 1. System Status 6. Diagnostics Terminal 10. System Setup 2. Date/Time Setup 7. Maintenance Log 11. Manifest Configuration 3. Main Lighting 8. OEM Diagnostics 12. Maintenance Log 4. Audio Alert Configuration 9. System Configuration 5. System Upload 10. System Data Paths GDU Page Group 1. RS-232 / ARINC 429 Configuration 4. Diagnostics 7. Airframe Configuration 2. GDU Status 5. Serial/Ethernet I/O 8. TAWS – B Setup 3. GDU Test 6. Alert Configuration GIA Page Group 1. RS-232 / ARINC 429 Configuration 3. GIA I/O Configuration 5. GIA Status 2. RS-485 Configuration 4. COM Setup 6. CAN Configuration GEA Page Group 1. Engine Data 2. GEA Status 3. GEA Configuration GTX Page Group 1. RS-232 / ARINC 429 Configuration 2. Transponder Configuration GRS Page Group 1. AHRS / Air Data Input 2. GRS / GMU Calibration GDC Page Group 1. ADC Configuration 2. GDC Configuration GFC Page Group 1. GFC Configuration 2. GFC Status GMA Page Group 1. GMA Configuration GDL Page Group 1. GDL 69 CAL Page Group 1. Fuel Tank Calibration 2. Flaps and Trim Calibration 3. HSCM Calibration Page 3-12 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 3.5 G1000 / GFC 700 Software Information 3.5.1 G1000 System Software Version The G1000 System Software Version controls the approved combination of software and configuration files for the G1000 in a specific aircraft. An electronic G1000 System Software image specifically created for Diamond DA40 aircraft is required to install software and configuration settings to a new G1000 system. The software image is an electronically compressed group of G1000 software and configuration files which are defined on STC General Arrangement drawings, listed in Table 1-2. The image is used to extract the system files to an SD memory card, which in turn is used to load files to the G1000. Software image part numbers are normally defined with the prefix “006-”. Alternatively, the installer may purchase a pre-made loader card directly from Garmin, normally defined by the part number prefix “010-”. NOTE Garmin recommends the use of SanDisk or Toshiba SD cards to load G1000 software and configuration files. If software loading problems occur when using another brand of card, replace the card with a SanDisk or Toshiba card and reattempt the software load. For software loading, a minimum of 64 MB is recommended. All software and configuration files were certified by Garmin and/or Diamond and are considered part of FAA-approved Type Design data. Approved software and hardware definitions for each STC Configuration is defined on the appropriate General Arrangement drawing listed in Table 1-2. IMPORTANT! To satisfy the G1000/GFC700 STC requirements for the DA 40, it is critic al that the technician use a loader card which contains the correct System Software Version when servicing the G1000 system. Approved System Software Versions are defined on the appropriate General Arrangement drawing (see Table 1-2). CAUTION Be cautious when using software loader cards during maintenance. The G1000 system immediately initializes the card upon power-up. On-screen prompts must be given careful attention in order to avoid potential loss of data. Always read through procedures given in Sections 5, 6, and 7, before attempting to use the software loader cards. CAUTION Remove Supplemental Data Cards (010-00330-41, 010-00330-42, or 010-00330-43) from the lower slot of the GDUs before loading any software. Supplemental Data Cards left inserted can become corrupt, making them unusable. Replacing corrupt cards is not covered under warranty. G1000 System Maintenance Manual – Diamond DA40/40F Page 3-13 190-00545-01 Revision E 3.5.2 Software Files Software files are defined by part number and version number on the General Arrangement drawing. See Table 1-2 for the correct General Arrangement drawing part numbers. Each G1000 / GFC 700 LRU reports the software version it currently contains to the user in two places. • Normal System Mode: The AUX – SYSTEM STATUS page lists each LRU and the reported software version. • Configuration Mode: The SYSTEM STATUS page (SYSTEM page group) reports more detailed LRU information, including software version, part number, and LRU status. Software files are loaded to LRUs from the SYSTEM UPLOAD page in configuration mode. See Section 3.6.5. 