Garmin DA 40 F System Maintenance Manual

G1000 System Maintenance Manual

Diamond DA 40 & DA 40 F

Including GFC 700 or KAP 140 AFCS

Contains FAA-Accepted Instructions

For Continued Airworthiness For

STC SA01444WI-D

190-00545-01

February 2013

Revision G

© Copyright 2008 - 2013 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. 151st Street

Olathe, KS 66062 USA

Telephone: [phone] www.garmin.com

Garmin (Europe) Ltd.

Liberty House

Bulls Copse Road

Hounsdown Business Park

Southampton, SO40 9RB, UK

Phone: [phone]

Fax: [phone]

RECORD OF REVISIONS

	Revision	Revision Date	Description	ECO #
			Update for Phase 7: Add KAP 140 alignment &
	B	1/03/2008	update FAR 91.411 & Appendix E testing.	51022
			General updates throughout where noted.
	C	3/28/2008	Update for minor change to STC	52069
	D	4/8/2008	Update for minor change to STC to add software	52347
			0321.19.
	E	5/04/09	Update for major change to STC to add software	58693
			0321.22
	F	11/12/10	Add Clarification to fuel probe re-calibration	76686
			procedures.
	G	2/14/13	Update for major change to STC to add software	99113
			0321.23 and hardware upgrades.

DOCUMENT PAGINATION

	Section	Pagination
	Table of Contents	i – viii
	Section 1	1-1 – 1-16
	Section 2	2-1 – 2-18
	Section 3	3-1 – 3-48
	Section 4	4-1 – 4-40
	Section 5	5-1 – 5-62
	Section 6	6-1 – 6-16
	Section 7	7-1 – 7-44
	Section 8	8-1 – 8-14
Page A		G1000 System Maintenance Manual – DA 40/40F
Revision G		190-00545-01

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 ANTIREFLECTIVE 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.

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 i
190-00545-01	Revision G

	TABLE OF CONTENTS
PARAGRAPH		PAGE
1	INTRODUCTION	1-1
1.1	CONTENT, SCOPE, PURPOSE..........................................................................................................	1-1
1.2	ORGANIZATION .............................................................................................................................	1-9
1.3	DEFINITIONS/ABBREVIATIONS....................................................................................................	1-10
1.4	PUBLICATIONS ............................................................................................................................	1-12
1.5	DISTRIBUTION .............................................................................................................................	1-14
1.6	REQUIRED MATERIALS & EQUIPMENT .......................................................................................	1-14
2	SYSTEM DESCRIPTION	2-1
2.1	STC REQUIREMENTS OVERVIEW..................................................................................................	2-1
2.2	EQUIPMENT DESCRIPTIONS...........................................................................................................	2-2
2.3	G1000 OPTIONAL INTERFACES .....................................................................................................	2-5
2.4	GFC 700 AFCS SYSTEM DESCRIPTION ........................................................................................	2-7
2.5	ELECTRICAL POWER DISTRIBUTION ...........................................................................................	2-13
2.6	LIGHTNING STRIKE PROTECTION................................................................................................	2-16
2.7	SHIELD BLOCK GROUNDS ...........................................................................................................	2-17
2.8	SENSOR INSTALLATIONS.............................................................................................................	2-17
2.9	BLOCK DIAGRAMS ......................................................................................................................	2-17
3	G1000 CONTROL & OPERATION	3-1
3.2	G1000 OPERATION MODES...........................................................................................................	3-3
3.3	G1000 CONFIGURATION MODE OVERVIEW..................................................................................	3-5
3.4	G1000 / GFC 700 SOFTWARE INFORMATION..............................................................................	3-14
3.5	G1000 SOFTWARE/CONFIGURATION PROCEDURE......................................................................	3-23
4	INSTRUCTIONS FOR CONTINUED AIRWORTHINESS	4-1
4.1	AIRWORTHINESS LIMITATIONS .....................................................................................................	4-1
4.2	SERVICING INFORMATION.............................................................................................................	4-2
4.3	MAINTENANCE INTERVALS...........................................................................................................	4-4
4.4	VISUAL INSPECTION......................................................................................................................	4-8
4.5	ELECTRICAL BONDING TEST.......................................................................................................	4-11
4.6	FUEL TANK PROBE RE-CALIBRATION ........................................................................................	4-13
4.7	GRS 77 EARTH MAGNETIC FIELD UPDATES...............................................................................	4-21
4.8	GSA 81 GREASING PROCEDURE .................................................................................................	4-21
4.9	FLAP POSITION DISCRETE INPUT CHECK ....................................................................................	4-22
4.10	SLIP CLUTCH TORQUE CHECK PROCEDURES..............................................................................	4-24
4.11	PFD/MFD POWER INTERRUPT FUNCTION CHECKS....................................................................	4-30
4.12	LIGHTNING PROTECTION FUSE REPLACEMENT ..........................................................................	4-35
4.13	COOLING FAN FUNCTION & FAN FAIL ANNUNCIATION TEST ....................................................	4-39
5	TROUBLESHOOTING	5-1
5.1	G1000 ALERTING SYSTEM............................................................................................................	5-2
5.2	SYSTEM ANNUNCIATIONS.............................................................................................................	5-5
5.3	DA 40/DA 40 F SPECIFIC ALERTS ..............................................................................................	5-12
5.4	TAWS TROUBLESHOOTING ........................................................................................................	5-14
5.5	GFC 700 AFCS TROUBLESHOOTING ..........................................................................................	5-15
5.6	BACKUP COMMUNICATIONS PATH CHECKS ...............................................................................	5-27
5.7	GDU 104X TROUBLESHOOTING .................................................................................................	5-42
5.8	GDU 104X ALERTS ....................................................................................................................	5-43
5.9	GIA 63 TROUBLESHOOTING........................................................................................................	5-50
5.10	GIA ALERT MESSAGES ...............................................................................................................	5-51
Page ii	G1000 System Maintenance Manual – Diamond DA40/40F
Revision G		190-00545-01

