G1000 System Maintenance Manual

3.3 REVERSIONARY M ODE ...................................................................................................................3-4 3.4 CONFIGURATION M ODE OVERVIEW ..............................................................................................3-5 3.5 CONFIGURATION M ODE NAVIGATION .........................................................................................3-11 4 G1000 CONTINUED AIRWORTHINESS 4.1 AIRWORTHINESS L IMITATIONS ......................................................................................................4-1 4.2 S ERVICING I NFORMATION ..............................................................................................................4-1 4.3 ON CONDITION S ERVICING ............................................................................................................4-1 4.4 M AINTENANCE REQUIREMENTS ....................................................................................................4-3 4.5 1000 HOUR I NSPECTION .................................................................................................................4-5 4.6 E LECTRICAL BONDING T EST ..........................................................................................................4-7 4.7 F UEL T ANK PROBE RE -CALIBRATION ............................................................................................4-8 4.8 GRS 77 E ARTH M AGNETIC F IELD UPDATES ................................................................................4-11 5 TROUBLESHOOTING 5.1 G1000 ALERTING S YSTEM .............................................................................................................5-2 5.2 S YSTEM ANNUNCIATIONS ..............................................................................................................5-4 5.3 DA 40-S PECIFIC ALERTS ................................................................................................................5-8 5.4 GDU 1040 TROUBLESHOOTING .....................................................................................................5-9 5.5 GDU 1040 ALERTS ........................................................................................................................5-9 5.6 GMA ALERTS...............................................................................................................................5-12 5.7 GIA 63 T ROUBLESHOOTING .........................................................................................................5-13 5.8 GIA ALERT M ESSAGES ................................................................................................................5-14 5.9 GEA T ROUBLESHOOTING ............................................................................................................5-19 5.10 GTX T ROUBLESHOOTING ...........................................................................................................5-20 5.11 GRS 77/GMU 44 T ROUBLESHOOTING ........................................................................................5-21 5.12 GDC 74A T ROUBLESHOOTING ...................................................................................................5-23 6 G1000 EQUIPMENT REMOVAL & REPLACEMENT 6.1 GDU 1040 MFD & PFD.................................................................................................................6-2 6.2 GMA 1347 AUDIO P ANEL ..............................................................................................................6-2 6.3 GIA 63 I NTEGRATED AVIONICS UNITS ..........................................................................................6-3 Page iv G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 6.4 GEA 71 E NGINE /AIRFRAME UNIT .................................................................................................6-3 6.5 GTX 33 T RANSPONDER .................................................................................................................6-4 6.6 GDC 74A AIR DATA COMPUTER ...................................................................................................6-4 6.7 GTP 59 OAT P ROBE ......................................................................................................................6-4 6.8 GRS 77 AHRS ...............................................................................................................................6-5 6.9 GMU 44 M AGNETOMETER .............................................................................................................6-5 6.10 CONFIGURATION M ODULE REMOVAL & REPLACEMENT .............................................................6-6 6.11 GEA 71 BACKSHELL T HERMOCOUPLE REMOVAL & REPLACEMENT ...........................................6-7 7 G1000 EQUIPMENT CONFIGURATION & TESTING 7.1 GDU 1040 MFD & PFD.................................................................................................................7-1 7.2 GMA 1347 AUDIO P ANEL ..............................................................................................................7-5 7.3 GIA 63 I NTEGRATED AVIONICS UNIT ............................................................................................7-8 7.4 GEA 71 E NGINE /AIRFRAME UNIT ...............................................................................................7-14 7.5 GTX 33 T RANSPONDER ...............................................................................................................7-17 7.6 GDC 74A AIR DATA COMPUTER .................................................................................................7-21 7.7 GRS 77 AHRS / GMU 44 M AGNETOMETER ................................................................................7-25 7.8 S OFTWARE /C ONFIGURATION T ROUBLESHOOTING ......................................................................7-34 8 SYSTEM RETURN TO SERVICE PROCEDURE 8.1 GPS F AILURE T EST ........................................................................................................................8-1 8.2 GIA F AILURE T EST ........................................................................................................................8-2 8.3 DISPLAY F AILURE T EST .................................................................................................................8-2 8.4 AHRS/ADC BACKUP P ATH T EST ..................................................................................................8-3 8.5 F LIGHT T EST ..................................................................................................................................8-4 8.6 M AINTENANCE RECORDS ...............................................................................................................8-4 APPENDIX A INSTALLATION DATA A.1 G1000 E QUIPMENT L IST .............................................................................................................. A-1 A.2 ADDITIONAL E QUIPMENT REQUIRED ........................................................................................... A-2 A.3 OPTIONAL E QUIPMENT ................................................................................................................ A-2 A.4 P ARTS L IST ................................................................................................................................... A-3 A.5 W EIGHT & BALANCE ................................................................................................................... A-5 APPENDIX B G1000 SOFTWARE/CONFIGURATION PROCEDURE B.1 S YSTEM P OWER UP ...................................................................................................................... B-2 B.2 MFD & PFD S OFTWARE L OAD .................................................................................................... B-3 B.3 INITIAL G1000 CONFIGURATION ................................................................................................. B-4 B.4 GIA S OFTWARE L OAD ................................................................................................................. B-5 B.5 GIA CONFIGURATION .................................................................................................................. B-7 B.6 F INAL LRU S OFTWARE L OAD ..................................................................................................... B-8 B.7 F INAL LRU CONFIGURATION .................................................................................................... B-14 B.8 S OFTWARE L OAD CONFIRMATION ............................................................................................. B-15 B.9 AVIATION D ATABASE L OADING ................................................................................................ B-16 B.10 F INAL S YSTEM T ESTING ............................................................................................................ B-16 G1000/DA40 System Maintenance Manual Page v 190-00303-03 Revision 6 LIST OF ILLUSTRATIONS FIGURE PAGE Figure 2-1. G1000 / DA 40 Panel Installation ..........................................................................................2-2 Figure 2-2. DA40 Panel (Rear View) .......................................................................................................2-4 Figure 2-3. GTP 59 OAT Probe................................................................................................................2-5 Figure 2-4. GRS 77 Mount .......................................................................................................................2-6 Figure 2-5. GMU 44 Installation...............................................................................................................2-7 