3.5.3 Configuration Files Configuration files are divided into groups, and are displayed at the System Upload page during the software/configuration loading process. There are three categories of configuration files: Default (shown as part of the Software Upload list) Options (See Section 3.5.3.1) Calibration (See Section 3.5.3.2) Configuration files contain preset selections for input/output channels, aircraft-specific settings, and LRU-specific settings. The following list describes each of the configuration files used by the G1000: AIRFRAME This file contains data such as airspeed parameters, engine/airframe sensor limitations, fuel tank parameters and alerting system settings that tailor a G1000 PFD or MFD to the DA 40. AIRFRAME ALERTS DA40-specific alerts are set when this file is loaded. SYSTEM This file configures the G1000 high-speed data bus (HSDB) to expect a PFD, MFD, and two GIAs (and GDL69 if configured). MANIFEST This file loads a manifest checklist of all software part numbers and versions associated with an approved system configuration. The G1000 performs a software check between each LRU’s reported version and the version contained on the manifest. If an inequality is detected for an LRU, this LRU is then excluded from the G1000 and a manifest alert is triggered to the operator. MFD1 This file configures MFD serial/discrete communication and alert system settings. PFD1 This file configures PFD serial/discrete communication and alert system settings. GIA1 / GIA2 These files configure GIA1/GIA2 serial/discrete communication settings. GMA_PIL This file configures GMA 1347 audio and serial communication settings. GTX1 This file configures GTX 33 transponder and serial communications settings. GEA1 This file configures GEA 71 engine/airframe parameters. GDC_PIL This file configures GDC 74A air data values for the DA 40. AUDIO This file configures audio alerts for the DA40. CAL: This file configures default fuel tank calibrations for the G1000. Page 3-14 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 IMPORTANT! Every attempt should be made to NOT re-load the CAL (calibration) file. If loaded, these files will reset the fuel probe calibration data to default values and invalidate the fuel tank quantity indications. The fuel calibration procedure is then subsequently required to be performed. 3.5.3.1 Options Configuration Files The following optional configurations appear at the System Upload page within the FILE menu, when the “Options” choice is selected from the AIRFRAME menu as shown: Optional configuration files are generally loaded after the default configuration is established during software loading. Each configuration option contains one or more of previously listed configuration files (and sometimes software files). It is important to note that although these files have the same name as the defaults, they are usually subsets, only providing the necessary configuration changes from the default files to activate the desired option. Each file affects the configuration one or more LRUs. For a summary relationship between configuration files and LRUs, refer to Table 3-1. DA40 F Option – Multiple Cylinders DA40 F Option – Single CHT / EGT DA40 F Option – Add Fuel Pressure Sensor DA40 Option – ADF DA40 Option – CO Guardian* DA40 Option – DME DA40 Option – Display Fuel Pressure DA40 Option – EASA Airspeed Tape DA40 Option – Extended Range Tanks DA40 Option – GDL69 DA40 Option – GFC 700 DA40 Option – No KAP 140 DA40 Option – TAS600 Series* DA40 Option – Stormscope* DA40 Option – TAWS (Requires a separate TAWS enable SD card) DA40 Option – ChartView (Requires a separate ChartView enable SD card) *Note these options not certified for activation under this STC. An alternate additional installation approval must be obtained for these options. G1000 System Maintenance Manual – Diamond DA40/40F Page 3-15 190-00545-01 Revision E 3.5.3.2 Calibration File Group The Calibration file group is selected from the AIRFRAME menu as shown: When selected, the Calibration file group displays two CAL configuration options in the FILE menu, one for standard range fuel tanks, and another for long-range fuel tanks. Fuel tank configuration limits are contained in these files, including preset empty and full calibration points. This file group is intended to be used only during factory calibration procedures and normally is never required to be loaded during maintenance. IMPORTANT! When the CAL configuration files are loaded, previous calibration data for the fuel tanks will be erased, causing the fuel quantity indicators to be invalid! It is critical that the CAL configuration files not be loaded during maintenance unless absolutely necessary. Fuel tank recalibration per Section 4.6 is required if these files are loaded. Page 3-16 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 The following table summarizes the G1000 configuration file structure, including default and optional configurations, and the LRUs affected by each. Table 3-1. LRU to Configuration File Relationship Summary LRU PFD MFD #1 GIA1 63 #2 GIA 63 GMA 1347 GTX 33 GEA 71 GDC 