5.11	GEA TROUBLESHOOTING ...........................................................................................................	5-55
5.12	GTX TROUBLESHOOTING ...........................................................................................................	5-55
5.13	GRS 77/GMU 44 TROUBLESHOOTING........................................................................................	5-56
5.14	GDC 74A TROUBLESHOOTING ...................................................................................................	5-57
5.15	GDL 69A TROUBLESHOOTING....................................................................................................	5-58
5.16	GDL 59 TROUBLESHOOTING ......................................................................................................	5-59
5.17	GSR 56 TROUBLESHOOTING.......................................................................................................	5-60
5.18	SYNTHETIC VISION AND PATHWAYS TROUBLESHOOTING .........................................................	5-61
5.19	ESP TROUBLESHOOTING.............................................................................................................	5-62
6	G1000 EQUIPMENT REMOVAL & REPLACEMENT	6-1
6.1	GDU 104X MFD & PFD...............................................................................................................	6-4
6.2	GMA 1347 AUDIO PANEL.............................................................................................................	6-4
6.3	GIA 63 (W) INTEGRATED AVIONICS UNITS..................................................................................	6-4
6.4	GEA 71 ENGINE/AIRFRAME UNIT ................................................................................................	6-5
6.5	GTX 33 TRANSPONDER ................................................................................................................	6-5
6.6	GTP 59 OAT PROBE .....................................................................................................................	6-6
6.7	GRS 77 AHRS ..............................................................................................................................	6-6
6.8	GMU 44 MAGNETOMETER ...........................................................................................................	6-7
6.9	GDL 69A.......................................................................................................................................	6-7
6.10	GSA 81 SERVOS............................................................................................................................	6-7
6.11	GSM 85 & GSM 86 SERVO MOUNTS............................................................................................	6-8
6.12	CONFIGURATION MODULE REMOVAL & REPLACEMENT .............................................................	6-8
6.13	GEA 71 BACKSHELL THERMOCOUPLE REMOVAL & REPLACEMENT.........................................	6-11
6.14	GA35 GPS/WAAS ANTENNAS...................................................................................................	6-12
6.15	GDL 59 DATALINK .....................................................................................................................	6-12
6.16	GSR 56 SATELLITE RECEIVER ....................................................................................................	6-12
6.17	IRIDIUM ANTENNA (OPTIONAL)..................................................................................................	6-13
6.18	WI-FI ANTENNA (OPTIONAL) .....................................................................................................	6-13
7	G1000 EQUIPMENT CONFIGURATION & TESTING	7-1
7.1	GDU 104X MFD & PFD...............................................................................................................	7-3
7.2	GMA 1347 AUDIO PANEL.............................................................................................................	7-7
7.3	GIA 63 INTEGRATED AVIONICS UNIT.........................................................................................	7-10
7.4	GEA 71 ENGINE/AIRFRAME UNIT ..............................................................................................	7-16
7.5	GTX 33 TRANSPONDER ..............................................................................................................	7-19
7.6	GDC 74A AIR DATA COMPUTER................................................................................................	7-21
7.7	GRS 77 AHRS / GMU 44 MAGNETOMETER...............................................................................	7-25
7.8	GDL 69 XM DATA LINK.............................................................................................................	7-36
7.9	GDL 59 DATALINK .....................................................................................................................	7-37
7.10	GSR 56........................................................................................................................................	7-39
7.11	GSA 81 SERVO............................................................................................................................	7-42
8	SYSTEM RETURN TO SERVICE PROCEDURE	8-1
8.1	SOFTWARE VERIFICATION ............................................................................................................	8-1
8.2	BACKUP PATH SYSTEM TESTING ..................................................................................................	8-2
8.3	GFC 700 GROUND CHECKOUT....................................................................................................	8-10
8.4	MAINTENANCE RECORDS ...........................................................................................................	8-13

G1000 System Maintenance Manual – Diamond DA40/40F	Page iii
190-00545-01	Revision G