Figure 2-6. G1000 in DA 40 Equipment Locations..................................................................................2-8 Figure 2-7. Remote Avionics Enclosure ...................................................................................................2-9 Figure 2-8. G1000/DA40 Electrical Distribution....................................................................................2-11 Figure 2-9. TVS & Fuse Installation.......................................................................................................2-12 Figure 2-10. Lightning Protection Components .....................................................................................2-13 Figure 2-11. Component Plate Dimensions ............................................................................................2-13 Figure 2-12. Component Wiring Diagram..............................................................................................2-14 Figure 2-13. SPIDER Ground Installation..............................................................................................2-16 Figure 2-14. MAP Sensor .......................................................................................................................2-17 Figure 2-15. Oil Pressure Sensor ............................................................................................................2-17 Figure 2-16. Oil Temperature Sensor .....................................................................................................2-18 Figure 2-17. Fuel Pressure Sensor ..........................................................................................................2-18 Figure 2-18. Tachometer Sensor.............................................................................................................2-19 Figure 2-19. Fuel Flow Sensor & Fire Sleeve ........................................................................................2-19 Figure 2-20. Fuel Flow Assembled.........................................................................................................2-20 Figure 2-21. Fuel Flow Bracket ..............................................................................................................2-20 Figure 2-22. CHT Probe .........................................................................................................................2-21 Figure 2-23. EGT Probe..........................................................................................................................2-21 Figure 2-24. Alternator Current Sensor Installation ...............................................................................2-22 Figure 2-25. Flight Instrumentation Interface.........................................................................................2-23 Figure 2-26. G1000 Engine/Airframe Interface......................................................................................2-24 Figure 2-27. G1000 Navigation/Communications..................................................................................2-25 Figure 3-1. GDU 1040 Control Interface..................................................................................................3-1 Figure 3-2. GMA 1347 Controls...............................................................................................................3-1 Figure 3-3. G1000 Softkeys ......................................................................................................................3-2 Figure 3-4. Normal Mode .........................................................................................................................3-3 Figure 3-5. MFD Failure Mode.................................................................................................................3-4 Figure 3-6. PFD Failure Mode..................................................................................................................3-4 Figure 3-7. G1000 LRU Configuration File Storage ................................................................................3-7 Figure 3-8. GRS/GDC Configuration Settings Storage ............................................................................3-8 Figure 3-9. SET>ACTV Diagram.............................................................................................................3-9 Figure 3-10. Loss of Communication .....................................................................................................3-10 Figure 3-11. Configuration Status...........................................................................................................3-10 Figure 3-12. Data Transmission Indicators.............................................................................................3-10 Figure 3-13. Configuration Page Navigator............................................................................................3-11 Figure 5-1. System Status Page (AUX Group Normal Mode)..................................................................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............................................................................................................5-4 Figure 5-7. GMA 1347 Data Paths .........................................................................................................5-12 Figure 5-8. GEA 71 Data Paths ..............................................................................................................5-19 Figure 5-9. GTX 33 Data Paths ..............................................................................................................5-20 Figure 5-10. GRS 77 Data Paths.............................................................................................................5-22 Page vi G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 Figure 5-11. GDC 74A Data Paths .........................................................................................................5-23 Figure 6-1. System Status Page (Configuration Mode) ............................................................................6-1 Figure 6-2. Configuration Module Installation .........................................................................................6-6 Figure 6-3. GEA Backshell Thermocouple...............................................................................................6-7 Figure 7-1. G1000 Normal Mode Check ..................................................................................................7-4 Figure 7-2. G1000 Reversionary Mode Check .........................................................................................7-4 Figure 7-3. Marker Beacon Symbology....................................................................................................7-7 Figure 7-4. GPS Signal Status.................................................................................................................7-11 Figure 7-5. G1000 Engine/Airframe Indicators ......................................................................................7-16 LIST OF TABLES TABLE PAGE Table 1-1. Required Documents ...............................................................................................................1-3 Table 1-2. Reference Documents..............................................................................................................1-3 Table 4-1. Required Maintenance.............................................................................................................4-3 Table 4-2. 1000 Hour Inspection Procedure .............................................................................................4-5 Table 6-1. Thermocouple Kit (011-00981-00) .........................................................................................6-7 G1000/DA 40 System Maintenance Manual Page 1-1 190-00303-03 Revision 6 1 INTRODUCTION 1.1 Content, Scope, Purpose This document provides Instructions for Continued Airworthiness (ICA) for the Garmin G1000 Integrated Cockpit avionics suite as installed in the Diamond Model DA 40 in accordance with the STC issued under FAA STC SA01254WI. 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 integrated cockpit system, as installed in the Diamond DA 40. 1.1.1 Applicability This document applies to all Diamond Aircraft Industries, Inc., Model DA 40 aircraft equipped with the G1000 cockpit installed in accordance with the STC issued under FAA STC SA01254 “original issue” configuration. G1000 System Maintenance Manual – Diamond DA40 190-00545-00 applies to later configurations. 