Modification Kit

Transcript

Single Engine MODIFICATION KIT MK400-34-01 TITLE WAAS UPGRADE FOR AVIDYNE ENTEGRA AND GARMIN GNS 430 EQUIPPED AIRPLANES EFFECTIVITY Model Serial Numbers 350 (LC42-550FG) 42001 thru 42084, 42501 400 (LC41-550FG) 41002 thru 41033, 41035 thru 41108, 41501 thru 41533 DESCRIPTION This modification kit provides instructions and parts to install Wide Area Augmentation System (WAAS) capability. APPROVAL FAA approval has been obtained on all technical data in this Modification Kit that affects type design. REFERENCE SB09-34-01 CHANGE IN WEIGHT AND BALANCE Refer to Table 9 in these instructions. March 9, 2009 Page 1 of 62 To obtain satisfactory results, procedures specified in this publication must be accomplished in accordance with accepted methods and prevailing government regulations. Cessna Aircraft Company cannot be responsible for the quality of work performed in accomplishing the requirements of this publication. Cessna Aircraft Company, Customer Service, P.O. Box 7706, Wichita, Kansas 67277, U.S.A. (316) 517-5800 Facsimile (316) 942-9006 COPYRIGHT!2009 MATERIAL INFORMATION MK400-34-01-1 contains the parts required to perform the primary steps of this Modification Kit. If the airplane does not have an Orbcomm or XM antenna installed on top of the fuselage, and it is determined that Steps 2.G. and 2.K. are not required to be completed, then MK400-34-01-1 is the only kit that will be required. If an Orbcomm or XM antenna is installed on top of the fuselage at approximately station 185.5, then Steps 2.G. and 2.K. are required to be completed, and MK400-34-01-2 will also be required. MK400-34-01-1 (required for all airplanes) PART NUMBER QUANTITY DESCRIPTION MK400-34-01-1 1 Kit, consisting of the following parts: 013-00245-00 1 Antenna, GA 37, GPS/WAAS + XM, GARMIN MS24693-C276 4 Screw, Machine, Flat head, 10-32 x1.0 inch NAS1149CO363R 4 Washer, Flat, #10 MS21083C3 4 Nut, Self Locking, Non Metallic, 10-32 MS51957-49 1 Screw, Machine HD, 8-32 x 1.0 inch 013-00235-00 1 Antenna, GA 35, GPS/WAAS, Garmin CTM-2 15 Cable Tie Mount 91802A197 4 Screw, 82 deg Oval HD, X-Recessed 8-32 x 3/4 inch Antenna Wedge Block, WAAS, Molded OR (use as supplied) Antenna Wedge Block, WAAS, Machined LB53404406 Rev A OR (use as supplied) LB53404405 Rev – 1 LB53404415 Rev – 1 Ground Braid Assembly, Exterior WAAS Antenna MS51957-51 1 Screw, Machine HD, 8-32 x 1.5 inch NAS1149FN832P 1 Washer, #8 MS21083C08 1 Nut, Self Locking, Low Height, 8-32 MK400-34-01 March 9, 2009 Page 2 PART NUMBER QUANTITY DESCRIPTION AN970-3 1 Washer, Large Area #10 TY242M 30 Wire Tie, Metal Insert 14285V86/1EA. 1 Mark 5 Mix Nozzles 225395-6 1 Connector, Straight Jack, BNC, RG 400, AMP 31-2381 1 AMP 90 Degree TNC Connectors. RG 400 20 ft RG 400 Type Coax Cable. (238.0 inches) 31-2373 2 Plug, Straight, TNC, Amphenol Mixed Filler 6.4 1 Mixed Dry Fillers 1 Instructions In addition to MK400-34-01-1, the following materials are necessary: NAME Silicone Caulk, White MIL-A-46-146 Jeffco Resin System – 5 fl oz MK400-34-01 March 9, 2009 NUMBER RTV 162 (White) or equivalent Jeffco Pack 5 QUANTITY MANUFACTURER USE 1 ea Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box1521 Wichita, KS 67218 To install antenna 1 ea Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box1521 Wichita, KS 67218 To install antenna Page 3 NAME Stabilant 22 Electrical Contact Enhancer (0.5 ml) Devcon Plastic Welder II, 47 ml Dev Pak NUMBER 005-010-MLS 14340V86 QUANTITY MANUFACTURER USE 1 ea Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box1521 Wichita, KS 67218 To install antenna 2 ea Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box1521 Wichita, KS 67218 To install antenna Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box1521 Wichita, KS 67218 To install antenna Application Gun (for 47/50 ml Devcon cartridges) 14280V86 (or equivalent) 1 Plastic Mixing Cup Evercoat “E”-cup (1 quart size) (or equivalent) 1 Procure locally To Mix Filler Isopropyl Alcohol TT-I-735 Grade B (1 quart size) (or equivalent) As required Procure locally To clean surface MK400-34-01-2 (required only for airplanes with Orbcomm or XM antennas installed on top of the fuselage): PART NUMBER QUANTITY DESCRIPTION MK400-34-01-2 1 Kit, consisting of the following parts: AL016CXMC36 1 sq ft Expanded Metal Foil (Aluminum Lightning Protection Mesh) Mixed Filler 6.4 1 Mixed Dry Fillers AT200Y 5 ft Sealant Tape 60002 2 sq ft Release Fabric, Polyester Peel Ply MK400-34-01 March 9, 2009 Page 4 PART NUMBER QUANTITY DESCRIPTION N-4 Airweave-3 1 sq ft Breather Cloth WL5200B-P3 1 sq ft Perforated Release Film P-3, Blue WL6400-60 3 ft Bagging Film 60 inch 7781 1 sq ft Glass Cloth In addition to MK400-34-01-2, the following materials are necessary: NAME NUMBER Jeffco Resin System – 5 fl oz Jeffco Pack 5 Rage Extreme Filler Evercoat 120 (or equivalent) Plastic Mixing Cup Isopropyl Alcohol QUANTITY Evercoat “E”cup (1 quart size) or equivalent TT-I-735 Grade B (1 quart size) (or equivalent) 2 ea 1 ea MANUFACTURER Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box1521 Wichita, KS 67218 Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box1521 Wichita, KS 67218 USE To install antenna To install antenna 2 ea Procure locally To Mix Filler As required Procure locally To clean surface REFERENCE DOCUMENTS Avidyne Reference documents. Contact Avidyne or an authorized Avidyne Service Center. Document Number 600-00141-00 600-00073-00 601-00006-081 601-00004-077 Rev Rev 06 Rev 20 Rev 01 Rev 01 601-00004-078 Rev 01 MK400-34-01 March 9, 2009 Description Avidyne Entegra and Envision PFD Installation Manual Avidyne Entegra and Envision MFD Installation Manual Avidyne Service Bulletin: Release 7 PFD Re-Installation for Service Avidyne Service Bulletin: Release 6 EX5000 MFD Field Loadable Upgrade to Release 7 Software 530-00195-() Rev 00 Avidyne Service Bulletin: Pre-Release 6 EX5000 MFD Field Loadable Software Upgrade to Release 7 Software 530-00195-() Rev 00 Page 5 Garmin Reference documents. Contact Garmin or an authorized Garmin Service Center. Document Number 005-C00221-00 190-00356-65 190-00357-06 190-00356-02 190-00356-63 Rev A A A A A Description 400W Series Master Data List 400W Series Instructions for Continued Airworthiness 