LIST OF ILLUSTRATIONS

FIGURE		PAGE
Figure 2-1. SVS/Pathways Feature ...........................................................................................................		2-6
Figure 2-2. AFCS System Block Diagram................................................................................................		2-9
Figure 2-3. GSA 81 & GSM 85 or GSM 86 ...........................................................................................		2-11
Figure 2-4.	G1000/DA40 Electrical Distribution (GFC 700 Aircraft)....................................................	2-14
Figure 2-5.	G1000/DA40 Electrical Distribution (KAP140 Aircraft) ....................................................	2-15
Figure 2-6. G1000/KAP 140 Block Diagram (no WAAS) .....................................................................		2-17
Figure 2-7. G1000/GFC 700 Block Diagram (WAAS shown)...............................................................		2-18
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......................................................................................................................		3-3
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. SYSTEM UPLOAD FIELDS (SW v0321.19 or earlier) .......................................................		3-5
Figure 3-9. SYSTEM UPLOAD FIELDS (SW v0321.22 or later) ..........................................................		3-5
Figure 3-10. SET>ACTV Diagram...........................................................................................................		3-7
Figure 3-11. Loss of Communication .......................................................................................................		3-8
Figure 3-12.	Configuration Status.............................................................................................................	3-8
Figure 3-13.	Data Transmission Indicators.............................................................................................	3-10
Figure 3-14. MFD Power Up Splash Screen System Software Version.................................................		3-14
Figure 3-15. MFD AUX –System Status Page System Software Version..............................................		3-14
Figure 3-16.	Options Configuration Files System Upload Page.............................................................	3-17
Figure 3-17.	Calibration Files System Upload Page...............................................................................	3-18
Figure 3-18. G1000 LRU Configuration File Storage ............................................................................		3-21
Figure 3-19. GRS/GDC Configuration Settings Storage ........................................................................		3-22
Figure 3-20.	Software/Configuration Overview .....................................................................................	3-23
Figure 3-21. Non-WAAS (GIA 63) System Status Page........................................................................		3-27
Figure 3-22. WAAS (GIA 63W) System Status Page ............................................................................		3-28
Figure 3-23. System Upload Page...........................................................................................................		3-28
Figure 3-24. GIA Boot Block Upload Page............................................................................................		3-31
Figure 3-25. GIA Boot Block Upload Complete Page ...........................................................................		3-32
Figure 3-26.	System Status Page (SW v0321.19 and earlier) .................................................................	3-33
Figure 3-27.	System Status Page (SW v0321.22 or later).......................................................................	3-33
Figure 3-28. System ID Location............................................................................................................		3-41
Figure 3-29. System Upload Page...........................................................................................................		3-43
Figure 3-30. DA40 Splash Screen for Non ESP Configurations ............................................................		3-45
Figure 3-31. DA40 FP Splash Screen for Non ESP Configurations.......................................................		3-45
Figure 3-32. DA40 Splash Screen for ESP Configurations ....................................................................		3-46
Figure 3-33. DA40 FP Splash Screen for ESP Configurations...............................................................		3-46
Figure 4-1.	Total Time In Service.............................................................................................................	4-3
Figure 4-2 Fuel Calibration Page (Calibration Table) .............................................................................		4-14
Figure 4-3 System Upload Page...............................................................................................................		4-15
Figure 4-4 Fuel Calibration Page.............................................................................................................		4-17
Figure 4-5 Fuel Calibration Page (Empty Calibration)............................................................................		4-18
Figure 4-6 System Upload Page...............................................................................................................		4-18
Figure 4-7 Fuel Calibration Page (5 Gallon Calibration).........................................................................		4-19
Figure 4-8 System Upload Page...............................................................................................................		4-20
Figure 4-9 Fuel Calibration Page (Calibration Complete).......................................................................		4-20
Figure 4-10. (SW v0321.19 or earlier) GIA I/O Page.............................................................................		4-22
Page iv	G1000 System Maintenance Manual – Diamond DA40/40F
Revision G		190-00545-01

Figure 4-11. (SW v0321.22 or later) GIA I/O Page................................................................................		4-23
Figure 4-12, GFC Status Page.................................................................................................................		4-24
Figure 4-13. GDU TEST Page................................................................................................................		4-30
Figure 4-14.	Backup Capacitor Test Selection .......................................................................................	4-32
Figure 4-15. Upload Complete Window.................................................................................................		4-33
Figure 4-16. BKUP CAPS Checkbox on GDU TEST Page ...................................................................		4-34
Figure 4-17.	Aircraft Fuselage Fuse Locations.......................................................................................	4-35
Figure 4-18.	Instrument Panel Detail A ..................................................................................................	4-36
Figure 4-19.	Instrument Panel Detail B ..................................................................................................	4-36
Figure 4-20.	Remote Avionics Enclosure Detail C.................................................................................	4-37

Figure 4-21. Remote Avionics Enclosure Detail D ................................................................................		4-38
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....................................................................................................		5-15
Figure 5-8, GFC Status Page...................................................................................................................		5-18
Figure 5-9. GMA 1347 Data Paths .........................................................................................................		5-27
Figure 5-10. GEA 71 Data Paths ............................................................................................................		5-28
Figure 5-11. GTX 33 Data Paths ............................................................................................................		5-29
Figure 5-12. GDC 74A Data Paths .........................................................................................................		5-30
Figure 5-13. GRS 77 Data Paths.............................................................................................................		5-31
Figure 6-1.	(SW v0321.19 or earlier) System Status Page (Configuration Mode) ..................................	6-1
Figure 6-2.	(SW v0321.22 or later) System Status Page (Configuration Mode) .....................................	6-2
Figure 6-3.	Configuration Module Installation .........................................................................................	6-9
Figure 6-4. GEA Backshell Thermocouple.............................................................................................		6-11
Figure 7-1. Non-WAAS (GIA 63) System Status Page............................................................................		7-2
Figure 7-2. WAAS (GIA 63W) System Status Page ................................................................................		7-2
Figure 7-3. G1000 Normal Mode Check ..........................................................................................		........7-5
Figure 7-4. G1000 Reversionary Mode Check .........................................................................................		7-6
Figure 7-5. MFD TAWS Page ..................................................................................................................		7-6
Figure 7-6. Marker Beacon Symbology....................................................................................................		7-9
Figure 7-7. SET>ACTV Softkey ............................................................................................................		7-10
Figure 7-8. AUX – GPS STATUS Page (MFD).....................................................................................		7-12
Figure 7-9.	Engine Instrument Pages......................................................................................................	7-17
Figure 7-10.	Engine Instrument Sub Pages.............................................................................................	7-18
Figure 7-11. GTX Configuration Page ...................................................................................................		7-20
Figure 7-12. EASA Airspeed Tape .........................................................................................................		7-23
Figure 7-13. GRS/GMU Calibration Page..............................................................................................		7-28
Figure 7-14. GRS/GMU Calibration Page..............................................................................................		7-30
Figure 7-15. GRS/GMU Calibration Page..............................................................................................		7-32
Figure 7-16.	Magnetometer Interference Test Page................................................................................	7-33
Figure 7-17. Normal Mode AHRS Check ..............................................................................................		7-35
Figure 7-18. Reversionary Mode AHRS Information.............................................................................		7-35
Figure 7-19. GSR 56 Configuration Page for Combination Option .......................................................		7-38
Figure 7-20.	Good Iridium Signal Strength ............................................................................................	7-38
Figure 7-21.	No Iridium Signal Strength ................................................................................................	7-39
Figure 7-22. GSR 56 Configuration Page for Combination Option .......................................................		7-40
Figure 7-23. GSR 56 Configuration Page for Standalone Option ..........................................................		7-40
Figure 7-24.	Good Iridium Signal Strength ............................................................................................	7-41
Figure 7-25.	No Iridium Signal Strength ................................................................................................	7-41
G1000 System Maintenance Manual – Diamond DA40/40F		Page v
190-00545-01		Revision G