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 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 Continued Airworthiness Provides maintenance instructions for continued airworthiness of the G1000 system. Section 5: Troubleshooting Provides troubleshooting information to aid in diagnosing and resolving potential problems with the G1000 system. Section 6: G1000 Equipment Removal & Replacement Gives instructions for the removal and replacement of G1000 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. Appendix A: Installation Data Gives a complete equipment/parts list and weight/balance data for the G1000 installation in the Diamond DA 40. Appendix B: G1000 Software/Configuration Procedure Provides a complete software/configuration loading procedure in cases where the G1000 system as a whole requires complete software/configuration update or reload. This is given in addition to individual LRU configuration instructions presented in Section 7. Page 1-2 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 1.3 Definitions/Abbreviations ADI: Attitude Display Indicator AHRS: Attitude Heading Reference System AMM: Airplane Maintenance Manual CDU: Control Display Unit CFR: Code of Federal Regulations EAU: Engine/Airframe Unit EIS: Engine Instrumentation Systems HIRF: High Intensity Radiated Fields HSDB: High-Speed Data Bus (Ethernet) IAU: Integrated Avionics Unit ICS: Inter-Com System LRU: Line Replaceable Unit MFD: Multi-Function Flight Display OAT: Outside Air Temperature PFD: Primary Flight Display STC: Supplemental Type Certificate S/W: Software TC: Type Certificate TSO: Technical Standard Order TVS: Transient Voltage Suppressor VHF: Very High Frequency 1.3.1 Units of Measure Unless otherwise stated, all units of measure are English units. G1000/DA 40 System Maintenance Manual Page 1-3 190-00303-03 Revision 6 1.4 Reference Publications The following documents are required by this maintenance manual to perform maintenance: Table 1-1. Required Documents Document Garmin Part Number G1000 Cockpit Reference Guide for DA40 190-00324-00 G1000/DA 40 Airplane Flight Manual Supplement 190-00303-02 Diamond DA 40 Wiring Diagram Diamond P/N: DA4-9231-60-1 Diamond DA 40 Airplane Maintenance Manual Diamond P/N 6.02.01 (Rev. 4 or later) The following documents provide additional information above and beyond the scope of this document: Table 1-2. Reference Documents Document Garmin Part Number G1000/DA 40 Master Drawing List 005-C0004-00 G1000/DA 40 Required Equipment List 005-00149-28 G1000/DA 40 Install Drawing 005-00149-01 G1000/DA 40 Post Installation Checkout Procedure 190-00303-06 G1000 Configuration Manual 190-00303-04 Aircraft Fastener Assembly Torque 005-00249-00 Aircraft Contact and Terminal Crimping 005-00249-01 Heat Shrink Tubing Application 005-00249-02 Aircraft Soldering 005-00249-03 1.5 Distribution This document is to be a permanent aircraft record and is distributed with a new G1000-equipped Diamond DA 40. Revisions to this document will be made by Garmin and will be distributed by Garmin per standard documentation revision procedures. Page 1-4 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 This page intentionally left blank. G1000/DA40 System Maintenance Manual Page 2-1 190-00303-03 Revision 6 2 SYSTEM DESCRIPTION G1000 system installation can be accomplished only after the following Diamond aircraft modifications have been installed: • OAM 40-061 Autopilot (optional) • OAM 40-68 Essential Bus • OAM 40-073/b Slick Start System • OAM 40-082/b IFR Lightning Protection • OAM 40-146 Remote Avionics Provisions • OAM 40-161/e G1000 Provisions Provisions with KAP 140 AFCS Or OAM 40-196 G1000 Provisions without KAP 140 AFCS • STC SA1850CH Hartzell Propeller The G1000 integrated cockpit is installed in the DA 40 using the equipment listed in this section as well as parts listed in Appendix A. 2.1 Equipment Descriptions 2.1.1 GDU 1040 MFD & PFD Two Garmin GDU 1040 CDUs 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 (See Figure 2-1). Electrical power to the PFD is from the ‘Essential’ power bus, whereas the MFD receives power from the ‘Main’ 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. The ‘GDL 69’ and ‘WX500’ circuit breakers, if installed, are pulled, banded with collars, and associated wires are disconnected and dressed with shrink tube. Two CDU cooling fans are also installed behind the panel as shown in Figure 2-2. Page 2-2 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 Figure 2-1. G1000 / DA 40 Panel Installation G1000/DA40 System Maintenance Manual Page 2-3 190-00303-03 Revision 6 2.1.2 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 ‘Avionics’ bus. The unit only powers up when the avionics master switch is turned on. The GMA 1347 interfaces with the existing marker beacon antenna as well as existing mic and phone jacks. 2.1.3 GIA 63 Integrated Avionics Unit (2) Two Garmin GIA 63 IAUs provide VHF COM, VHF NAV, GPS NAV and other various navigation functions. GIAs provide communication interface to all other G1000 LRUs in the system. Both GIAs are located remotely beneath the baggage compartment in a sheetmetal enclosure, as shown in Figure 2-6 and Figure 2-7. 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 ‘Avionics’ bus and powers up when the avionics master switch is turned on. Both GIA 63s interface to the following equipment: • .....Existing KAP 140 Flight Control System (GIA 2) • .....Existing VOR/LOC/Glideslope Antenna System • .....Existing VHF COM 1 & 2 Antennas • .....Existing GPS 1 & 2 Antennas 2.1.4 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 as depicted in Figure 2-2 and Figure 2-6. Power is received from the ‘Essential’ power bus. The GEA interfaces to the following: • .....Manifold Pressure Sensor (MAP) • .....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 2.1.5 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 (See Figure 2-6 and Figure 2-7). Power is received from the ‘Essential’ bus. The GTX 33 interfaces with the existing transponder antenna. Page 2-4 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 Figure 2-2. DA40 Panel (Rear View) G1000/DA40 System Maintenance Manual Page 2-5 190-00303-03 Revision 6 2.1.6 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 sheetmetal rack. Power is received from the ‘Essential’ bus. The GDC 74A connects to existing pitot/static ports as shown in Figure 2-2 and Figure 2-6. 2.1.7 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 as shown in Figure 2-3. Figure 2-3. GTP 59 OAT Probe Page 2-6 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 2.1.8 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 (see Figure 2-4 and Figure 2-6). 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. Figure 2-4. GRS 77 Mount G1000/DA40 System Maintenance Manual Page 2-7 190-00303-03 Revision 6 2.1.9 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 as shown in Figure 2-5 and Figure 2-6. Figure 2-5. GMU 44 Installation Page 2-8 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 2.2 Equipment Locations GDC 74A GDC 74A Figure 2-6. G1000 in DA 40 Equipment Locations G1000/DA40 System Maintenance Manual Page 2-9 190-00303-03 Revision 6 2.3 Remote Avionics Enclosure A remote avionics enclosure allows LRUs to be inserted vertically, from above. The enclosure is also cooled with an avionics fan and duct assembly as shown in Figure 2-6 and Figure 2-7. The enclosure is installed as shown in Figure 2-7. 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 (see Section 2.5). Figure 2-7. Remote Avionics Enclosure Page 2-10 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 Figure 2-7. Remote Avionics Enclosure, Cont. G1000/DA40 System Maintenance Manual Page 2-11 190-00303-03 Revision 6 2.4 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. Only the #2 GIA 63 and the GMA 1347 are connected to this bus. Figure 2-8. G1000/DA40 Electrical Distribution Page 2-12 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 2.5 Lightning Strike Protection The following modifications to the aircraft provide additional protection of G1000 equipment from the effects of lightning strike. 2.5.1 Alternator / Battery Voltage Suppressors & Fuses 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 , as shown in Figure 2-9 . Fuses are easily removed by twisting the fuse holder cap counter-clockwise and removing the fuse. Figure 2-9. TVS & Fuse Installation G1000/DA40 System Maintenance Manual Page 2-13 190-00303-03 Revision 6 2.5.2 GIA / AHRS Lightning Protection 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 (see Figure 2-7 and Figure 2-10). The dimensions for the mounting block are provided in Figure 2-11. 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). Figure 2-12 shows the wiring setup on the block for one set of components. Power is returned to the LRU after passing through the resistor and voltage suppressor. Figure 2-10. Lightning Protection Components Figure 2-11. Component Plate Dimensions Page 2-14 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 Figure 2-12. Component Wiring Diagram G1000/DA40 System Maintenance Manual Page 2-15 190-00303-03 Revision 6 2.5.3 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: • A 1000-hour visual inspection of all G1000 equipment, including voltage suppressors, resistors, fuses, etc. • A n electrical bonding check of G1000 equipment every 1000 hours or anytime a lightning strike occurs or is suspected. • Regular replacement (every 2 years) 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. Page 2-16 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 2.6 SPIDER Grounds Most G1000 connectors employ a SPIDER grounding system to provide necessary ground reference to shielding and/or transducers. A single 16-gauge wire is connected locally to the airframe. Additional ‘spider’ wires, 24-gauge, are used to connect shield grounds. The assembly is fastened directly to the backshell housing with two screws. Figure 2-13 shows an example SPIDER installation. Figure 2-13. SPIDER Ground Installation G1000/DA40 System Maintenance Manual Page 2-17 190-00303-03 Revision 6 2.7 Sensor Installations 2.7.1 Manifold Air Pressure A Kulite MAP sensor measures manifold air pressure. The sensor, manifold hose, and adapter fittings are installed as shown in Figure 2-14. Figure 2-14. MAP Sensor 2.7.2 Oil Pressure A Kulite pressure sensor measures oil pressure. The sensor, oil pressure hose, and fittings are installed as shown in Figure 2-15. Figure 2-15. Oil Pressure Sensor 2.7.3 Oil Temperature A Norwich Aero Products oil temperature sensor is used to measure oil temperature. The sensor is installed as shown in Figure 2-16. Page 2-18 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 Figure 2-16. Oil Temperature Sensor 2.7.4 Fuel Pressure A Kulite pressure sensor is used to measure fuel pressure. The sensor, fuel hose, O-rings, and associated fittings are installed as shown in Figure 2-17. Figure 2-17. Fuel Pressure Sensor 2.7.5 Tachometer