400W Series Upgrade Installation Manual 400W Series Installation Manual 400W Series Airplane Flight Manual Supplement (AFMS) ACCOMPLISHMENT INSTRUCTIONS 1. The accomplishment instructions consist of 4 basic steps for ease of installation. They are as follows: " The installation of the Antenna Wedge Block and the removal of the optional Orbcomm Weather System or XM Antenna (Step 2). " The Avidyne EXP5000 Primary Flight Display (PFD) and Multi-Function Display (MFD) upgrade to Release 7 Software (Step 3). " The Garmin GNS 430 (non-WAAS) upgrade to the Garmin GNS 430W (WAAS) (Step 4). " The operational checkout and airplane Return To Service procedures (Step 5). These steps can be performed at different times and at different facilities, but must be accomplished in sequence. Each step can be signed off as having complied with that specific step per this Modification Kit. However, the Modification Kit cannot be signed off as having been complied with, until all steps have been accomplished in accordance with this Modification Kit. 2. Third Party Work and Avionics Parts Requirement A. This Modification Kit is intended to be accomplished by a Cessna Authorized Service Station. Depending on the capabilities of the individual Service Station performing this modification, other appropriately rated avionics facilities may need to be used for the requirements to upgrade, configure, or test the Avidyne Entegra and the Garmin GNS 430 GPS avionics equipment. The Cessna Service Station may coordinate with authorized Garmin and Avidyne Avionics Service Centers to perform the equipment upgrades. NOTE: The return of the PFD to the Avidyne factory must be scheduled and coordinated through an authorized Avidyne Service Center in advance. Contact Avidyne Product Support at Telephone (888) 723-7592, or Fax (781) 402-7599 for more information. There may be a substantial lead time for scheduling this upgrade and the turn around time required for Avidyne to perform the Release 7 upgrades. There may be a fee from Avidyne to perform this upgrade. Plan accordingly. NOTE: Both of the Garmin GNS 430 GPS Navigator units need to be replaced with the Model GNS 430W WAAS GPS Navigation units. The upgrades to the new GNS 430W WAAS GPS Navigation units must be accomplished through a Garmin Authorized Service Center. The original units that are installed in the airplane will be sent to Garmin for a core credit and Garmin will replace them with two MK400-34-01 March 9, 2009 Page 6 GNS 430W GPS WAAS Navigator units. Contact a Garmin authorized Service Center to schedule and pre-arrange the replacement of the units. Contact Garmin at Telephone (800) 800-1020, or Fax (913) 397-8282 for additional information. Both GPS units must be upgraded so that all GPS equipment is at the same hardware and software levels. There will be a fee from Garmin to upgrade each of the units to GNS 430W models. 3. Existing Orbcomm and XM Weather System Installations. A. Determine if the optional Orbcomm Weather System or XM antennas are installed on the airplane. B. The Service Station should advise the owner of the following information before work begins: If the owner chooses to install the Garmin GNS 430W WAAS upgrades, the existing optional Orbcomm or XM antennas mounted on top of the fuselage will be removed from the airplane. The Orbcomm functionality on the Avidyne MFD will be turned off. If the XM Weather system is installed, all XM functionality will remain operational when the installation is completed, except that the existing XM antenna (either under the glare shield or on top of the fuselage) will be replaced with a combined GPS-WAAS / XM Antenna, located on the antenna shelf. The owner should consider the benefits of having the Garmin WAAS upgrades, compared to the alternative of keeping the Orbcomm system. C. Cessna Service Letter SL-06-003 provided for the relocation of the XM antenna from underneath the glare shield to the top of the fuselage, in place of the Orbcomm antenna. If the XM antenna has been located on top of the fuselage per SL-06-003, then the XM antenna will be removed from the fuselage top and replaced with the new GPS-WAAS 2 / XM Antenna located on the antenna shelf. D. If the airplane does not already have XM Weather installed, an XM Weather Receiver can be installed per Cessna Service Letter SL-04-008, using the Garmin GA 37 GPS-WAAS / XM Antenna as instructed in this document, in place of the antenna called out in SL-04-008. 4. Chart and NavData Subscriptions: Inform the owner of the airplane that the Jeppesen NavData databases must be updated to the current revision following upgrade of the MFD. If the owner has a subscription to Jeppesen CMax™ Chart Data, inform the owner that the Jeppesen Chart Data may also need to be reloaded to the MFD once the upgrades are completed. The same applies for the both the Garmin GNS430W units as well. It is the owner’s responsibility to update the databases. For more information about these databases, contact Jeppesen, Avidyne, or Garmin. The airplane should not be flown under Instrument Flight Rules (IFR) unless the chart and database cycles are current in the GNS430W units and on the MFD. NOTE: For the Garmin GNS430W WAAS units, the owner must contact Jeppesen to convert their Jeppesen NavData subscription to a WAAS NavData subscription. The database formats for the WAAS approved GNS430W units are different from the non-WAAS GNS430 databases. MK400-34-01 March 9, 2009 Page 7 ACCOMPLISHMENT INSTRUCTIONS NOTE: (Refer to item 1 in the Preliminary Information section.) This Modification Kit provides three installation/upgrade procedures that do not have to be performed at the same time, or at the same Service Station; but they must be performed in sequence. Those procedures are: 1 – The Antenna Wedge Block installation and Antenna Replacement, 2 - The Avidyne EXP5000 Primary Flight Display (PFD) and EX5000 Multi-Function Display (MFD) Release 7 Upgrades, 3 – Garmin GNS 430W WAAS GPS Navigation Unit Upgrade. If the procedures are performed at different times, and/or at different Service Stations, each procedure that was complied with must be signed off in the airplane’s logbooks, and the applicable ‘Operational Checks’ must be accomplished for that procedure. Only after all three procedures are completed, can this Modification Kit be completely signed off as being accomplished. NOTE: Thoroughly read, review and understand these instructions before beginning this upgrade. 