Figure 8-1.	PFD RS-232/ARINC 429 Configuration Page.......................................................................	8-7
Figure 8-2.	GIA1 RS-232/ARING 429 Configuration Page.....................................................................	8-8
Figure 8-3.	GIA1 RS-485 Configuration Page .........................................................................................	8-9
Figure 8-4.	Pre-Flight Test......................................................................................................................	8-10

Page vi	G1000 System Maintenance Manual – Diamond DA40/40F
Revision G	190-00545-01

LIST OF TABLES

TABLE		PAGE
Table 1-1. MDL Configurations Summary...............................................................................................		1-2
Table 1-2. Required Documents .............................................................................................................		1-12
Table 1-3. Previously Approved Type Design........................................................................................		1-13
Table 1-4.	Reference Publications ..........................................................................................................	1-13
Table 1-5.	Loader Card to Configuration Relationship Summary..........................................................	1-15
Table 3-1.	Data Transmission Indicators ..................................................................................................	3-9
Table 3-2.	Page Navigation SW v0321.19 or earlier ..............................................................................	3-11
Table 3-3. Page Navigation SW v0321.22..............................................................................................		3-12
Table 3-4. Page Navigation SW v0321.23..............................................................................................		3-13
Table 3-5.	LRU to Configuration File Relationship Summary...............................................................	3-19
Table 4-1.	Maintenance Intervals..............................................................................................................	4-4
Table 4-2.	Visual Inspection Procedure....................................................................................................	4-8
Table 4-3. GSM 86 Measured Torque ....................................................................................................		4-28
Table 4-4. Power Interrupt Category A (200mS) Mod Status ................................................................		4-30
Table 4-5. Power Interrupt Category A (200mS) Mod Status ................................................................		4-31
Table 4-6.	Lightning Protection Fuse Part Numbers ..............................................................................	4-35
Table 5-1.	Aural and Audio Alerts............................................................................................................	5-4
Table 5-2.	System Failure Troubleshooting..............................................................................................	5-6
Table 5-3.	Engine Airframe Instrument Failures ....................................................................................	5-10
Table 5-4. ADF/DME Failure.................................................................................................................		5-11
Table 5-5.	Warning Alerts ......................................................................................................................	5-12
Table 5-6.	Caution Alerts........................................................................................................................	5-12
Table 5-7.	Message Advisory Alerts (SW v0321.22 and earlier) ...........................................................	5-13
Table 5-8. TAWS Troubleshooting ........................................................................................................		5-14
Table 5-9. AFCS Annunciation Troubleshooting ...................................................................................		5-16
Table 5-10. AFCS General Troubleshooting ..........................................................................................		5-17
Table 5-11.	PFT Faults (Monitor Processor) ..........................................................................................	5-24
Table 5-12. Normal Mode Faults (Monitor Processor)...........................................................................		5-24
Table 5-13.	PFT Faults (Control Processor) ...........................................................................................	5-25
Table 5-14.	Normal Mode Faults (Control Processor)............................................................................	5-25
Table 5-15.	Data Path Failure Troubleshooting......................................................................................	5-32
Table 5-16. PFD1 ARINC 429 ...............................................................................................................		5-33
Table 5-17. MFD1 ARINC 429 ..............................................................................................................		5-34
Table 5-18. GIA1 RS-232.......................................................................................................................		5-35
Table 5-19. GIA1 ARINC 429................................................................................................................		5-37
Table 5-20. GIA2 RS-232.......................................................................................................................		5-38
Table 5-21. GIA2 ARINC 429................................................................................................................		5-39
Table 5-22. GIA1 RS-485.......................................................................................................................		5-40
Table 5-23. GIA2 RS-485.......................................................................................................................		5-41
Table 5-24. GDU 104X Common Problems...........................................................................................		5-42
Table 5-25. GDU 104X Software/Configuration Alerts .........................................................................		5-43
Table 5-26.	Database Alerts....................................................................................................................	5-44
Table 5-27.	Cooling Alerts .....................................................................................................................	5-45
Table 5-28.	Datacard Alerts....................................................................................................................	5-46
Table 5-29.	Key Alerts............................................................................................................................	5-46
Table 5-30.	Miscellaneous Alerts ...........................................................................................................	5-47
Table 5-31. GMA Common Problems....................................................................................................		5-49
Table 5-32. GMA Alerts .........................................................................................................................		5-49
Table 5-33. COM Troubleshooting.........................................................................................................		5-50
G1000 System Maintenance Manual – Diamond DA40/40F		Page vii
190-00545-01		Revision G