A tachometer provides engine RPM measurements to the G1000 system. The tachometer is installed as shown in Figure 2-18. G1000/DA40 System Maintenance Manual Page 2-19 190-00303-03 Revision 6 Figure 2-18. Tachometer Sensor 2.7.6 Fuel Flow A Shadin fuel flow sensor is used to measure fuel flow. The fuel flow sensor/fuel hose assembly is surrounded by a fire-resistant sleeve, as detailed in Figure 2-19 and Figure 2-20. The fuel flow/fire sleeve assembly is mounted to a field-fabricated bracket as shown in Figure 2-21. Figure 2-19. Fuel Flow Sensor & Fire Sleeve Page 2-20 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 Figure 2-20. Fuel Flow Assembled Figure 2-21. Fuel Flow Bracket G1000/DA40 System Maintenance Manual Page 2-21 190-00303-03 Revision 6 2.7.7 Cylinder Head Temperature Thermocouples Four thermocouples are used to measure cylinder head temperatures. A sensor is installed in each cylinder head. An example is shown in Figure 2-22. Figure 2-22. CHT Probe 2.7.8 Exhaust Gas Temperature Thermocouples Four thermocouples are used to measure exhaust gas temperatures. A sensor in installed in each exhaust header primary pipe. An example installation is shown in Figure 2-23. Figure 2-23. EGT Probe Page 2-22 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 2.7.9 Alternator Current Sensor A current sensor is used to measure alternator current output. The sensor is installed behind the circuit breaker panel as shown in Figure 2-24. Figure 2-24. Alternator Current Sensor Installation G1000/DA40 System Maintenance Manual Page 2-23 190-00303-03 Revision 6 2.8 G1000 System Communications 2.8.1 Flight Instrumentation The GRS 77 AHRS, GDC 74A Air Data Computer, and GMU 44 Magnetometer are responsible for providing the G1000 system with flight instrumentation. Data consists of aircraft attitude, heading, altitude, airspeed, vertical speed, and outside air temperature information, all displayed on the PFD (data is displayed on the MFD in reversionary mode only). Primary data outputs from the GRS and GDC are sent directly to the PFD via ARINC 429. Secondary data paths connect the GRS and GDC to the MFD. Additional communications paths connect the GRS and GDC to both GIA 63 units, providing quadruple redundant interface. The GRS 77 receives GPS data from both GIAs, airspeed data from the GDC, and magnetic heading from the GMU. Using these three external sources, combined with internal sensor data, the GRS accurately calculated aircraft attitude and heading. Figure 2-25. Flight Instrumentation Interface Page 2-24 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 2.8.2 Engine Indicator System The GEA 71 provides engine/airframe data to the G1000 system. The unit interfaces to transducers shown in Figure 2-25 (see Section 2.1.4). Analog data is received from the transducers and is converted to digital signal by the GEA 71. Digital information is then sent through the primary RS-485 serial path to the #1 GIA 63. From the GIA, data is sent through the HSDB connection to the PFD, then on to the MFD for display. A backup data path from the GEA to the #2 GIA 63, then on to the MFD, exists in the event the primary path fails. Figure 2-26. G1000 Engine/Airframe Interface G1000/DA40 System Maintenance Manual Page 2-25 190-00303-03 Revision 6 2.8.3 Communications/Navigation Systems The GIA 63 IAUs contain VHF COM, VHF NAV, and GPS receivers. COM and NAV audio is sent via digital audio to the GMA 1347 Audio Panel. GPS information is sent to the GRS 77 AHRS and both displays for processing assistance. The GTX 33 Mode S Transponder communicates with both GIAs. Transponder data is sent from the GIAs to the PFD where control and operation occurs. The #2 GIA outputs analog HSI signals to the Honeywell KC 140. The GMA 1347 Audio Panel controls the display reversionary mode. Figure 2-27. G1000 Navigation/Communications Page 2-26 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 This page intentionally left blank. G1000/DA 40 System Maintenance Manual Page 3-1 190-00303-03 Revision 6 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 various GDU 1040 buttons. Figure 3-2 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 Figure 3-1. GDU 1040 Control Interface 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 3-2. GMA 1347 Controls Page 3-2 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 3.1 User Interface 3.1.1 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. 3.1.2 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 3-3. G1000 Softkeys G1000/DA 40 System Maintenance Manual Page 3-3 190-00303-03 Revision 6 3.2 G1000 Normal Mode To start the G1000 system in Normal Mode: 1. Turn on the master switch. The following G1000 equipment is powered on: • GDU 1040 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 2. Turn on the DA 40 avionics switch. The following G1000 equipment is powered on: • No. 2 GIA 63 Integrated Avionics Unit • GMA 1347 Digital Audio Panel 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 3-4. Normal Mode Page 3-4 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 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 on the GMA 1347 audio panel activates the manual reversionary mode. Figure 3-5. 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 3-6. PFD Failure Mode G1000/DA 40 System Maintenance Manual Page 3-5 190-00303-03 Revision 6 3.4 Configuration Mode Overview The Configuration Mode exists to provide the 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. The Configuration Mode contains certain pages and settings that are critical to aircraft operation and safety. Such 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. For a complete description and breakdown of each Configuration Mode page, refer to the G1000 Configuration Manual, Garmin part number 190-00303-04. 3.4.1 Loader Card Interface The G1000/DA 40 SW Loader Card interface exists to provide a means of loading software and configuration files to the system and LRUs. The G1000/DA 40 SW Loader Card uses a 128 MB Secure Digital (SD) data card that contains: • All G1000 LRU Software Files • All G1000 Configuration Files All software and configuration files were pre-determined by Garmin and/or Diamond during design of the system. During removal and replacement of LRUs, software and configuration files may need to be reloaded (See Sections 6 & 7). To satisfy TC/STC requirements for the DA 40, it is critical that the technician uses the correct G1000/DA 40 SW Loader Card part number when servicing the G1000 system. The G1000/DA 40 SW Loader Card part number defines all files specific to the G1000 system as installed in the DA 40. Refer to Appendix A for approved card part numbers. Approved Loader Card part numbers for the DA 40 can also be found in the Required Equipment List, Garmin P/N 005-00149-28. Always use caution when using SW Loader Cards during maintenance. The G1000 system is designed to immediately initialize 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, 7, and/or Appendix B before attempting to use the SW Loader Cards. CAUTION NOTE CAUTION Page 3-6 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 3.4.2 Configuration Files A G1000/DA 40 SW Loader Card typically contains the following configuration files: • 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. • SYSTEM: This file configures the G1000 Ethernet to expect a PFD, MFD, and two GIAs. • MANIFEST: This file loads a manifest of all software part numbers and versions associated with an approved system configuration. • 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. • GMA1: This file configues 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. • GDC1: This file configures GDC 74A air data values for the DA 40. The above files are loaded during the configuration processes listed in Section 7 and Appendix B. Each file is sent directly to the applicable LRU. The same file is also stored in PFD internal configuration memory. The PFD also sends a copy of all configuration files to it’s connector configuration module. If the PFD is replaced, the configuration module retains all configuration files in the aircraft. The GRS 77 AHRS and GMU 44 Magnetometer do not utilize a configuration file. However, these LRUs do require several calibrations during installation checkout to tailor sensor characteristics to a specific DA 40 airframe. While performing maintenance on these units, re-calibration may be required. See Section 7.7.3 for more information on re-calibration criteria. NOTE G1000/DA 40 System Maintenance Manual Page 3-7 190-00303-03 Revision 6 3.4.3 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. Figure 3-7 and Figure 3-8 illustrate where the various configuration files are stored. Figure 3-7. G1000 LRU Configuration File Storage Page 3-8 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 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. Rather, it stores calibration data recorded during installation calibration procedures. Figure 3-8. GRS/GDC Configuration Settings Storage 3.4.4 SET>ACTV Interface Throughout various 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 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. 