1. If not previously accomplished, refer to Cessna Service Bulletin SB-08-004 “Pilots Operating Handbook Revisions” and update the Pilot’s Operating Handbook (POH) to the version listed in that Service Bulletin, or any later POH revision. 2. Perform the Antenna Wedge Block Installation and Antenna Replacement as follows: NOTE: Refer to the appropriate 350/400 Airplane Maintenance Manual (AMM) for detailed instructions on disconnecting batteries and removal of interior panels and furnishings. A. Gain access to the interior of the airplane, to perform the Antenna Wedge Block installation and Antenna Replacement as follows: (1) Make sure that the left and right battery master switches and all other electrical switches are set to the OFF position. (2) Disconnect Electrical Power from the airplane. (a) Disconnect the left and right airplane batteries. (b) Disconnect the external electrical power at the ground power receptacle. (c) Attach maintenance warning tags to the batteries and the ground power receptacle that have “DO NOT CONNECT ELECTRICAL POWER – MAINTENANCE IN PROGRESS” written on them. (3) Put a tail stand under the tail section of the airplane. (4) Remove the pins attaching the rear seat backs to the rear seat back bar. Remove the rear seat back and the bottom seat cushions from the rear seat positions and remove the rear seat back bar. (5) Remove the right front seat from the airplane. (6) Remove the right cabin door tread and hardware. (7) Remove all the interior upholstery panels along the right side of the airplane, as necessary to gain access to the antenna coax cables. MK400-34-01 March 9, 2009 Page 8 (8) Remove the forward overhead console assembly. Use care when disconnecting the oxygen hose and the wire harnesses. Be sure to carefully disconnect the compass lighting wire when removing the forward overhead. (9) Remove the aft overhead upholstery from over the baggage compartment. (10) Remove the cargo net on the floor of the baggage compartment. (11) Remove the baggage netting and brackets that divides the baggage compartment from the aft baggage shelf. (12) Remove the cushion from the aft bulkhead and remove the padded carpeting in the aft baggage shelf. (13) If installed, remove the air-conditioning evaporator cover located in the baggage compartment area. (14) Remove the pitch servo access panel located on floor of the aft baggage shelf. (15) Remove the ELT access panel located on the aft bulkhead. (16) Remove the avionics bay access cover located in the floor of the main baggage compartment area. (17) Remove the glare shield. Carefully disconnect the lighting wires attached to the glare shield. (18) Loosen the four locking screws on each of the Primary Flight Display (PFD) and MultiFunction Displays (MFD). (19) Remove the PFD from the Instrument Panel. Disconnect the three electrical connectors on the back of the PFD. Disconnect the pitot and static lines from the back of the PFD. (20) Remove the MFD from the right side of the instrument panel. Disconnect the P530 connector. Disconnect the Orbcomm BNC connector from the MFD. Label the coax cable as “Orbcomm” if not already labeled. (21) Remove the two Garmin GNS 430 Navigation units from the radio trays. (22) Behind the baggage bulkhead, disconnect the BNC and remote switch connector on the ELT, and remove the ELT from the mount behind the baggage bulkhead. Turn the switch on the ELT to the ‘OFF’ position. (23) Unbolt and remove the ELT support bracket from the airplane. B. Remove the existing GPS antennas and coax cables as follows: (1) Disconnect the GPS 1 and GPS 2 RG400 coax cables from the two Garmin GA56 GPS antennas. NOTE: The GA 56 antennas are on the antenna shelf behind the aft baggage bulkhead, aft of the ELT mount. (2) Identify and label the GPS 1 and GPS 2 coax cables. (3) Remove and discard the BNC connector at the antenna end of the GPS 1 coax cable. MK400-34-01 March 9, 2009 Page 9 (4) Disconnect the BNC connector at the GPS connector position on the back of the GNS 430 # 1 radio tray. Pull the GPS 1 coax cable out of the wire bundles, and discard the GPS 1 coax cable. NOTE: The GPS 1 radio tray is in the top position above the throttle controls and the GPS 2 radio tray is located below the throttle controls. (5) Do not remove the GPS 2 coax cable. Remove and discard the BNC connector at the antenna end of the GPS 2 coax cable, as close to the connector as possible. NOTE: Use an ohm meter first to verify that the GPS 2 coax cable is actually going to the GPS 2 radio tray. (6) Remove and discard the two Garmin GA 56 GPS antennas from the antenna shelf. C. (Figure 22.) (For airplanes equipped with the optional Orbcomm Weather System only). Remove the Orbcomm Antenna and coax cable as follows: (1) Disconnect the Orbcomm coax cable at the antenna end, located on the inside of the upper fuselage at approximately FS 190.0. (2) Remove the tie wraps securing the Orbcomm coax cable in place and removes this coax cable all the way back to the MFD. Remove and discard the Orbcomm coax cable. (3) Remove the Orbcomm antenna. Do not discard the antenna at this time. (4) Carefully remove the gasket material from the antenna and the skin of the airplane. Care should be taken not to damage the lightning protection mesh on the fuselage. Remove all old RTV where the antenna was located. D. (Figures 22, 23, and 24.) Remove the XM antenna as follows: NOTE: The existing XM antenna (if installed) may be mounted either underneath the glare shield (behind the MFD) or on top of the fuselage above the baggage compartment, at approximately FS 190.0. (1) Locate the antenna. (2) Disconnect the XM coax cable from the antenna and label the cable as ‘XM’. (3) If the XM antenna was mounted underneath the glare shield, remove the antenna, the mounting brackets, and all the hardware. Do not remove the long bracket attached to the instrument panel. (4) If the XM antenna was mounted on the top of the fuselage above the baggage