Table 5-34. NAV Troubleshooting .........................................................................................................		5-50
Table 5-35. GS Troubleshooting.............................................................................................................		5-50
Table 5-36. GPS Troubleshooting ..........................................................................................................		5-50
Table 5-37. COM Alerts .........................................................................................................................		5-51
Table 5-38. NAV AlertsFailure Message ...............................................................................................		5-52
Table 5-39.	Glideslope Alerts .................................................................................................................	5-53
Table 5-40. GPS Alerts ...........................................................................................................................		5-53
Table 5-41. GIA Cooling Alerts .............................................................................................................		5-54
Table 5-42.	GIA Configuration Alerts....................................................................................................	5-54
Table 5-43. GEA Common Problems .....................................................................................................		5-55
Table 5-44. GEA Alerts ..........................................................................................................................		5-55
Table 5-45. GTX Alerts ..........................................................................................................................		5-55
Table 5-46. AHRS Common Problems...................................................................................................		5-56
Table 5-47. GRS Alerts...........................................................................................................................		5-56
Table 5-48. GMU Alerts .........................................................................................................................		5-57
Table 5-49. Air Data Common Problems ...............................................................................................		5-57
Table 5-50. GDC Alerts..........................................................................................................................		5-57
Table 5-51. GDL 69A Common Problems .............................................................................................		5-58
Table 5-52. GDL 69A Alerts ..................................................................................................................		5-59
Table 5-53. GDL 59 Troubleshooting.....................................................................................................		5-59
Table 5-54. GDL 59 Alerts .....................................................................................................................		5-59
Table 5-55. GSR 56 Troubleshooting .....................................................................................................		5-60
Table 5-56. GSR 56 Alerts......................................................................................................................		5-60
Table 5-57. SVS Troubleshooting ...........................................................................................................		5-61
Table 5-58. SVS-Related Alert Messages...............................................................................................		5-61
Table 5-59. ESP Troubleshooting............................................................................................................		5-62
Table 5-60. ESP-Related Alert Messages ...............................................................................................		5-62
Table 6-1. Equipment Removal and Replacement Software Check .........................................................		6-2
Table 6-2.	Configuration Module Kit – 011-00979-00.............................................................................	6-9
Table 6-3.	Thermocouple Kit (011-00981-00) .......................................................................................	6-11
Table 7-1:	Engine/Airframe Instrument Checks.....................................................................................	7-18
Table 7-2.	Airspeed Test.........................................................................................................................	7-23
Table 7-3. EASA Airspeed Tape Test ....................................................................................................		7-23
Table 7-4.	Vertical Speed Test Tolerances .............................................................................................	7-24
Table 7-5. GRS/GMU Calibration Requirement Matrix.........................................................................		7-26
Table 7-6.	Magnetometer Interference Test Sequence (Example)..........................................................	7-33
Table 8-1.	Return To Service Software Check .........................................................................................	8-1
Table 8-2.	GPS Failure Test......................................................................................................................	8-3
Table 8-3.	GIA Failure Test......................................................................................................................	8-4
Table 8-4.	Display Failure Test.................................................................................................................	8-6

Page viii	G1000 System Maintenance Manual – Diamond DA40/40F
Revision G	190-00545-01

1 INTRODUCTION

1.1Content, 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.

1.1.1Applicability

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 within 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.

G1000 System Maintenance Manual – Diamond DA40/40F	Page 1-1
190-00545-01	Revision G

1.1.2Identifying 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	Aircraft	Upgrades Available	G1000 System
	Configuration	System		Software Version
			Major Functions Added
			• G1000 & GFC 700 AFCS
			• WAAS
			• Coupled baro-VNAV
			• GDU Charts	0369.13
			• Misc. GDU v8.02 features
			Hardware Added
			GDU 1044 MFD Optional
			GIA 63W Integrated Avionics (qty 2)
			GA35 GPS/WAAS antennas (qty 2)
			Major Functions Added
			• Misc. GDU v8.20 features
			Hardware Added	0321.17
			GIA 63W P/N 011-01105-01
		G1000 &	GDC 74A P/N 011-00882-10
			Major Functions Added
	-1 Configuration	GFC 700
			• Misc. GDU v9.01 features
		with WAAS		0321.18
			Hardware Added
			None
			Major Functions Added
			• Misc. GDU v9.01 features
			(Non WAAS Support)	0321.19
			Hardware Added
			None
			Major Functions Added
			• Import Flt Plans from SD Card
			• Temporary Waypoints
			• Flight Data Logging to SD Card	0321.22
			• GDL69 Aviator Pro features
			• Misc. GDU v9.15 features
			Hardware Added
			None

Page 1-2	G1000 System Maintenance Manual – Diamond DA40/40F
Revision G	190-00545-01

Table 1-1. MDL Configurations Summary (Cont.)

	MDL	Aircraft	Upgrades Available		G1000 System
	Configuration	System			Software Version
			Major Functions Added
			• Optional Electronic Stability & Protection
			• Optional GDL 59 /GSR 56B to include
				WWWx, SMS Text Messaging and TEL
				functionality
			• Optional GSR 56B standalone to
				include WWWx, SMS Text Messaging
				and TEL functionality
			• Addition of Profile View
			• Addition of Synthetic Vision (SVS)
			• Addition of Enhanced Search and
		G1000 &		Rescue (SAR)
	-1 Configuration		•	Add optional installation of GSA 81 -20
		GFC 700		servos and GSM 86 servo mounts.	0321.23
	(Cont)	with
			• Automated Slip Clutch Test for GSM 86
		WAAS
				Installations
			• Misc. GDU v12.05 features
			Hardware Added
			•	GDU 1040 P/N 011-00972-10
			•	GDU 1042 P/N 011-01080-10
			•	GDU 1044 P/N 011-01078-10
			•	GIA63W P/N 011-01105-20
			•	GMU44 P/N 011-00870-10
			•	GDL59 P/N 011-01746-00
			•	GSR56 P/N 011-02268-00
			•	GSM86 P/N 011-01904-03
			•	GSA81 P/N 011-00878-20
			Major Functions Added
			• G1000 & GFC 700 AFCS
			• Coupled baro-VNAV		0369.13
			• GDU Charts
			• Misc. GDU v8.02 features
			Hardware Added
			GDU 1044 MFD Optional
			Major Functions Added
			• Misc. GDU v8.20 features		0321.17
			Hardware Added
		G1000 &	GDC 74A P/N 011-00882-10
	-2 Configuration	GFC 700	Major Functions Added
		without	• Misc. GDU v9.01 features
		WAAS	(Non WAAS Support)		0321.19
			Hardware Added
			None
			Major Functions Added
			• Import Flt Plans from SD Card
			• Temporary Waypoints
			• Flight Data Logging to SD Card		0321.22
			• GDL69 Aviator Pro features
			• Misc. GDU v9.15 features
			Hardware Added
			None

G1000 System Maintenance Manual – Diamond DA40/40F	Page 1-3
190-00545-01	Revision G

Table 1-1. MDL Configurations Summary (Cont.)