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! WARNING G1000/DA 40 System Maintenance Manual Page 3-9 190-00303-03 Revision 6 In the first example shown in Figure 3-9, 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. Figure 3-9. SET>ACTV Diagram Page 3-10 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 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 G1000 SW Loader Card. Section 7 describes this method for each LRU). A blank active column, as shown in Figure 3-10, represents loss of communication between the display and the particular unit. See Section 5 for more details on troubleshooting. Figure 3-10. Loss of Communication 3.4.5 Configuration Prompts When configuration settings are changed, the technician receives on-screen prompts and/or confirmations such as those shown in Figure 3-11. Section 7 and Appendix B show other prompts encountered during the configuration process. Figure 3-11. Configuration Status 3.4.6 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 3-12. Data Transmission Indicators G1000/DA 40 System Maintenance Manual Page 3-11 190-00303-03 Revision 6 3.5 Configuration Mode Navigation Using the FMS knob as described in Section 3.1.1 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 Configuration manual, Garmin part number 190-00303-04. The following diagram shows the layout and organization of Configuration Mode page groups and pages. Figure 3-13. Configuration Page Navigator Page 3-12 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 This page intentionally left blank. G1000/DA 40 System Maintenance Manual Page 4-1 190-00303-03 Revision 6 4 G1000 Continued Airworthiness 4.1 Airworthiness Limitations The G1000 integrated cockpit is airworthy when installed and configured in accordance the STC issued under FAA Project #ST3636WI-A. The Airworthiness Limitations section is FAA-approved and specifies maintenance required under §§ 43.16 and 91.403 of Title 14 of the Code of Federal Regulations, unless an alternative program has been FAA-approved. The G1000 system possesses the following maintenance airworthiness limitations: Every 2 years, replace all lightning protection 3.2 Amp slow-blow fuses. There are five total fuses in the following locations: • Two fuses mounted behind the instrument panel, near the circuit breaker panel. Each fuse in wired inline with a voltage suppressor. • Three fuses mounted on the field-fabricated lightning protection component block, which is attached to the forward portion of the remote avionics enclosure. Each fuse is mounted to the side of the block, and each is labeled. Replacement consists of twisting each fuse holder cap counter-clockwise, removing each fuse and replacing with a new fuse. For detailed drawings, see Section 2.5. There are no other maintenance airworthiness limitations associated with this type design change. The G1000/DA 40 Airplane Flight Manual Supplement defines all other airworthiness limitations. 4.2 Servicing Information G1000 LRU maintenance is ‘on condition’ only. No component-level overhaul is required for this type design change. 4.3 On Condition Servicing ‘On Condition’ replacement and/or servicing should occur when an item exhibits conditions, symptoms, and/or abnormalities defined in Section 5 of this manual. Replacement and/or servicing should be made only after the technician troubleshoots the system to the extent determined necessary by using the guidance in this manual along with common maintenance practices. It is impossible to provide guidance for every conceivable failure scenario within the scope of this manual. Every effort has been made to provide comprehensive guidance for possible failures. The information in this document should always be combined with common sense and a thorough knowledge of the system. Use sound avionics maintenance practices when working around or on G1000 equipment. IMPORTANT Page 4-2 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 The remainder of this document is organized in the following fashion: • Section 4.3 lists maintenance requirements related to the G1000 system. • Section 6 gives instructions regarding the removal and replacement of G1000 equipment and parts. • Section 7 gives configuration and testing instructions to be accomplished if G1000 equipment or parts are removed/replaced. • Section 8 specifies system return-to-service procedures. Before removing any G1000 LRU, it is required that technicians verify the LRU software version and part numbers against Appendix A. The beginning of Section 6 provides instructions to check the software part number and version of each LRU before removing a unit. Procedures in Section 7 require the same check after LRU replacement and software loading. 4.3.1 Recommended Tools The following tools are needed to perform maintenance tasks on G1000 equipment: • Mili-ohm Meter, OR 9 Agilent 34410A Ammeter or equivalent 9 Fluke 187 Voltmeter or equivalent 9 Power Supply capable of providing 1 amp current • #2 Phillips Screwdriver • 3/32nd Hex Tool • Digital Level (Required for AHRS ‘Procedure A’ Calibration) • A VHF NAV/COM/ILS ramp tester or equivalent. • A transponder ramp tester or equivalent. • A pitot/static ramp tester. • Outdoor line-of-site to GPS satellite signals or GPS indoor repeater. • Headset/Microphone. • Ground Power Unit (Capable of supplying 28 Vdc) G1000/DA 40 System Maintenance Manual Page 4-3 190-00303-03 Revision 6 4.4 Maintenance Requirements The following table shows systems and items that must undergo tests or checks at specific intervals. If the interval is shown to be in flight time as well as calendar years, the first interval reached should be used as the limit. Table 4-1. Required Maintenance Item Description/Procedure Interval Initials G1000 LRUs GDU 1040 PFD & MFD See Section 6.1 for removal & replacement. On Condition GMA 1347 See Section 6.2 for removal & replacement. On Condition GIA 63 IAU (Qty. 2) See Section 6.3 for removal & replacement. On Condition GEA 71 EAU See Section 6.4 for removal & replacement. On Condition See Section 6.5 for removal & replacement. On Condition GTX 33 Mode S Transponder Test according to Title 14 CFR §§ 91.411 and 91.413 as well as Part 43 Appendix F. See Section 7.5.3. 1000 Hours or 2 Years See Section 6.6 for removal & replacement. On Condition Pitot/Static Leak Test. See Section 7.6.3. 1000 Hrs or 2 Years Altimeter Function Test. See Section 7.6.3. 2000 Hours or 4 Years Airspeed Function Test. See Section 7.6.3. 2000 Hours or 4 Years GDC 74A Vertical Speed Function Test. See Section 7.6.3. 2000 Hours or 4 Years See Section 6.7 for removal & replacement On Condition GRS 77 AHRS Magnetic variation database update. See Section 4.7. On Condition GMU 44 Magnetometer See Section 6.7.1 for removal & replacement. On Condition G1000 Accessories Configuration Module Replacement (Qty 4) See Section 6.8 for removal & replacement. On Condition OAT Probe See Section 6.6.1 for removal & replacement. Refer to Section 2.1.6.1 for installation drawing. On Condition PFD, MFD, & GIA Cooling Fans (Qty 3) Refer to Figure 2-2 and/or Figure 2-7 for installation drawings. On Condition Page 4-4 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 Table 4-1. Required Maintenance, Cont. Item Description/Procedure Interval Initials G1000 Lightning Protection GIA / AHRS Resistors Replace all three resistors located at the remote avionics enclosure. Refer to Section 2.5.2 for installation drawings. Replace After Suspected / Actual Lighting Event TVS Unit Replacement (Qty 5) Replace all five voltage suppressor units: 9 Battery & Alternator Voltage Suppressors are located behind instrument panel near the circuit breakers 9 GIA1, GIA2, and AHRS Voltage Suppresors are located at the remote avionics enclosure. Refer to Section 2.5 for installation drawings. Replace After Suspected / Actual Lighting Event 3.2 Amp Slow-blow Fuse Replacement (Qty 5) Replace all five 3.2 Amp slow-blow fuses: 9 Battery & Alternator side fuses are located behind the instrument panel near the circuit breakers. 9 GIA1, GIA2, and AHRS fuses are locate at the remote avionics enclosure. Refer to Section 2.5 for installation drawings. Every 2 Years or After Suspected / Actual Lighting Event Visual Inspection Perform a visual inspection following the procedure given in Section 4.5. 1000 Hours Electrical Bonding Test Perform a bonding resistance check of all G1000 equipment as described in Section 4.6. 1000 Hours or After Suspected / Actual Lighting Event Engine/Airframe Sensors MAP Sensor Refer to Section 2.4.1 for installation drawing. On Condition Oil Pressure Sensor Refer to Section 2.4.2 for installation drawing. On Condition Oil Temperature Sensor Refer to Section 2.4.3 for installation drawing. On Condition Fuel Pressure Sensor Refer to Section 2.4.4 for installation drawing. On Condition Tach Sensor Refer to Section 2.4.5 for installation drawing. On Condition Fuel Flow Sensor Refer to Section 2.7.6 for installation drawing. On Condition CHT Probes (Qty 4) Refer to Section 2.7.7 for installation drawing. On Condition EGT Probes (Qty 4) Refer to Section 2.7.8 for installation drawing. On Condition Alternator Current Sensor Refer to Section 2.7.9 for installation drawing. On Condition Fuel Tank Quantity Sending Units Should one or both fuel quantity transducers fail, replace according to instructions in Diamond DA 40 Aircraft Maintenance Manual. The new replacement fuel quantity probe(s) must be re-calibrated according to the procedure set forth in Section 4.7. On Condition G1000/DA 40 System Maintenance Manual Page 4-5 190-00303-03 Revision 6 4.5 1000 Hour Inspection Perform a visual inspection every 1000 airframe hours and check for corrosion, damage, or other defects for each of the items listed in Table 4-2. Replace any damaged parts as required. Inspection may require the temporary removal of a unit or units to gain access to connectors. Follow guidance in Section 6 for equipment removal and replacement. Refer to the Diamond DA 40 Airplane Maintenance Manual for instructions on removing any access panels. Table 4-2. 