compartment, carefully remove the antenna and gasket material from the skin of the airplane. Do not damage the lightning protection mesh on the fuselage. (5) Remove and discard the SMA connector from the antenna end of the XM coax cable. (6) Remove the XM coax cable from the wire bundle between the XM antenna and the floor of the avionics bay in the baggage compartment area. Leave the XM coax cable connected to MK400-34-01 March 9, 2009 Page 10 the XM receiver in the avionics bay. The XM coax cable will later be rerouted to the aft of the airplane. E. (Figures 5 and 6.) Modify the Antenna Shelf as follows: (1) (Figure 6.) Create a template out of a piece of aluminum sheet as shown. NOTE: The template will be used as the guide for drilling the new holes in the antenna shelf. The elongated hole shown in Figure 6 will not be elongated in the drill template. See note on Figure 6. NOTE: Make sure that holes in the drill template match the hole locations on the GA 37 Antenna. (2) (Figures 5 and 6.) Put the drill template on the antenna shelf, over the original left (pilot) side GA56 antenna mount location. Position the drill template to best align the aft mounting holes as closely as possible. (3) (Figure 5 and 6.) Temporarily tape the drill template in place at the best location on the antenna shelf. NOTE: Due to the restricted access at the antenna shelf, a compact right angle drill head, or equivalent may be necessary to drill the holes on the antenna shelf. (4) Using the drill template, drill the four mounting holes using a 0.221 inch diameter drill bit. (5) Using the drill template, drill the two large holes for the two coax connectors using a 0.625 inch diameter drill bit. Alternatively, these two large holes may be made using a small tungsten carbide rotary grinding tool attached to a rotary type hand-held tool, or equivalent. (6) Remove the drill template. (7) (Figure 6.) After the two holes have been drilled, the 0.625 inch diameter hole on the forward end of the hole pattern must be blended with the original aft large hole on the shelf. Using a marking pen, draw lines connecting the two holes as shown. (8) (Figure 6.) Use a rotary type hand-held or equivalent tool and carefully remove the material along the lines between the new and original large holes. (9) Vacuum out any debris from the antenna shelf and the surrounding area, including the belly of the airplane. F. (Figures 7 and 8.) Mount the GA 37 antenna and re-route coax cable as follows: (1) (Figures 7 and 8.) Mount the GA 37 (013-00245-00) antenna on the antenna shelf as shown. NOTE: Install the GA 37 antenna so that the blue banded TNC connector is located forward when mounted. (2) (Figure 1.) Locate the XM coax cable that was previously pulled out of the wire bundle, and route this coax cable along the right side of the fuselage with the wire bundle that runs along the right elevator push tube as shown. Feed the coax cable through the same routing used by the existing GPS 2 coax cable. MK400-34-01 March 9, 2009 Page 11 (3) Locate the antenna ends of the existing XM and GPS 2 coax cables. Cut off any excess length from the XM cable. Make sure the labels remain attached to the coax. (4) (Figures 2 and 4.) Using two 31-2373 TNC connectors, install one connector onto the antenna end of the XM coax cable, and one connector onto the antenna end of the GPS 2 coax cable. (5) (Figures 1, 2 and 4.) Connect the GPS 2 coax cable and the XM coax cable to the GA 37 Antenna. NOTE: The GPS 2 coax cable connects to the forward blue banded connector. The XM coax cable connects to the aft yellow banded connector. (6) (Figures 1 and 3.) Secure the XM and GPS 2 coax cables in place with the wire bundles along the right side of the fuselage, using TY242M tie-wraps as required. (7) Make sure the coax cables and all other wiring remains secured so they will not touch or interfere with the motion of the elevator push tube or autopilot servos that are mounted in this area. NOTE: If an XM system is not installed, make sure that the unused connector cap on the GA37 antenna is removed so it does not become FOD. G. (For airplanes equipped with the optional Orbcomm or XM antenna mounted on the fuselage exterior only). Repair the existing hole locations for the XM or Orbcomm antenna as follows: NOTE: The original hole locations that were used for the previously installed Orbcomm or XM antenna are located approximately 5 inches aft of the location for the new Garmin GA 35 antenna and the wedge block. The new WAAS antenna must be located further forward than the old Orbcomm or XM antenna, therefore the old antenna holes and footprint must be repaired before proceeding with the wedge installation and new antenna mounting. NOTE: Use plastic or similar material to cover the aft interior of the airplane before beginning the work. (1) Repair the interior side of the fuselage as follows: (a) (Figure 16.) Locate the aft overhead air conditioning bracket on the inside of the airplane, above the aft baggage compartment. With a marker, draw around the aft overhead console bracket to record its position. (b) With a plastic scraper or similar device, gently remove the aft overhead console bracket, by tapping or prying against the adhesive. (c) Use a palm sander or 90 degree rotary type tool and 80-120 grit sandpaper and remove the surface gloss of the resin on the inside of the fuselage where the mounting holes for the original antenna installation went through the fuselage. Surface prep enough area to make a patch that is approximately 4 inches by 4 inches. Sand off any excess adhesive from where the bracket was removed, but do not remove the marks made around the aft overhead console bracket. Do not sand into the glass reinforcement fibers. (d) Use Isopropyl Alcohol and a lint free cloth to thoroughly clean the interior side of the fuselage that was sanded. MK400-34-01 March 9, 2009 Page 12 NOTE: Use the clean side of the lint free cloth for each wipe until the area is thoroughly cleaned of all contaminants. (e) (Figure 26.) Use 7781 Glass Cloth and make or shape the interior repair ply so that it will extend approximately 0.50 inch beyond the Orbcomm or XM antenna screw mounting holes as shown. NOTE: The orientation of the 7781 Glass Cloth is not important for this repair. NOTE: Jeffco resin has a very short pot life of approximately 15 minutes. Steps 2.G.