	MDL	Aircraft	Upgrades Available		G1000 System
	Configuration	System			Software Version
			Major Functions Added
			• WAAS
			• GDU Charts		0369.13
			• Misc. GDU v8.02 features
			Hardware Added
			GIA 63W Integrated Avionics (qty 2)
			GA35 GPS/WAAS antennas (qty 2)
			Major Functions Added
			• Misc. GDU v8.20 features
			Hardware Added		0321.17
			GIA 63W P/N 011-01105-01
			GDC 74A P/N 011-00882-10
			Major Functions Added
			• Misc. GDU v9.01 features		0321.18
			Hardware Added
			None
			Major Functions Added
			• Misc. GDU v9.01 features
			(Non WAAS Support)		0321.19
			Hardware Added
			None
		G1000 with	Major Functions Added
			• Import Flt Plans from SD Card
	-3 Configuration	WAAS &
			• Temporary Waypoints
		No AP
			• Flight Data Logging to SD Card
					0321.22
			• GDL69 Aviator Pro features
			• Misc. GDU v9.15 features
			Hardware Added
			None
			Major Functions Added
			• Optional GDL 59 /GSR 56B to include
				WWWx, SMS Text Messaging and TEL
				functionality
			• Optional GSR 56B standalone to include
				WWWx, SMS Text Messaging and TEL
				functionality
			• Addition of Profile View
			• Addition of Synthetic Vision (SVS)		0321.23
			•	Addition of Enhanced Search and Rescue
				(SAR)
			• Misc. GDU v12.05 features
			Hardware Added
			•	GDU 1040 P/N 011-00972-10
			•	GIA63W P/N 011-01105-20
			•	GMU44 P/N 011-00870-10
			•	GDL59 P/N 011-01746-00
			•	GSR56 P/N 011-02268-00

Page 1-4	G1000 System Maintenance Manual – Diamond DA40/40F
Revision G	190-00545-01

Table 1-1. MDL Configurations Summary (Cont.)

	MDL	Aircraft	Upgrades Available	G1000 System
	Configuration	System		Software Version
			Major Functions Added
			• GDU Charts	0369.13
			• Misc. GDU v8.02 features
			Hardware Added
			GDU 1044 MFD Optional
			Major Functions Added
			• Misc. GDU v8.20 features	0321.17
			Hardware Added
			GDC 74A P/N 011-00882-10
		G1000	Major Functions Added
			• Misc. GDU v9.01 features
		without
	-4 Configuration		(Non WAAS Support)	0321.19
		WAAS &
			Hardware Added
		No AP
			None
			Major Functions Added
			• Import Flt Plans from SD Card
			• Temporary Waypoints
			• Flight Data Logging to SD Card	0321.22
			• GDL69 Aviator Pro features
			• Misc. GDU v9.15 features
			Hardware Added
			None
			Major Functions Added
			• Misc. GDU v8.20 features
			Hardware Added	0321.17
			GIA 63W P/N 011-01105-01
			GDC 74A P/N 011-00882-10
			Major Functions Added
			• Misc. GDU v9.01 features	0321.18
			Hardware Added
			None
		G1000 with	Major Functions Added
			• Misc. GDU v9.01 features
	-5 Configuration	WAAS &
		Honeywell	(Non WAAS Support)	0321.19
		KAP 140	Hardware Added
			None
			Major Functions Added
			• Import Flt Plans from SD Card
			• Temporary Waypoints
			• Flight Data Logging to SD Card	0321.22
			• GDL69 Aviator Pro features
			• Misc. GDU v9.15 features
			Hardware Added
			None

G1000 System Maintenance Manual – Diamond DA40/40F	Page 1-5
190-00545-01	Revision G

Table 1-1. MDL Configurations Summary (Cont.)

	MDL	Aircraft	Upgrades Available		G1000 System
	Configuration	System			Software Version
			Major Functions Added
			• Optional GDL 59 /GSR 56B to include
				WWWx, SMS Text Messaging and TEL
				functionality
			• Optional GSR 56B standalone to include
				WWWx, SMS Text Mesaging and TEL
				functionality
		G1000 with	•	Addition of Profile View
	-5 Configuration	WAAS &	•	Addition of Synthetic Vision (SVS)	0321.23
	(Cont)	Honeywell	•	Addition of Enhanced Search and Rescue
		KAP 140		(SAR)
			• Misc. GDU v12.05 features
			Hardware Added
			•	GDU 1040 P/N 011-00972-10
			•	GIA63W P/N 011-01105-20
			•	GMU44 P/N 011-00870-10
			•	GDL59 P/N 011-01746-00
			•	GSR56 P/N 011-02268-00
			Major Functions Added
			• Misc. GDU v8.20 features		0321.17
			Hardware Added
			GDC 74A P/N 011-00882-10
			Major Functions Added
			• Misc. GDU v9.01 features
		G1000	(Non WAAS Support)		0321.19
			Hardware Added
		without
			None
	-6 Configuration	WAAS &
		Honeywell	Major Functions Added
		KAP 140	• Import Flt Plans from SD Card
			• Temporary Waypoints
			• Flight Data Logging to SD Card		0321.22
			• GDL69 Aviator Pro features
			• Misc. GDU v9.15 features
			Hardware Added
			None

Page 1-6	G1000 System Maintenance Manual – Diamond DA40/40F
Revision G	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 for approved G1000 system software versions.

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 dedicated AFCS mode control keys on the left side of the display (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 1-7
190-00545-01	Revision G

Check for Optional Installations

Identify all installation options currently installed on the aircraft which interface to the G1000 and check each that applies in the following list. These options may need to be re-configured if a new system software version is loaded or an LRU is removed or replaced.