1000 Hour Inspection Procedure Item Description/Procedure Initials To gain access for the following inspections: 1. Remove the instrument panel cover as described in the DA 40 Aircraft Maintenance Manual. GDC 74A Air Data Computer a) Visually inspect the GDC 74A unit, mount, and connector for corrosion or other defects. b) Ensure that pitot/static plumbing is secure and in good condition. GEA 71 Engine/Airframe Unit a) Inspect the GEA 71 unit, rack, and connectors for corrosion or other defects. Battery & Alternator Voltage Suppressors (2) a) Inspect both voltage suppressors and associated wiring for cracks, chaffing, or other defects. b) Remove each voltage suppressor fuse and inspect the fuse filament. Ensure that the fuse is in good condition. CDU Fans a) Inspect both CDU fans for accumulation of dirt and other damage. Remove excess dirt as required. b) Ensure that both fans are operational. GDU 1040 MFD & PFD a) Remove the MFD and PFD as described in Section 6. b) Inspect the mounting surface, copper bonding fingers and connector for corrosion, heavy oxidation, or other damage. c) Reinstall the MFD and PFD. To gain access for the following Inspections: 1. Remove rear baggage compartment floor. 2. Remove baggage compartment shell. Refer to the DA 40 Aircraft Maintenance Manual for removal instructions. GRS 77 a) Inspect the GRS 77 unit, rack, and connector for corrosion or other defects. b) Inspect both braided ground straps to the GRS rack and ensure they are in good condition. Remote Avionics Enclosure a) Inspect the outer area around the enclosure for damage. b) Inspect the antenna connection junction. c) Inspect the aluminum ground strap. d) Inspect the GIA/AHRS voltage suppressors, resistors, and fuses mounted to the front of the enclosure (refer to Section 2.5 for drawings): i. Inspect each voltage suppressor and associated wiring for cracks, chaffing, or other defects. ii. Remove each voltage suppressor fuse and inspect the fuse filament. Ensure that each fuse is in good condition. iii. Inspect each lightning protection resistor and associated wiring for cracks, chaffing, or other defects. e) Loosen the screws securing the top half of the avionics enclosure. f) Remove the top half of the enclosure and inspect the bottom mounting tray and all connectors. g) Reinstall the top avionics enclosure. Page 4-6 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 Item Description/Procedure Initials GIA Avionics Fan a) Inspect remote avionics fan for dirt accumulation and other damage. Remove excess dirt as required. b) Ensure that the fan is operational. The GMU 44 is mounted below the starboard wing. Refer to Figure 2-5 and Figure 2-6 for the following inspection. GMU 44 a) Remove the three Phillips screws holding the GMU access plate to the wing. b) Carefully lower the assembly and inspect the GMU 44 and rack. c) Inspect the mounting hardware and GMU 44 for corrosion or other damage. d) Reinstall the GMU 44 beneath the wing. For all other equipment installed under this STC listed in this maintenance manual, use the inspection procedures set forth in Chapter 05 of the DA40 Airplane Maintenance Manual. IMPORTANT G1000/DA 40 System Maintenance Manual Page 4-7 190-00303-03 Revision 6 4.6 Electrical Bonding Test The airframe bonding test is described in the DA40 AMM in Section 51-80-00 on Page 201. The following bonding test is provided for G1000-equipped DA 40 aircraft as a requirement beyond what is given in Section 51-80-00. 4.6.1 Requirements All G1000 equipment must be installed. Remove the instrument panel cover, baggage compartment floor, and baggage compartment to gain access to required areas. Remove the co-pilot seat to gain access to the OAT probe base, following instructions in the DA 40 AMM. 4.6.2 Test Equipment A mili-ohm meter and Kelvin probes are recommended for this test. However, a standard voltmeter, power supply, and ammeter may be substituted. The following procedure is written using the voltmeter, power supply and ammeter. All test equipment must have valid calibration records. 4.6.3 Procedure 1. Connect the positive lead of the power supply to the engine compartment grounding bracket (battery negative connection to the airframe). Connect/touch the positive lead of the voltmeter to the same point. Ensure that the voltmeter and power supply probes do not touch, so as not to induce contact resistance. 2. Touch negative lead of power supply to each of the test points listed while performing Step 3. At each point, configure the power supply to produce 1 amp before measuring voltage. (Use an ammeter to ensure current is within 1 amp ±1 mili-amp at each point) 3. Set the voltmeter to measure mili-volts and null the reading. Measure the voltage from the engine grounding bracket to each of the following points and record the voltage. (Perform Step 2 at each point to ensure that exactly 1 amp ±1 mili-amp is present before measuring) a) Top metal case of PFD: __________ mili-volts b) Top metal case of MFD: __________ mili-volts c) Top metal case of GMA 1347: __________ mili-volts d) GEA 71 Body: __________ mili-volts e) GDC 74A Body: __________ mili-volts f) OAT Probe Base Nut (inside fuselage): __________ mili-volts g) GIA 1 Top: __________ mili-volts h) GIA 2 Top: __________ mili-volts i) GTX 33 Top: __________ mili-volts j) GRS 77 metal base: __________ mili-volts 4. Ensure that at each point, no more than 2.5 mili-volts (2.5 mΩ) are present. In this case, voltage is equivalent to resistance (Ω), given that precisely 1 amp reference current is present. NOTE Page 4-8 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 4.7 Fuel Tank Probe Re-Calibration The fuel tank quantity probes are calibrated at the aircraft factory to ensure their measuring accuracy. Should either fuel tank probe fail and require replacement, the new probe(s) must be calibrated by performing the following procedure. 1. Level the aircraft, following instructions in the DA40 Airplane Maintenance Manual. 2. Fill each fuel tank with 0.5 gallons fuel (unusable fuel, refer to DA 40 AFM). Use proper precautions when handling fuel. Ensure that the aircraft is grounded correctly and that there is adequate ventilation. Each time the G1000 system is powered down, it is imperative that the system be allowed to stabilize for AT LEAST three minutes before proceeding with the procedure. 3. Start the PFD and MFD in Configuration Mode. 4. On the PFD, go to the GEA Page Group (this procedure must be performed using only the PFD). 5. Select the Fuel Calibration page (3rd page in GEA group), shown below: 6. This page is protected and requires a keystroke password to perform the calibration. Press the following softkeys in sequence: a) softkey 12 (Far Right softkey) b) softkey 11 c) softkey 10 d) softkey 9 NOTE G1000/DA 40 System Maintenance Manual Page 4-9 190-00303-03 Revision 6 7. Press the L RESET softkey. Press ENTER to acknowledge the following prompt: 8. Ensure that the CAL VAL indication for the Left 1 Sub-Tank is stable. 9. Press the L EMPTY softkey. 10. Press the R RESET softkey. Press ENTER to acknowledge the following prompt: 11. Ensure that the CAL VAL indication for the Right 1 Sub-Tank is stable. 12. Press the R EMPTY softkey. 13. Observe the CAL VAL indications for both Right 1 and Left 1 Sub-Tanks and record the readings in the following tables. The CAL VAL values should fall between –1 and 0 as shown in the following examples: LEFT 1 SUB-TANK Calibrated Value (CAL VAL) Range Actual Useable Fuel Minimum Allowed Indication Maximum Allowed Indication Record Actual Indicated CAL VAL Here Is CAL VAL Within Specified Range? Yes / No 0 -1 0 5 4 6 RIGHT 1 SUB-TANK Calibrated Value (CAL VAL) Range Actual Useable Fuel Minimum Allowed Indication Maximum Allowed Indication Record Actual Indicated CAL VAL Here Is CAL VAL Within Specified Range? Yes / No 0 -1 0 5 4 6 14. Fill each fuel tank with 5 gallons ± 0.1 gallons usable fuel. 15. Allow the system to stabilize before taking readings. Page 4-10 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 16. Record ‘5 gallon’ CAL VAL indications for both Right 1 and Left 1 Sub-Tanks in the tables above. The CAL VAL values should fall between 4 and 6 gallons as shown in the following examples: a) If both CAL VAL values fall within the specified ranges, the calibration is finished. b) If any CAL VAL value is outside of the specified ranges, perform the full-tank calibration procedure in Section 4.7.1. 4.7.1 Full Tank Calibration Perform this procedure ONLY if the preliminary calibration failed. Only the failed tank(s) need to be calibrated at full fuel level. 1. Fill the failed fuel tank(s) to maximum capacity. 2. Allow system to stabilize. 3. Ensure that the CAL VAL indication for the failed tank is stable before proceeding. 4. If the right tank failed, press the R FULL softkey. Likewise, if the left tank failed, press the L FULL softkey. 5. Drain the failed fuel tank(s). 6. Add 0.5 gallons (unusable fuel) to the failed tank(s). 7. Observe the CAL VAL indications for the failed tank(s) and record the readings in the following tables. The CAL VAL values should fall between –1 and 0 for the failed tank(s). FAILED LEFT 1 SUB-TANK Calibrated Value (CAL VAL) Range Actual Useable Fuel Minimum Allowed Indication Maximum Allowed Indication Record Actual Indicated CAL VAL Here Is CAL VAL Within Specified Range? Yes / No 0 -1 0 5 4 6 FAILED RIGHT 1 SUB-TANK Calibrated Value (CAL VAL) Range Actual Useable Fuel Minimum Allowed Indication Maximum Allowed Indication Record Actual Indicated CAL VAL Here Is CAL VAL Within Specified Range? Yes / No 0 -1 0 5 4 6 8. Fill the failed fuel tank(s) with 5 gallons ± 0.1 gallons usable fuel. 9. Allow the system to stabilize before taking readings. 10. Record ‘5 gallon’ CAL VAL indications for the failed tank(s) in the tables above. a) If the CAL VAL value(s) fall within the specified ranges, the calibration is finished. G1000/DA 40 System Maintenance Manual Page 4-11 190-00303-03 Revision 6 b) If any CAL VAL value is outside of the specified ranges, the fuel quantity system requires service. 