(1)(f) through 2.G.(1)(l) must be accomplished within that 15 minute time period, before the resin sets up and is no longer workable. Ensure that the caul sheets and repair plies are cut out, test fitted, and ready to install before the resin packets are opened and mixed. (f) Mix the contents of one Jeffco Pack 5 resin kit together. Reserve 1 fl oz of mixed resin (without filler) for wetting out the interior repair plies and the fuselage surfaces. Pour 4 fl oz of the mixed resin into a container and combine with one Mixed Filler 6.4 dry filler pack. Thoroughly mix the resin and fillers together to create an adhesive paste. (g) Prepare the interior repair ply by wetting it out with a portion of the 1 fl oz of reserved mixed Jeffco resin. Fiber content of the 7781 Cloth should be from 54% to 62% by weight. (h) Lightly wet the surface prepared region on the interior side of the fuselage using a small amount of the reserved mixed Jeffco resin. (i) On the interior side of the fuselage, lay-up the single repair ply and ensure that it extends a minimum of 0.5 inch on all sides of the old antenna holes to be patched. (j) Apply the following materials over the interior fuselage repair ply in this order: Polyester Peel Ply Release Fabric, Perforated Release Film, Breather Cloth, and Bagging Film. (k) Apply a caul sheet or equivalent support on the interior side of the fuselage, which will maintain the contour of the fuselage bond seam and support the entire repair ply during cure. (l) From the exterior side of the airplane, fill in the antenna holes using the Jeffco Resin and Mixed Filler adhesive paste. The antenna holes should be filled with adhesive paste until flush with the exterior surface of the fuselage. (m) Allow the interior repair ply and the adhesive paste in the antenna holes to pre-cure for at least three hours at room temperature not less than 77° Fahrenheit. NOTE: If the room temperature is below 77° Fahrenheit, then shop heaters or heat lamps may be placed in the room nearby to raise the ambient temperature to at least 77° Fahrenheit, but should not be placed in close proximity to the repair area. Excessive external heat applied to the repair area during the pre-cure could cause the resin to exotherm (become extremely hot and possibly cause a fire). (2) Repair the exterior side of the fuselage as follows: (a) Use a palm sander with 120-grit sandpaper or 90-degree rotary type tool with ScotchBright pad or equivalent, and sand the cured filler paste where the antenna holes were filled. Sand the exterior side of the fuselage smooth to match the fuselage contour. MK400-34-01 March 9, 2009 Page 13 (b) Use a palm sander with 120-grit sandpaper or 90 degree rotary type tool with ScotchBright sanding pad or equivalent, and remove a minimum of three inches of paint and filler (only) beyond each of the old antenna screw mount holes and center antenna connector hole to expose the lightning protection mesh (also called expanded metal foil). Do not sand through the lightning protection mesh during this step. (c) (Figure 13.) Temporarily put the old Orbcomm or externally mounted XM antenna on the exterior side of the fuselage and with a marker, outline the base of the antenna on the fuselage to produce a footprint of the antenna on the fuselage skin. (d) Remove the Orbcomm or externally mounted XM antenna and discard. (e) (Figure 27.) Use a palm sander with 120-grit sandpaper or 90 degree rotary type tool with Scotch-Bright pad or equivalent and remove the lightning protection mesh up to 1.0 inch beyond the footprint of where the Orbcomm or tail mounted XM antenna was installed. (f) (Figure 27.) Verify that there are at least 2.0 inches of lightning protection mesh exposed but not removed, beyond the lighting protection mesh that was removed around the antenna footprint. Use a palm sander with 120 grit sandpaper or 90 degree rotary type tool with Scotch-Bright pad or equivalent and remove any additional paint and filler as needed to provide the 2.0 inch minimum exposed lightning protection mesh. NOTE: It is permissible to remove up to an additional 10% or a total of three square inches of the exposed lightning protection mesh (not including what was removed for the antenna foot print) when removing the paint and filler, without the need to repair the lightning protection mesh in the area where it was removed. If more than 10% or a total of three square inches of the exposed lightning protection mesh is removed, additional lightning protection mesh will need to be repaired. (g) (Figure 26.) Use 7781 Glass Cloth and make or shape the exterior repair ply so that it will extend approximately 0.50 inch beyond the Orbcomm or XM antenna screw mounting holes as shown. NOTE: The orientation of the 7781 Glass Cloth is not important for this repair. (h) Cut a repair section of AL016CXMC36 Bare Aluminum Mesh large enough to overlap the exposed lightning protection mesh on the fuselage exterior by a minimum of 1.0 inch on all sides. (i) Use Isopropyl Alcohol and a lint free cloth to thoroughly clean the exterior side of the fuselage that was sanded. Use the clean side of the lint free cloth for each wipe until the area is thoroughly clean of all contaminants. NOTE: Jeffco has a very short pot life of approximately 15 minutes. Steps 2.G.(2)(j) through 2.G.