DA40 / DA40 F:

ADF

DME GDL 69

Extended Range Fuel Tanks Standard GFC 700 Enhanced GFC 700

Electronic Stability and Protection (ESP)

No Autopilot Installed (No KAP140 or GFC 700) EASA Airspeed Tape (EASA Registered Aircraft Only) Display of Fuel Pressure Gauge

TAWS ChartView

Enhanced Search and Rescue (SAR)

Synthetic Vision and Pathway (SVS)

GDL 59 Data Link & GSR 56 Satellite Receiver Standalone GSR 56 Satellite Receiver

DA40 F Only:

Fuel Pressure Sensor Installed

One CHT and EGT sensor installed

Four CHT and EGT sensors installed

The following are provisional options not certified by any Garmin STC. To enable these interfaces, a separate installation approval is required.

Avidyne TAS 600

WX500 Stormscope

CO Guardian

Page 1-8	G1000 System Maintenance Manual – Diamond DA40/40F
Revision G	190-00545-01

1.2Organization

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.

G1000 System Maintenance Manual – Diamond DA40/40F	Page 1-9
190-00545-01	Revision G

1.3Definitions/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
ESP:	Electronic Stability and Protection
GA	Go Around
GDC	Garmin Air Data Computer
GDL:	Garmin Data Link
GDU:	Garmin Display Unit
GEA:	Garmin Engine Airframe Unit
GFDS:	Garmin Flight Data Service
GIA:	Garmin Integrated Avionics
GMA:	Garmin Marker Beacon & Audio Panel Unit
GMU:	Garmin Magnetometer Unit
GPS:	Global Positioning System
GRS:	Garmin Reference System
GS:	Glideslope
GSA:	Garmin Servo Actuator
GSM:	Garmin Servo Mount
GSR:	Garmin Satellite Radio
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
Page 1-10		G1000 System Maintenance Manual – Diamond DA40/40F
Revision G		190-00545-01

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
SAR	Search and Rescue
STC:	Supplemental Type Certificate
SVS	Synthetic Vision System
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

1.3.1Units of Measure

Unless otherwise stated, all units of measure are English units.

G1000 System Maintenance Manual – Diamond DA40/40F	Page 1-11
190-00545-01	Revision G

1.4Publications

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	Diamond Wiring Diagram
	OR
		(Diamond Part Number, -05 applies to GFC700 aircraft)
	DA4-9231-60-05
	6.02.01	Diamond DA 40 Airplane Maintenance Manual (Diamond Part Number)
	005-00400-92	Instl,Pitch Servo,GFC700 with GSM 86, Diamond DA40/40F
	005-00400-93	Instl,Pitch Trim Servo,GFC700 with GSM 86, Diamond DA40/40F
	005-00400-94	Instl,Roll Servo,GFC700 with GSM 86, Diamond DA40/40F
	005-00464-10	Installation Modification, G1000/GFC700, WAAS, Diamond DA40/40F
	005-00464-15	Installation Modification, G1000, WAAS, No Autopilot, Diamond DA40/40F
	005-00464-00	Installation Modification, G1000/KAP140, WAAS, Diamond DA40/40F
	005-00464-07	Antenna Install, GDL59/GSR56, DA40/40F
	005-00464-08	GDL59/GSR56 Install, DA40/40F
	005-00464-06	Wiring Diagram,GDL59/GSR56 in DA40/40F
	005-00464-12	Wiring Diagram, GTX 33 Relocation, Diamond DA40 / DA 40 F
	005-00464-13	Wiring Routing, GTX 33 Relocation, Diamond DA40 / DA 40 F
	190-00355-04	GDL 69 Series XM Satellite Radio Activation Instructions

Page 1-12	G1000 System Maintenance Manual – Diamond DA40/40F
Revision G	190-00545-01

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	SA01389WI
005-00336-19	Pitch Trim Servo Installation, GFC700 AFCS, Diamond DA40/40F

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
	190-00492-08	Airplane Flight Manual Supplement: G1000 Synthetic Vision And Pathways Option
	190-00492-09	Airplane Flight Manual Supplement: G1000 Electronic Stability and Protection (ESP)
		Option for the Diamond DA40/DA40F
	190-00492-10	Airplane Flight Manual Supplement: G1000 Integrated Avionics System with GFC 700
		Automatic Flight Control System – Diamond Model DA40 & DA40F
	190-00492-11	Airplane Flight Manual Supplement: G1000 Integrated Avionics System – Diamond
		Model DA40 & DA40F
	190-00492-12	Airplane Flight Manual Supplement: G1000 Integrated Avionics System – Diamond
		Model DA40 & DA40F
	190-00324-07
	190-00324-08
	190-00324-09	G1000/GFC700 DA 40 Cockpit Reference Guide*
	190-00324-10
	190-00324-11
	190-00355-04	GDL 69/69A XM Satellite Radio Activation Instructions
	190-00303-72	GSA8X/GSM85(A) Installation Manual

*See AFMS for correct CRG P/N required.

G1000 System Maintenance Manual – Diamond DA40/40F	Page 1-13
190-00545-01	Revision G

1.5Distribution

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 ‘Dealer Resource Center’.

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.

1.6Required Materials & Equipment

The following test equipment is required to conduct and complete all post installation checkout procedures in this section (All test equipment should have current calibration records):

A ground power unit capable of supplying 28 Vdc power to the aircraft systems and avionics.

Outdoor line-of-site to GPS satellite signals or GPS indoor repeater.

Outdoor line-of-site to Iridium satellite signal.

Headset/Microphone.