4.8 GRS 77 Earth Magnetic Field Updates The GRS 77 utilizes an Earth magnetic field model which is updated once every five years. The update is expected to be available from Garmin in each of the following years: 2005, 2010, 2015, and every five years thereafter, so long as the GRS 77 remains a Garmin-supported product. The G1000 system alerts the operator that the magnetic field database is out of date by issuing the message “AHRS SERVICE – AHRS Magnetic-field model needs update” (Ref. Section 5.11). Contact Garmin for update instructions. Page 4-12 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 This page intentionally left blank . G1000/DA40 System Maintenance Manual Page 5-1 190-00303-03 Revision 6 5 TROUBLESHOOTING This section provides instructions and guidance for G1000 system troubleshooting, as installed in the Diamond Model DA 40. Sections 6, 7 and 8 provide detailed instructions on equipment removal, replacement, configuration, and return-to-service testing. Anytime a G1000 component or LRU is removed, swapped, or replaced, the technician must follow the procedures given in Sections 6, 7 and 8 to ensure proper operation of the system. Troubleshoot the G1000 system by first identifying, then isolating the specific failure to the responsible LRU. There are several indications that the G1000 presents to the pilot or technician, showing overall system condition. A course of action should be determined based on the information presented on the display. This section shows possible scenarios likely to be encountered during normal operation and gives troubleshooting guidance to the technician to resolve problems. Figure 5-1. System Status Page (AUX Group Normal Mode) The 5 th AUX group page on the MFD provides LRU health status by means of a green check or a red ‘X’. Also, LRU software versions are shown along with other database versions and dates. If a red ‘X’ is shown for an LRU, see the appropriate LRU troubleshooting section of this chapter for guidance. Typically, the G1000 Alerting system provides alerts/annunciations in conjunction with the information presented at the 5th AUX page. IMPORTANT Page 5-2 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 5.1 G1000 Alerting System Annunciation Window Alerts Window Alerts Softkey Annunciation System Annunciations Figure 5-2. Alerts & Annunciations The G1000 Alert System conveys alerts to the pilot using combinations of the following features: Annunciation Window: The Annunciation Window displays abbreviated annunciation text. The Annunciation window is located to the right of the Altitude and Vertical Speed windows on the display. All 12 DA 40-specific annunciations can be displayed simultaneously. Alert Window: The Alert window displays alert text messages. Up to 64 prioritized alerts can be displayed in the Alert window. Pressing the ALERTS softkey displays the Alerts window. Pressing the ALERTS softkey again removes the Alerts window from the display. Softkey Annuncation: When the G1000 Alerting System issues an alert, the ALERTS softkey is used as a flashing annunciation to accompany the alert. During the alert, the ALERTS softkey assumes a new label consistent with the alert level (WARNING, CAUTION, or ADVISORY). Pressing the softkey annunciation acknowledges the presence of the alert and returns the softkey to its previous ALERTS label. System Failure Annunciations: Typically, a large red X appears in windows when a failure is detected in the LRU providing the information to the window. G1000/DA40 System Maintenance Manual Page 5-3 190-00303-03 Revision 6 The G1000/DA 40 Alert System uses three levels: WARNING: This level of alert requires immediate pilot attention. A warning alert is accompanied by an annunciation in the Annunciation Window. Warning alert text appearing in the Annunciation Window is always RED. A warning alert is also accompanied by a flashing WARNING softkey annunciation, as shown in Figure 5-3 , along with a continuos aural tone. Pressing the WARNING softkey acknowledges the presence of the warning alert and stops the aural tone. Pressing the ALERTS softkey displays the related alert message in the Alert Window. Figure 5-3. WARNING Softkey Annunciation CAUTION: This level of alert indicates the existence of abnormal conditions on the aircraft that may require pilot intervention. A caution alert is accompanied by an annunciation in the Annunciation Window. Caution alert text appearing in the Annunciation Window is yellow. A caution alert is also accompanied by a flashing CAUTION softkey annunciation, as shown in Figure 5-4 , along with a single aural tone. Pressing the CAUTION softkey acknowledges the presence of the caution alert. Pressing the ALERTS sofkey displays the related alert message in the Alert Window. Figure 5-4. CAUTION Softkey Annunciation MESSAGE ADVISORY: This level of alert provides general information to the pilot. A message advisory alert does not appear in the Annunciation Window. A message advisory alert is only accompanied by a flashing ADVISORY softkey annunciation, as shown in Figure 5-5 . Pressing the ADVISORY softkey acknowledges the presence of the message advisory alert and displays the advisory message in the Alert Window. Figure 5-5. ADVISORY Softkey Annunciation Page 5-4 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 5.2 System Annunciations If data fields become invalid due to an LRU failure, the PFD/MFD typically annunciates the failure with a large red X, as shown in Figure 5-6. No. 1 GIA 63 No. 2 GIA 63 No. 1 GIA 63 No. 2 GIA 63 Attitude: GRS 77 AHRS Heading: GRS 77 or GMU 44 GDC 74A Air Data Computer GTP 59 OAT Probe or GDC 74A ADC GTX 33 Transponder or #1 & 2 GIA 63 GPS Receivers in #1, or #2 GIA 63 No. 1 & 2 GIA 63 or GEA 71 or Equivalent Engine/Airframe Sensors Figure 5-6. System Annunciations G1000/DA40 System Maintenance Manual Page 5-5 190-00303-03 Revision 6 The following table provides basic troubleshooting guidance for LRU failures: Invalid Data Field Associated LRU(s) Solution NAV1 & COM1 GIA1 • Check configuration settings for GIA1 and the PFD. Check Ethernet interconnect from GIA1 to the PFD. Switch GIA1 and GIA2, to verify location of problem: 9 If problem follows unit, replace defective unit. 9 If problem persists, replace defective PFD. NAV2 & COM2 GIA2 Check configuration settings for GIA2 and the MFD. Check Ethernet interconnect from GIA2 to the MFD. Switch GIA1 and GIA2, to verify location of problem: 9 If problem follows unit, replace defective unit. 9 If problem persists, replace defective MFD. GPS INTEG & Time GIA1 or GIA2 Check GPS1 and GPS2 signal strength on the 3rd AUX page. Check corresponding GPS antenna and cable. Check Ethernet interconnect from PFD to GIA1 or MFD to GIA2. Switch GIA1 and GIA2, to verify location of problem: 9 If problem follows unit, replace defective unit. 9 If problem persists, replace defective MFD or PFD. XPDR FAIL GTX 33 Check GTX RS-232 configuration settings for GIA1, GIA2, and GTX 33. Replace defective GTX 33. TAS FAIL AIRSPEED FAIL ALTITUDE FAIL VERT SPEED FAIL GDC 74A Inspect GDC 74A pitot/static plumbing integrity. Inspect pitot/static ports and associated equipment. For TAS failure, also check GTP 59 OAT probe as stated below. Check GDC ARINC 429 configuration settings for the PFD, MFD, GIA1, and GIA2. 9 If PFD, MFD, and GIA configuration settings are correct, replace defective GDC configuration module according to Section 6.8. 9 If problem persists, replace defective GDC 74A. OAT GTP 59 See above guidance for GDC 74A troubleshooting. Replace GTP 59 probe: 9 If problem persists replace GDC 74A with a known good unit. Page 5-6 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 Invalid Data Field Associated LRU(s) Solution ATTITUDE FAIL GRS 77 Check GRS ARINC 429 configuration settings for the PFD, MFD, GIA1, and GIA2. Replace defective GRS 77. HDG FAIL GRS 77 & GMU 44 Replace the GMU 44 with a known good unit: 9 If problem persists, replace defective GRS 77. GRS 77 & GMU 44 If this message persists, perform AHRS calibration procedures as described in Section 7.7.3. Engine/Airframe Sensors (All Invalid) GEA 71 Check GEA 71 RS-485 configuration settings for GIA1 and GIA2. Reconfigure the GEA 71 per Section 7.4.2. Check GEA – GIA1 and GEA – GIA2 Wiring. Replace defective GEA 71. G1000/DA40 System Maintenance Manual Page 5-7 190-00303-03 Revision 6 The following table provides guidance for troubleshooting individual engine/airframe sensor failures. Be sure to also follow previous guidance given for the GEA 71. The technician should troubleshoot to isolate the fault by checking sensor-to-GEA wiring, replacing the suspect sensor, and finally by replacing the GEA 71. Replace one part at a time. Refer to Section 7.4.3 to check for correct operation of the sensors and GEA 71 after any part has been replaced. Invalid Field Sensor Solution Tachometer Check tachometer – GEA wiring. Replace tachometer sensor. Refer to Figure 2-18. Replace defective GEA 71. MAP Sensor Check MAP sensor – GEA wiring. Replace MAP sensor. Refer to Figure 2-14. Replace defective GEA 71. Fuel Flow Check fuel flow sensor – GEA wiring. Replace fuel flow sensor. Refer to Figure 2-20 and Figure 2-21. Replace defective GEA 71. CHT Probes (4) Check CHT probe – GEA wiring. Replace CHT probe. Refer to Figure 2-22. If all 4 CHT indicators are flagged, check the following: Replace backshell thermocouple and/or configuration module in GEA connector. See Sections 6.10 & 6.11. Replace defective GEA 71. EGT Probes (4) Check EGT probe – GEA wiring. Replace EGT probe. Refer to Figure 2-23. If all 4 EGT indicators are flagged, try the following: Replace backshell thermocouple and/or configuration module in GEA connector. See Sections 6.10 & 6.11. Replace defective