(2)(p) must be accomplished within that 15 minute time period, before the resin sets up and is no longer workable. Ensure that the caul sheets and repair plies are cut out, test fitted, and ready to go before the resin packets are opened and mixed. (j) Mix the contents of one Jeffco Pack 5 resin kit together. Reserve 1 fl oz of mixed resin (without filler) to use in the following steps for wetting out the repair plies and the fuselage surfaces. Pour 4 fl oz of the mixed resin into a container and combine with one Mixed Filler 6.4 dry filler pack. Thoroughly mix the resin and fillers together to create an adhesive paste. MK400-34-01 March 9, 2009 Page 14 (k) Prepare the 7781 Glass Cloth and AL016CXMC36 Bare Aluminum Mesh plies by wetting out with a portion of the 1 fl oz of Jeffco resin. Fiber content should be from 54% to 62% by weight. (l) Lightly wet surface prepared region of the exterior fuselage skin using the remaining reserved mixed Jeffco resin. (m) On the exterior side of the fuselage, lay-up the single repair ply of 7781 Glass Cloth, and make sure that it extends a minimum of 0.5 inch beyond all sides of the old antenna holes to be patched. (n) On the exterior side of the fuselage repair, place the ALO16CXMC36 Bare Aluminum Mesh repair piece over the 7781 Glass Cloth repair ply. Make sure that the mesh repair piece overlaps the exposed lightning protection mesh on the fuselage by a minimum of 1.0 inch on all sides. (o) Apply the following materials over the interior fuselage repair ply in this order: Polyester Peel Ply Release Fabric, Perforated Release Film, Breather Cloth, and Bagging Film. (p) To maintain the external fuselage contour, apply a sand bag to the exterior of the fuselage, which covers the entire repair area. (q) Allow the exterior repair ply to pre-cure for at least three hours at room temperature not less than 77° Fahrenheit. CAUTION: If the room temperature is below 77° Fahrenheit, then shop heaters or heat lamps may be placed in the room nearby to raise the ambient temperature to at least 77° Fahrenheit, but should not be placed in close proximity to the repair area. Excessive external heat applied to the repair area during the pre-cure could cause the resin to exotherm (become extremely hot and possibly cause a fire). (r) (Table 1.) After the minimum three hour pre-cure is completed, perform the final cure of the interior glass repair ply, the adhesive paste, and the exterior glass and mesh repair plies at 77° Fahrenheit for seven days or at 212° Fahrenheit for two hours. Use Table 1 for other time and temperature options. NOTE: To save time, the final cure of the repair area may be performed simultaneous with the final cure of the Antenna Wedge Block Installation, at the end of Step 2.H. MK400-34-01 March 9, 2009 Page 15 TABLE 1 Cure Temperature (F°) 77 87 97 107 117 127 137 147 157 167 177 187 197 207 217 Cure Time (Hours) 168.0 76.0 40.0 24.0 16.0 11.0 8.0 6.1 4.8 4.0 3.3 2.8 2.4 2.1 1.9 Cure Times for Jeffco Resin and Filler Mix Adhesives. H. (Figures 9, 10, and 11.) Install the Antenna Wedge Block as follows: NOTE: The installation of the Garmin GA 35 GPS/WAAS (GPS 1) Antenna, which will be mounted above the baggage door on top of the fuselage, requires the installation of a 14° wedge block (LB53404405 or LB53404406, as supplied). The purpose of this block is to level the antenna with respect to the horizon during flight, so that the GPS / WAAS antenna has a good angle of view of the satellites. (1) Make sure that the interior of the airplane is covered with plastic or similar material to avoid damage to the upholstery. (2) (Figure 13 and 14) Use masking tape to mask off the top of the fuselage as shown. (3) (Figure 16.) Locate the two air-conditioning duct brackets on the interior side of the fuselage at approximately FS 185.5. NOTE: If an Orbcomm or XM antenna repair was performed earlier in these instructions, the aft air-conditioning duct bracket was removed at that time and will be reinstalled in later steps. (4) (Figures 9 and 16.) On the centerline of the interior side of the fuselage, locate and mark the center between the forward and aft air conditioning duct brackets for the antenna connector hole. The location of this hole will be at approximately FS 185.5. (5) (Figure 16.) From the fuselage interior, use a #40 (0.098 inch) size drill bit and drill a pilot hole between the two air-conditioning duct brackets as marked in the previous step. If the aft MK400-34-01 March 9, 2009 Page 16 air conditioning bracket was removed, use the marked position of the aft A/C bracket as the reference for centering the hole. (6) (Figures 9, 14, and 16.) Drill a 1.25 inch hole through the top of the fuselage at the location where the #40 (0.098 inch) pilot hole was drilled. (7) (Figures 9 and 15.) Drill a #13 ( 0.184 inch) hole approximately 1.8 inches aft of the 1.25 inch hole, on the fuselage centerline. (8) (Figures 13, 14, and 19.) Temporarily position the wedge block on top of the 1.25 inch holes that was drilled and mark a footprint outline around the base of the wedge block onto the masking tape. NOTE: Position the antenna wedge block slightly forward, so that the 1.25 inch hole in the fuselage is aligned towards the aft side of the larger opening in the wedge block, for clearance of the TNC connector. Refer to Figure 19 for an example of proper wedge offset. (9) Remove the wedge block and carefully cut through the tape along the footprint of the wedge block with a razor blade or utility type knife. Do not damage the lightning protection mesh underneath the paint. (10) (Figure 15.) Remove the tape from the footprint area of the antenna only, leaving the surrounding area masked off. (11) (Figures 17 and 18.) Use a Scotch-Brite sanding disk attached to a rotary tool or manually hand sand and remove the paint and primer of the footprint area until at least 90% of the metallic lightning protection mesh in the footprint area is exposed. Do not sand into or through the metallic lightning protection mesh. The mesh layer is very thin and extreme care must be taken to sand only until the bare metal of the mesh is exposed. The exposed mesh should have a glossy sheen to it when completed. Be particularly careful not to damage or remove the mesh around the smaller hole, as this will be used later for grounding the antenna. Minor damage to the mesh is acceptable only as long as it does not exceed 10% of the surface area of the footprint. See Figure 18 for an example of the completed sanding job. (12) Using 80–120 grit paper or equivalent sanding material, surface prep (scuff) the mating face of the antenna wedge block that will be mounted against the skin of the fuselage. NOTE: The fuselage mating surface of the wedge block does not have the Heli-Coil inserts visible. (13) Clean all the dust and debris away from the sanded areas. Use Isopropyl Alcohol and a rag to thoroughly clean the surface prepared areas. (14) To prevent accidental contamination