74B GDL 69A FILE NAME AIRFRAME AIRFRAME ALERTS SYSTEM PFD 1 MANIFEST CAL** MFD GIA 1 AUDIO GIA 2 AUDIO GMA GTX 1 GEA 1 GDC 1 GDL Default Config** X X X X X X X X X X X X X Std Range Fuel Tank ** X Calibration** Extended Range Fuel Tank ** X Multiple Cylinders X X Single CHT X X Single EGT X X Add Fuel Pressure Sensor X ADF X CO Guardian* X X X DME X Display Fuel Pressure X EASA Airspeed Tape X Extended Range Tanks X X X X GDL69 X X X GFC700 X X X X NO KAP 140 X X X TAS600 Series* X Stormscope* X TAWS*** X X CONFIGURATIONS Options Configuration ChartView*** X *Noted options are not certified for activation under this STC. An alternate additional installation approval must be obtained for these options. **IMPORTANT! RELOADING THE CAL FILE REQUIRES FUEL TANK RECALIBRATION! ***NOTE: To enable the TAWS or ChartView functions, a separate “Unlock” SD Card is required. See the appropriate General Arrangement drawing for card part numbers. When the TAWS option is loaded, note that it overwrites the AIRFRAME and AIRFRAME ALERTS configuration files. ChartView overwrites the AIRFRAME file only. If, during maintenance, the default PFD configuration files are ever reloaded, the TAWS and/or ChartView options must be reactivated. See Section 3.6.9 and 3.6.10 for instructions on reactivating TAWS and ChartView, respectively. G1000 System Maintenance Manual – Diamond DA40/40F Page 3-17 190-00545-01 Revision E 3.5.4 Configuration File Storage The G1000 system is designed to store all configuration settings in various places so that the configuration is retained in the aircraft during maintenance of units. During system configuration, each file is sent directly to the applicable LRU where it is stored in local LRU memory (except GRS 77 & GDC 74A). Each file is also stored in PFD internal memory. The PFD also sends a copy of all configuration files to the ‘Master Configuration module’, located in the connector backshell (see Section 6.13). If the PFD is replaced, the configuration module retains all configuration files in the aircraft. NOTE The GRS 77 AHRS and GMU 44 Magnetometer do not have a configuration file. However, these LRUs do store calibration data acquired during the post installation checkout, which are characteristic to the specific installation. While performing maintenance on these units, re-calibration may be required. See Section 7.7.1 for more information on re-calibration criteria. High-Speed Data Bus (Ethernet) G1000 Master Configuration Module (Located in PFD backshell connector) GDU 1040 PFD GDU 1040 MFD Contains 'ACTIVE' MFD settings. No. 1 GIA 63 No. 2 GIA 63 GEA 71 Contains 'ACTIVE' configuration settings internally. The GEA 71 configuration module is NOT used for configuration settings. The GEA 71 uses PFD internal configuration files for backup. GMA 1347 Audio Panel Contains 'ACTIVE' GMA settings. Uses PFD internal configuration files for backup. GTX 33 Contains 'ACTIVE' transponder settings internally. The GTX 33 uses PFD internal configuration files for backup. RS-232 RS-485 RS-232 RS-485 RS-232 RS-232 Contains 'ACTIVE' configuration settings internally. GIA1 uses PFD internal configuration files for backup. Contains 'ACTIVE' PFD settings. Represents 'SET' column for all LRUs. Stores all configuration files in internal memory. Uses master configuration module for backup. Master configuration module contains identical backup configuration files of PFD configuration memory. PFD cross-checks these backup files against files contained within PFD memory. PFD self-configures to match master configuration module. Contains 'ACTIVE' configuration settings internally. GIA2 uses PFD internal configuration files for backup. The MFD uses PFD internal configuration files for backup. Figure 3-13. G1000 LRU Configuration File Storage Page 3-18 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 The GRS 77 and GDC 74A configuration modules function differently than the rest of the system. The GDC 74A’s configuration file is loaded directly to GDC internal memory. A copy of the file is stored in the GDC configuration module. The GRS 77 configuration module does not store any configuration settings. Instead, it stores calibration data recorded during installation calibration procedures. GRS 77 AHRS GRS 77 Config Module (Located in GRS backshell connector) Stores a copy of AHRS/Magnetometer calibration values that are recorded upon completion of post-installation calibration procedures. The GRS 77 stores calibration data internally. The GRS 77 also stores factory calibration data internally. Should internal memory or the configuration module fail, AHRS ouput data flags invalid. GRS Internal Memory Contains internal sensor calibration data that is not