A VHF NAV/COM Test Set

Air Data Test Set

L-Band Multi-Function Test Set

The following materials are defined on the applicable General Arrangement Drawing (see STC MDL):

G1000/DA40 Software Image

SD Card,GDU10XX BB Ldr,v2.03 (May be required. Refer to Section 3.5.3)

SD Card,G1000,GIA6X BBL 4.01(May be required. Refer to Section 3.5.7)

SD Card,GDU10xx Supp SVS, (TRN/OBS/APT DB/SUPP/SAFE TAXI)*

SD Card,GDU10xx TAWS Unlock (Optional)

SD Card,GDU10XX,Chart Unlock, Light AC (Optional)

SD Card, GDU1XXX Enhanced AFCS Unlock (Optional)

SD Card, G1000, Enhanced SAR Unlock (Optional)

SD Card,GDU10xx SVS Unlock,1 PFD (Optional)

*Terrain database cards are required by this STC. However, the newer updated cards which provide SafeTaxi and Chart capability are an optional upgrade. If these newer cards are not installed, the existing installed cards must still be used. Reference the applicable General Arrangement Drawing (see STC MDL). See the applicable General Arrangement Drawing for each configuration in Master Drawing List, 005-00400-01 for additional details.

Table 1-5 lists the loader cards used in this upgrade and is derived from the appropriate General Arrangement drawing for each configuration listed on MDL 005-00400-01. The appropriate General Arrangement drawing should be followed if any differences exist.

Page 1-14	G1000 System Maintenance Manual – Diamond DA40/40F
Revision G	190-00545-01

Table 1-5. Loader Card to Configuration Relationship Summary

	Legend
R	Required
O	Optional
*	See Note 1
†	See Note 2
NA	Not Applicable

		010 - P/N		-1	-2	-3	-4	-5	-6
				Config	Config	Config	Config	Config	Config
		and
	Qty	006 - P/N	Description
		(Where Applicable)
	1 ea	010-00369-XX	SD Card,G1000,DA40	R	R	R	R	R	R
		006-B0321-XX	Ldr
			SD Card,GDU10xx Supp
	2 ea	010-00330-43	SVS	R	R	R	R	R	R
			(TRN/OBS/APT
			DB/SUPP/SAFE TAXI)
	1 ea	010-00330-51	SD Card,GDU10xx	O	O	O	O	O	O
			TAWS Unlock
	1 ea	010-00330-53	SD Card,GDU10XX,Chart	O	O	O	O	O	O
			Unlock, Light AC
	1 ea	010-00330-02	SD Card,GDU10XX BB	*	*	*	*	*	*
		006-B0874-00	Ldr,v2.03
	1 ea	010-00533-00	SD Card,G1000,GIA6X	†	†	†	†	†	†
		006-B0538-00	BBL 4.01
	1 ea	010-00330-5B	SD Card, GDU1XXX	O	NA	NA	NA	NA	NA
			Enhanced AFCS Unlock
	1 ea	010-00330-59	SD Card, G1000,	O	O	O	O	O	O
			Enhanced SAR Unlock
	1 ea	010-00330-54	SD Card,GDU10xx SVS	O	O	O	O	O	O
			Unlock,1 PFD

(*) Note 1 - REQUIRED - Only if determined necessary to update GDU 104X boot block per section 3.5.3 procedures. (†) Note 2 – REQUIRED - Only if determined necessary to update GIA 63 boot block per section 3.5.7 procedures.

The G1000/ DA40 Software Image file, Boot Block update for the GDU 104X and GIA 63 may be electronically sourced via the listed 006- P/N. through Garmin to facilitate building a boot block software SD Card. If desired, technician may purchase the Boot Block cards as a higher – level assembly produced by Garmin, defined per the 010 – P/Ns shown above.

NOTE

When an option is enabled for the first time (normally at the Diamond factory), the G1000 writes its unique system ID to the physical card and locks the files to this unique ID. This prevents the unlock card from ever being used to activate the feature in other G1000 systems. The unlock card is forever tied to the specific aircraft in which it was used for the first time. For situations where the feature must be re-activated, this card must be used. If the original G1000 feature unlock card is not available the technician may purchase the unlock cards as a higher – level assembly produced by Garmin, defined per the 010 – P/Ns shown above or contact Garmin customer support.

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2 SYSTEM DESCRIPTION

2.1STC 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.

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2.2Equipment Descriptions

2.2.1GDU 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.

For MDL configurations -1,-3 and -5 only, this STC installation approves alternate part numbers for the displays that accept external video input and have an additional HSDB Ethernet connection. There are no mechanical or electrical interface changes needed for these new part number displays. Refer to the applicable General Arrangement Drawing listed in Table 1-2 for part number information.

NOTE

While the alternate part numbers of displays authorized by this STC include an external video input and HDSB Ethernet connection, this STC does not approve any interfaces to these ports. These ports are not configured on by this STC. Any interfaces to these ports will require activation of these ports and additional airworthiness approvals will be required.

2.2.2GMA 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.

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2.2.3GIA 63 or GIA 63W Integrated Avionics Unit (2)

NOTE

For MDL configurations -1,-3 and -5 only, this STC installation approves alternate part number ‘-20’ GIA63Ws. The installation of these units will require software version 0321.23 or later as well as mechanical and wire harness changes to relocate the GTX33 transponders (refer to Section 2.2.5). Refer to the applicable General Arrangement Drawing listed in Table 1-2 for part number and software information.

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)

2.2.4GEA 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.

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2.2.5GTX 33 Mode S Transponder

The Garmin GTX 33 provides Mode A, C, and S altitude and position reporting information to the G1000 system.

•Aircraft with GIA 63W P/N 011-01105-00 or 011 01105-01, the unit is mounted in the remote avionics enclosure below the baggage compartment.

•Aircraft with GIA 63W P/N 011-01105-20, the unit is mounted on the outboard side of the remote avionics enclosure below the baggage compartment.

Power is received from the ‘Essential’ bus. The GTX 33 interfaces with the existing transponder antenna.

2.2.6GDC 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.

2.2.7OAT 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.

2.2.8GRS 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.

2.2.9GMU 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.

2.2.10 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.

2.2.11 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 fieldfabricated component bracket with resistors, voltage suppressors and attached wiring is fastened to the forward portion of the enclosure.

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