of nearby fuselage surfaces with resin while bonding the antenna wedge block in place, leave the original masking tape in place and apply additional masking tape to protect the larger area around the antenna wedge block mounting point. (15) (Figure 19.) Use a 1.0 inch diameter piece of masking tape to mask off the lightning mesh around the #13 (0.185 inch) size drilled antenna ground hole. The masking tape will prevent bonding resin from contaminating the exposed lightning protection mesh. The tape will be removed once the wedge is bonded onto the fuselage and the resin has cured. MK400-34-01 March 9, 2009 Page 17 (16) Mix the contents of one Jeffco Pack 5 resin kit together. Reserve 1 fl oz of mixed resin (without filler) to use in the following step for wetting out the mating surfaces of the wedge and fuselage. Pour 4 fl oz of the mixed resin into a container and add one Mixed Filler 6.4 dry filler pack. Thoroughly mix the resin and fillers together to create an adhesive paste. (17) Wet out the mating surfaces of the wedge and fuselage with the mixed resin without fillers that was reserved in the previous step. (18) Apply the Jeffco and Filler Mix adhesive paste to the antenna wedge block. There should be enough Jeffco and Filler Mix adhesive paste between the antenna wedge block and the fuselage to completely fill the gap between the two components. When applying the Jeffco and Filler Mix Adhesive paste to the antenna wedge block, tamp the paste down with a stir stick or spatula to help prevent voids in the Jeffco and Filler Mix adhesive once the antenna wedge block is positioned in place on the fuselage. (19) (Figures 10 and 19.) Mount the antenna wedge block onto the fuselage as shown. (20) (Figure 19.) Allow the Jeffco and Filler Mix adhesive paste to squeeze out as shown. Make sure that the wedge is aligned in the same position where it was marked at and that the wedge centerline is aligned with the fuselage centerline. NOTE: In order to maintain clearance of the TNC connector, position the antenna wedge block slightly forward so that the 1.25 inch hole in the fuselage is aligned towards the aft side of the larger opening in the wedge block. Refer to Figure 19. (21) Firmly hold the wedge block in place – use a second person if required. Use a wooden stir stick or a small piece of plastic to remove the excess paste, creating a radiused fillet around the outside of the base of the wedge. (22) Gently clean all excess Jeffco and Filler Mix Adhesive from in and around the antenna wedge block using a clean, lint free cloth moistened with isopropyl alcohol. (23) Recheck the wedge position and securely tape the wedge block down in several directions across the top of the fuselage to prevent any movement of the block during the cure cycle. NOTE: Make sure that the masking tape that is on the fuselage is not between the fuselage and the antenna wedge block. Remove the tape as required. (24) Apply a small weight of 1 to 2 pounds to the top of the antenna wedge block. (a) Allow the antenna wedge block installation to pre-cure for at least three hours at room temperature not less than 77° Fahrenheit. NOTE: If the room temperature is below 77° Fahrenheit, then shop heaters or heat lamps may be placed in the room nearby to raise the ambient temperature to at least 77° Fahrenheit, but should not be placed in close proximity to the repair area. Excessive external heat applied to the repair area during the pre-cure could cause the resin to exotherm (become extremely hot and possibly cause a fire). (25) After the minimum three hour pre-cure is completed, perform the final cure of the adhesive on the wedge block at 77° Fahrenheit for seven days or at 212° Fahrenheit for two hours. Use Table 1 for other time and temperature options. (26) Once fully cured, remove the weight, the circular tape over the small hole, and all other protective tape and material. MK400-34-01 March 9, 2009 Page 18 I. Install the new GPS 1 Coax Cable as follows: (1) (Figures 2 and 4). Crimp a 225395-6 BNC connector to one end of the 238.0 inch long section of RG 400 coax cable. Label this end of the coax cable, identifying it as GPS 1. Connect this end of the coax cable to the GPS connector position on the back of the GPS 1 radio tray. (2) (Figure 1.) Route the coax cable along with the existing wire bundles, along the right side of the instrument panel and above the right control stick grip. Continue routing the RG-400 coax cable with existing wire bundles along the right side of the fuselage, then up the right aft side of the door frame to the center of the overhead, and then aft along the center overhead area to the GA35 antenna. (3) (Figure 3.) Use TY242M tie-wraps as necessary to secure the coax cable to existing wire bundles. NOTE: Make sure that the coax cable is securely fastened up and away from the right control stick grip linkage, and that the control stick has free and clear movement in all directions once the RG-400 coax cable is installed. (4) Install the CTM-2 Tie Blocks anywhere as necessary to keep the RG-400 coax cable secure. They should be placed 6-8 inches apart. Mark the areas where the CTM-2 Tie-Blocks will be placed. Use 80-120 grit sand paper to surface prep the areas on the fuselage where the CTM-2 Tie-blocks will be located. Use 80-120 grit sand paper to surface prep the base of the CTM-2 Tie-block. (5) (For airplanes that were equipped with the optional Orbcomm or XM antenna mounted on the fuselage exterior only.) Use 80-120 grit sand paper to surface prepare the area on the fuselage where the aft air conditioning support bracket was removed, and on the base of the aft air-conditioning bracket. (6) Clean the surface prepared areas with a clean lint-free rag and Isopropyl Alcohol. (7) Use 14340V86 Devcon Plastic Welder II, 14285V86 Mark 5 Mix Nozzles, and 14280V86 Devcon Application Gun to secure the CTM-2 Tie Blocks to the fuselage. (8) Use 14340V86 Devcon Plastic Welder II adhesive to bond the aft air-conditioning support bracket back in its original marked position. (9) Tape the CTM-2 Tie-blocks and the aft air-conditioning support bracket (if applicable) in place until the 14340V86 Devcon Plastic Welder II adhesive cures. Remove the