GEA 71. Oil Pressure Sensor Check oil pressure sensor – GEA wiring. Replace oil pressure sensor. Refer to Figure 2-15. Replace defective GEA 71. Oil Temperature Sensor Check oil temperature sensor – GEA wiring. Replace oil temperature sensor. Refer to Figure 2-16. Replace defective GEA 71. Alternator Current Sensor Check current sensor sensor – GEA wiring. Replace current sensor. Refer to Figure 2-24. Replace defective GEA 71. Fuel Quantity Sensors (2) Check fuel quantity sensor – GEA wiring. Replace fuel quantity sensor. Refer to the DA40 AMM. Replace defective GEA 71. Page 5-8 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 5.3 DA 40-Specific Alerts The following alerts are configured specifically for the DA 40: WARNING Alerts: Annunciation Window Alert Message Solution ALTERNATOR Alternator failed. Battery is only elec. source. • Check alternator current sensor for proper operation. If current sensor is OK, troubleshoot alternator & aircraft electrical system according to DA 40 Airplane Maintenance Manual instructions. OIL PRES LO Oil pressure is below 25 psi. Check aircraft oil level. Troubleshoot oil pressure sensor for proper operation. If oil pressure sensor is OK, troubleshoot engine oiling system according to DA 40 Airplane Maintenance Manual instructions. FUEL PRES LO: Fuel pressure is below 14 psi. FUEL PRES HI Fuel pressure is greater than 35 psi. Troubleshoot fuel pressure sensor for proper operation. If fuel pressure sensor is OK, troubleshoot fuel pump and associated fuel systems per DA 40 Airplane Maintenance Manual instructions. STARTER ENGD Starter is engaged. Prepare to start aircraft engine. DOOR OPEN Canopy and/or rear door is not closed and locked. Close canopy and/or rear door. If alert does not disappear, check canopy/door discrete sensor for proper operation. TRIM FAIL Autopilot automatic trim has failed. Troubleshoot autopilot per DA 40 Airplane Maintenance Manual instructions. CAUTION Alerts Annunciation Window Alert Message Solution L FUEL LOW Left fuel quantity is less than 3 gallons. R FUEL LOW Right fuel quantity is less than 3 gallons. Check fuel level. If reading is inaccurate, recalibrate fuel probes per Section 4.6. LOW VOLTS On-board voltage is below 24 volts. Inspect GEA 71 connector & wiring. Troubleshoot aircraft electrical system according to DA 40 Airplane Maintenance Manual instructions. PITOT FAIL Pitot heat is inoperative. PITOT OFF Pitot heat is off. Check pitot heat switch position. Inspect GEA 71 connector & wiring. Troubleshoot pitot heat system per DA 40 Airplane Maintenance Manual instructions. G1000/DA40 System Maintenance Manual Page 5-9 190-00303-03 Revision 6 MESSAGE ADVISORY Alerts Message Advisory Solution PFD FAN FAIL – The cooling fan for the PFD is inoperative. MFD FAN FAIL – The cooling fan for the MFD is inoperative. GIA FAN FAIL – The cooling fan for the GIAs is inoperative. Ensure that the CDU FAN and/or AV FAN circuit breakers are closed. Check cooling fan wiring. Replace cooling fan. Refer to Figure 2-2 and/or Figure 2-7 for installation drawings. From this point forward, all other message advisory alerts are standard to the G1000 system and are not specific to the DA 40. Messages are grouped according to LRU. 5.4 GDU 1040 Troubleshooting 5.4.1 GDU 1040 Common Problems Symptom Recommended Action Display will not track photocell Check display lighting settings on the Main Lighting page: 9 If problem persists, replace defective unit. Keypad/bezel will not track photocell Check keyboard lighting settings on the Main Lighting page: 9 If problem persists, replace defective unit. Display will not track dimmer bus Check display lighting settings on the Main Lighting page. Switch MFD and PFD: 9 If problem follows unit, replace defective unit. Keypad/bezel will not track dimmer bus Check keyboard lighting settings on the Main Lighting page. Switch MFD and PFD: 9 If problem follows unit, replace defective unit. 5.5 GDU 1040 Alerts 5.5.1 Software/Configuration Alerts Failure Message Cause Solution SW MISMATCH – GDU software version mismatch. Xtalk is off. The system has found the PFD and MFD software versions do not match. MANIFEST – PFD1 software mismatch. Communication Halted. The system has detected an incorrect software version loaded in the PFD. MANIFEST – MFD software mismatch. Communication Halted. The system has detected an incorrect software version loaded in MFD. Load correct software version. See Section 7.1 for GDU 1040 Software Loading procedure. MFD1 CONFIG – configuration error. Config service req’d. PFD1 CONFIG – configuration error. Config service req’d. A configuration mismatch has occurred between the display and the Master Configuration Module. Reconfigure MFD and/or PFD as described in Section 7.1.2. If unable to reconfigure, replace defective master configuration module as described in Section 6.8. 5.5.2 Database Alerts Failure Message Cause Solution MFD1 DB ERR – MFD1 aviation database error exists. The MFD has encountered an error in the Jeppesen aviation database. Reload Jeppesen database. Replace the MFD. NOTE Page 5-10 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 PFD1 DB ERR – PFD1 aviation database error exists. The PFD has encountered an error in the Jeppesen database. Reload Jeppesen database. Replace the PFD. MFD1 DB ERR – MFD1 basemap database error exists. The MFD has encountered an error in the basemap database. Replace the MFD. PFD1 DB ERR – PFD1 basemap database error exists. The PFD has encountered an error in the basemap database. Replace the PFD. MFD1 DB ERR – MFD1 terrain database error exists. The MFD has encountered an error in the terrain database. Confirm terrain datacard is inserted properly. Replace terrain datacard. Replace the MFD. PFD1 DB ERR – PFD1 terrain database error exists. The PFD has encountered an error in the terrain database. Confirm terrain datacard is inserted properly. Replace terrain datacard. Replace the PFD. DB MISMATCH – Aviation database version mismatch. Xtalk is off. The system has found the Jeppesen aviation database cycles in the PFD and MFD do not match. Load current database versions. 5.5.3 Cooling Alerts Failure Message Cause Solution MFD1 COOLING – has poor cooling. Reducing power usage. MFD1 has exceeded its operating temperature range. Check MFD Fan for proper operation. Replace the MFD. If problem persists contact Garmin. PFD1 COOLING – has poor cooling. Reducing power usage. The PFD has exceeded it’s operating temperature range. Check PFD Fan for proper operation. Replace the PFD. If problem persists contact Garmin. 5.5.4 Key Alerts Failure Message Cause Solution MFD1 “key” KEYSTK – key is stuck. The SYSTEM has determined a key is stuck on MFD1. Exercise stuck key. Replace the MFD. PFD1 “key” KEYSTK – key is stuck. The system has determined a key is stuck on the PFD. Exercise stuck key. Replace the PFD. G1000/DA40 System Maintenance Manual Page 5-11 190-00303-03 Revision 6 5.5.5 Miscellaneous Alerts Failure Message Cause Solution XTALK ERROR – A flight display cross talk error has occurred. A communication error has occurred between the MFD and PFD. Check the System Configuration page: 9 Ensure that MFD1 and PFD1 are green. 9 If configuration is not correct, reconfigure the PFD and MFD per instructions in Section 7.1.2. Check Ethernet interconnect. Replace PFD with a known good unit to verify location of problem: 9 If problem persists, replace MFD. 9 If problem does not persist, replace PFD. DATA LOST – Pilot stored data lost. Recheck settings. Pilot stored data has been lost. Cycle power to PFD: 9 If problem persists, replace PFD. MFD1 SERVICE – needs service. Return unit for repair. The system has determined MFD1 needs service. Replace MFD. PFD1 SERVICE – needs service. Return unit for repair. The system has determined the PFD needs service. Replace the PFD. Page 5-12 G1000/DA40 System Maintenance Manual Revision 6 190-00303-03 5.6 GMA Alerts Failure Message Cause Solution GMA1 SERVICE – GMA1 needs service. Return unit for repair. The system has determined that the GMA 1347 needs service. GMA1 FAIL – GMA1 in inoperative. The system has detected a failure in the GMA 1347. Replace GMA 1347. MANIFEST – GMA1 software mismatch. Communication Halted. The system has detected an incorrect software version loaded in GMA 1347. See Section 7.2.1 for GMA 1347 Software Loading procedure. GMA1 CONFIG – GMA1 configuration error. Config service req’d. The system has detected a GMA 1347 configuration mismatch. See Section 7.2.2 for GMA 1347 Configuration Loading procedure. 5.6.1 GMA Redundant Paths Failure Message Cause Solutions BACKUP PATH – Audio panel using backup data path. The GMA 1347 is using a backup RS-232 data path. Check GIA RS-232 configuration settings: 9 If configuration is not correct, reconfigure GIAs as described in Section 7.3.2. Check wiring. Replace GMA 1347 with a known good unit, to verify location of problem: 9 If problem persists, replaced GIA1. 9 If problem does not persist, replace GMA 1347. ETHERNET ETHERNET ETHERNET ETHERNET RS-232 Primary Data Path Secondary Data Path GMA 1347 GMA 1347 GDU 1040 PFD No. 1 GIA 63 GDU 1040 MFD GDU 1040 PFD GDU 1040 MFD No. 2 GIA 63 RS-232 Figure 5-7. GMA 1347 Data Paths G1000/DA40 System Maintenance Manual Page 5-13 190-00303-03 Revision 6 5.7 GIA 63 Troubleshooting 5.7.1 COM Symptom Recommended Action Weak COM transmit power Check COM antenna and cabling. Switch GIA1 and GIA2, to identify whether the unit or connectors/wiring is at fault (Both GIAs must be configured when swapped, see Section 7.3.2): 9 If problem follows unit, replace defective unit per Section 6.3. Weak COM receiver Check COM antenna and cabling. Switch GIA1 and GIA2, to identify whether the unit or connectors/wiring is at fault (Both GIAs must be configured