installation-specific. Data is stored from factory calibrations. GDC 74A Air Data Computer GDC 74A Config Module (Located in GDC backshell connector) Stores a copy of the GDC 74A configuration file. The GDC 74A stores the GDC1 configuration file internally. The GDC 74A also stores factory calibration data internally. Should internal memory or the configuration module fail, loss of some or all airdata outputs will result. GDC Internal Memory Contains internal sensor calibration data that is not installation-specific. Data is stored from factory calibrations. Figure 3-14. GRS/GDC Configuration Settings Storage G1000 System Maintenance Manual – Diamond DA40/40F Page 3-19 190-00545-01 Revision E 3.6 G1000 Software/Configuration Procedure This section summarizes the procedures required to load software and configuration files to the G1000. It is intended to work as a central guide for technicians to use while performing maintenance on the aircraft. In sections of this manual where software is required to be reloaded, these sections will make reference back to this Section for instructions. The technician should use proper judgment regarding the context of maintenance required while following this section. The following diagram depicts an overview of the software/configuration sequence for the G1000 system. This applies mostly to a new G1000 system which has not previously been powered up and is for informative purposes only. GDU 104X Software Load Software is first loaded to the MFD, then to the PFD. From the factory, G1000 units do not contain aircraft-specific software or configuration settings. Load software to the MFD first, and then load to the PFD. G1000 System Upload Selection After software is loaded to the MFD and PFD, the displays should all be placed in configuration mode. Using the PFD, the technician goes to the System Upload Page. At the System Upload page, appropriate software and configuration files are selected to create an automated load profile. Once all desired files are checked, the G1000 automatically loads the selected files in the correct sequence to the LRUs. G1000 System Software Verification After software and configuration is loaded to the system, the technician verifies that each LRU reports the correct version and software part number. Figure 3-15. Software/Configuration Overview Page 3-20 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 3.6.1 System Power Up Apply power to the G1000 by doing the following: 1. Ensure there are no database cards inserted in the MFD and PFD lower card slots. If there are, remove them until instructed to install them. 2. Turn on the ground power unit, if used. 3. Turn on the BAT side master switch. 4. Turn on the AVIONICS MASTER switch. At this moment, all G1000 equipment should be receiving power. 3.6.2 MFD & PFD Boot Block Software Check 1. Pull the MFD and PFD circuit breakers. 2. While holding the ENT key on the MFD, restore power by closing the MFD circuit breaker. 3. When the words appear in the upper left corner of the MFD, release the ENT key. 4. Repeat Steps 2 and 3 for the PFD. 5. At this point, both GDUs should be operating in configuration mode, displaying the System Status page. 6. Activate the cursor on both displays and scroll through the list of LRUs. Highlight ‘PFD1’ on the PFD, and ‘MFD1’ on the MFD. 7. Check the currently reported GDU boot block software version, indicated by ‘BB Version’ on each display. IMPORTANT! If the GDU boot block software is less than 2.03, the boot block must be updated prior to loading GDU 8.20 software. Continue to the next section, Updating GDU Boot Block. If the reported version is already 2.03, boot block is correct and does not require updating. If GDU 9.01 software is being loaded (System Software 0321.18 or later), the boot block will update automatically; the technician may skip to the GDU software loading section. 3.6.3 Updating GDU Boot Block 1. Obtain the GDU boot block update software. Refer to the appropriate General Arrangement drawing (see Table 1-2) for the boot block software P/N. NOTE The GDU boot block update may be obtained by downloading the electronic file from Garmin (see GA dwg for 006- P/N, accessible via the dealer web site). This electronic download may be used to build an SD card to update the GDU boot block. In addition, the installer may obtain a pre-manufactured update card from Garmin, via the listed 010- card part number in the General Arrangement drawings. 2. Pull the MFD and PFD circuit breakers. 3. Insert the boot block update card into the MFD. 4. While holding the ENT key on the MFD, restore power by closing the MFD circuit breaker. 5. When the words appear in the upper left corner of the MFD, release the ENT key. G1000 System Maintenance Manual – Diamond DA40/40F Page 3-21 190-00545-01 Revision E 6. The system automatically compares the existing GDU 104X boot block with the version on the boot block update card. If a difference exists, the GDU prompts to load new boot block: 7. MAKE CERTAIN that power will remain applied to the system with no possibility of accidental shutdown. Press the ENT key and new boot block will be loaded: 8. Remove the GDU Boot Block update card from the MFD and install in the PFD. 9. Repeat Steps 4 through 7 for the PFD. 10. When finished updating both displays, remove the boot block update card, and pull the MFD and PFD circuit breakers to remove power from the displays. 3.6.4 MFD & PFD Software Load Follow this procedure to load software to the MFD and PFD. 1. After verifying and/or updating GDU boot block, insert the correct G1000 software loader card which is applicable for the desired STC configuration into the MFD top card slot (see appropriate GA drawing in Table 1-2). 2. With the G1000 systems powered on, pull the MFD and PFD circuit breakers. 3. While holding the ENT key on the MFD, restore power by closing the MFD circuit breaker. 4. When the words appear in the upper left corner of the MFD, release the ENT key. 5. Press the ENT key to acknowledge the following prompt to load new software (NOTE: A softkey labeled ‘YES’ appears in the lower right corner and may be used in lieu of the ENT key): 6. The following screen is displayed: Page 3-22 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 7. New software is loaded to the MFD. When complete, the display starts in configuration mode. 8. Remove the software loader card from the MFD and insert it into the top card slot of the PFD. Repeat Steps 3 through 7 for the PFD. 3.6.5 G1000 System Software Upload The System Upload page allows a technician to load LRU software and system configuration files individually or in an automated sequence. Depending on what maintenance is performed, software and/or configuration files may need to be reloaded to LRUs. Follow the steps below as a guide to use the System Upload page. 1. On the PFD, go to the System Upload page using the small FMS knob. IMPORTANT! It is at this step where the G1000 will be configured as a DA 40 or DA 40F. Ensure that the correct airframe type is selected before proceeding; otherwise, incorrect configuration information will be loaded. 2. Activate the cursor and rotate the small FMS knob to active the drop-down menu. Highlight the airframe type in the AIRFRAME field. Select the appropriate aircraft type (DA 40 or DA 40F) and press the ENT key. IMPORTANT! It is at this step where the choice is given to load WAAS or non-WAAS G1000 software. Be sure to select the correct option. Loading the wrong software into GIA63/63W units may cause an inoperable condition that is not covered by warranty. Loading the incorrect software may make the GIA 63 or GIA 63W inoperable and necessitate returning the unit to Garmin for non-warranty repair. No warning appears if the wrong software is selected. 3. Once an airframe type is selected the cursor moves to the FILE window. Rotate the small FMS knob to active the drop-down menu. Move the cursor to highlight the appropriate aircraft model (WAAS or non-WAAS) and press ENT. G1000 System Maintenance Manual – Diamond DA40/40F Page 3-23 190-00545-01 Revision E 4. The PRODUCT window will populate and display software and default configuration file lists for each G1000 LRU. The LRU VERS column shows the currently loaded software version in the LRU, whereas the CARD VERS column shows the LRU software version stored on the loader card. Each check designates a file to be loaded to the G1000. If an inequality between the LRU VERS and CARD VERS columns is detected, the SOFTWARE and CONFIGURATION boxes will be pre-selected (checked) for each LRU reporting a different software version than the one on the card. The following softkeys provide an easy way to select files: CHK ALL: Selects all files, both configuration and software CHK SW: Selects all SW files only. CHK CFG: Selects all configuration files only. CLR ALL: Clears all selections. LOAD: Starts the software loading process. NOTE If this is the first time loading software and configuration to a new installation, it is advised to leave all check boxes selected. However, for maintenance purposes, it may not be necessary to reload all software and configuration files. The technician should be sure of the software requirements and load the appropriate files, including any options (see Section 3.6.6). If there is any doubt, the CHK ALL softkey is recommended. It is also highly recommended that the CAL configuration file NOT be loaded unless replacing the fuel probes. If this file is inadvertently reloaded, the fuel probes MUST be recalibrated per Section 4.6. 5. After verifying that the desired software and configuration files are checked, press the LOAD softkey. The G1000 system automatically begins loading software and default configuration files to the selected LRUs in the proper order. IMPORTANT! If non-WAAS GIA 63s are installed, the software boot block version must be checked while software is being loaded to EACH GIA 63. Wait until the software loading process begins to load the GIA 63 software. On the MFD, go to the System Status page and activate the cursor. Highlight GIA1. Observe the DESCRIPTION field. When it changes to read ‘G1000 GIA 6X BBL’, verify that the reported VERSION is 4.01 or higher. Repeat this for GIA2. If either GIA 63 has software boot block less than version 4.01, current boot block software must be loaded per Section 3.6.7 after the current GIA software load process completes. There is no need to interrupt the GIA system software from loading. 6. When the system finishes loading, it prompts the technician accordingly. Press the ENT key to acknowledge that the upload is finished: Page 3-24 G1000 System Maintenance Manual – Diamond DA40/40F Revision E 190-00545-01 7. Verify that each column indicates in green when the loading process has finished and inspect the SUMMARY window as well to ensure that the load is successful. 3.6.6 Loading Airframe Options After the base factory defaults are loaded to the G1000, the technician must check and verify which equipment or installation options exist on the aircraft. See the options list in 3.5.3. If the DA 40 aircraft being updated is equipped any additional equipment options, follow this procedure to load them. NOTE TAWS and ChartView options are covered in a separate section. See Sections 3.6.9 and 3.6.10 for TAWS and ChartView, respectively. 1. At the System Upload page, activate cursor and rotate the FMS knob once to activate the AIRFRAME menu. 2. Select ‘Options’ from the AIRFRAME window and press ENT. 3. From the FILE window, and select the desired airframe option to load. 4. Press the ENT key. 5. At this point, any applicable configuration and software files will be displayed in the PRODUCT window. 6. After reviewing the files to be loaded, press the LOAD ALL softkey. 7. Monitor the status of the upload. When the upload is finished, press ENT to acknowledge. 8. View the SUMMARY field and ensure that all items are ‘complete’: Verify that PASS appears in green at the check box for each file. 9. Repeat for each additional option configuration. G1000 System Maintenance Manual – Diamond DA40/40F Page 3-25 190-00545-01 Revision E 3.6.7 GIA 63 Boot Block Update For GIA 63s, boot block version 4.01 or higher is required to work with version 5.31 or later operating system software. There may be instances during maintenance where an older GIA may be installed from a spares pool or as a replacement. It is important to verify boot block during operating system software loading to ensure version 4.01 or higher is present (refer to Step 5 of 3.6.5). If it was determined in the software loading procedure that the GIA 63s did not have boot block version 4.01 or higher, follow this procedure to update the GIA 63’s software boot block. Note that this does not apply to GIA 63Ws. IMPORTANT! It is critical that electrical power be kept on during the boot block update procedure. Take steps to ensure that a 28 VDC ground power supply is properly connected and is not disturbed during the update. 1. Obtain the required GIA 63 Boot Block loader card from Garmin. The card part number is listed on the appropriate General Arrangement drawing. Alternatively, the GIA boot block update may be obtained by downloading the electronic file from Garmin, accessible via the dealer web site (see GA dwg for approved 006- P/N). This electronic download may be used to build an SD card to update the GIA boot block. 2. Insert the card into the top slot of the PFD and apply system power to the G1000. 3. On the PFD, go to the System Upload page using the FMS knob. 4. Activate the cursor and in the AIRFRAME field select GIA Boot Block. Press the ENT key. 5. The cursor drops down to the FILE field. Rotate the small FMS knob and select GIA Boot Block 4.01 and press the ENT key. 6. Verify that the SOFTWARE boxes are check for both GIA 1 and GIA 2. 7. MAKE CERTAIN that power will remain applied to the system with no possibility of accidental shutdown. Press the LOAD softkey. 8. The GIA boot block software is loaded. Be sure to not remove electrical power from the G1000 dur

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