tape after the adhesive is cured. Allow to cure for at least 30 minutes. (10) (Figures 2 and 4.) Using one 31-2381 90° TNC Connector, install the connector onto the antenna end of the GPS 1 coax cable. Label this end of the coax cable as GPS 1. (11) (Figure 3.) Use TY242M tie-wraps as necessary to secure the coax cable to existing wire bundles and to the CTM-2 Wire Tie Blocks. Make a service loop with the remaining length of RG400 coax cable near the GA35 antenna. MK400-34-01 March 9, 2009 Page 19 J. Mount the GA 35 GPS 1 Antenna as follows: (1) (Figure 10.) Use 005-010-MLS Stabilant 22 Contact Enhancer to treat the exposed area of the exterior fuselage Lightning Protection Mesh inside the aft hole of the wedge block. Treat the terminal ends of the LB53404415 Ground Braid Assembly and treat the hardware that will be used to mount the Ground Braid. Treat the face area of the GA 35 antenna that is located around the forward RH mounting hole. NOTE: 005-010-MLS Stabilant 22 Electrical Contact Enhancer is to be added to terminated connections to enhance conductivity. Ensure the terminals are clean before applying Stabilant 22. Stabilant 22 (005-010-015 or 005-010-MLS) can be applied in concentrated or diluted form. To dilute, mix 15 ml of Stabilant 22 (005-010-015) with 3.75 ml of Isopropanol 99%, or 4 parts Stabilant 22 to 1 part Isopropanol, in a sealable container (e.g. a touch up paint container). Apply concentrated or diluted Stabilant 22 on the terminals of connectors by coating each terminal. The supplied brush, or similar, can be used for application. Ensure connectors and receptacles are free from moisture. If necessary, dry the connectors using a heat gun. (2) (Figure 10.) Install the LB53404415 Ground Braid Assembly. Using MS51957-51 or MS51596-49 Screws (use whichever one will give at least two threads protrusion through the nut on the other side), AN970-3 Large area washer, NAS1149FN832P #8 Washer, and MS21083C08 Self Locking Nut, attach the components as shown. Make sure that the AN970-3 Large Area Washer has metal to metal contact with the lightning protection mesh at the small hole. (3) (Figures 10, 19.) The opposite end of the LB53404415 Ground Braid Assembly will be mounted in the spot-face area at the forward right corner of the antenna wedge block assembly. First install the 91802A197 screw through the forward RH mounting hole of the GA 35 antenna. Place the ring terminal end of the ground strap onto the screw, and place the GA 35 antenna onto the antenna wedge block. (4) Use an ohm meter to check the resistance between the GA 35 antenna base and the Lightning Protection Mesh on the fuselage of the airplane. The total resistance should be less than 25 milliohms. (5) Mount the GA 35 antenna to the antenna wedge block using the remaining three 91802A197 screws. NOTE: Torque the screws 17- 21 in/lbs. Do not over torque, as damage may occur to the antenna wedge block. (6) Apply a thin bead of the RTV-162 (white) over the head of the four mounting screws of the GA 35 antenna. Do not apply excessive amounts of RTV-162. Smooth out the RTV-162 when finished. (7) Mask off any areas where the RTV is not to be used, and apply a thin bead of RTV-162 around the perimeter of the seam of the GA 35 antenna and the antenna wedge block. Allow the RTV-162 to cure and then remove the masking tape. (8) Mask off any areas where the RTV should not be applied, and apply a thin bead of RTV-162 silicone around the base of the antenna wedge block and the fuselage skin. (9) Use a wooden stir stick or a plastic handle to create a radiused fillet in the RTV-162 around the base of the Antenna Wedge Block. Apply enough RTV to cover up the residue from the bonding paste. Allow the RTV-162 to cure and remove any masking tape. MK400-34-01 March 9, 2009 Page 20 (10) Route the TNC connector on the GPS 1 coax cable through the hole in the fuselage and connect it to the GA35 antenna. NOTE: A long needle nose plier may be required to turn the threaded TNC barrel nut onto the connector of the GA 35 antenna. K. Cosmetic finish, prime, and paint the repaired Orbcomm or XM antenna patch as follows: NOTE: If desired, this step may be performed after all other work on the airplane is completed. However the patch repair should not be exposed to direct sunlight until the airplane has been properly primed or painted. (1) Apply Evercoat Rage Extreme Body Filler to the area affected by the optional Orbcomm or externally mounted XM antenna repair, the old antenna holes, and the area surrounding the antenna wedge block as needed to fill in any gaps or low spots in the repair area. Use a minimum amount of the Evercoat Rage Extreme Body Filler to maintain a desired finish. (Refer to Chapter 51 of the Airplane Maintenance Manual.) (2) Prime and paint the repair area as needed. (Refer to Chapter 51 of the Airplane Maintenance Manual.) L. Reassemble the airplane as follows: (1) Inspect for security of the installations, cables, and wiring, and inspect all the areas of the airplane for FOD. Ensure that no cables or wiring interfere with the free movement of the flight controls. (2) Vacuum out all the compartments of the airplane that were opened. (3) Reinstall the ELT mounting bracket using the original hardware. (4) Reinstall the ELT onto the mounting bracket and secure in place using the latch assembly on the mounting bracket. Reconnect the BNC connector and the remote switch connector on the ELT unit. Place the ELT switch back to the ARM position. (5) Inspect the baggage compartment and avionics bay areas for FOD. Install the avionics bay access cover located in the floor. (6) Inspect the antenna shelf and the ELT area for FOD. Install the ELT access panel located on the aft bulkhead. (7) Inspect the pitch servo access compartment for FOD. Reinstall the pitch servo access panel located on floor of the aft baggage shelf. If equipped with the air-conditioning evaporator, make sure the screws at the leading edge of the access cover are attached into the nutplates on top of the evaporator assembly. (8) If equipped, reinstall the air-conditioning evaporator cover located in the baggage compartment area. (9) If performing the Avidyne Release 7 upgrade at this time, go to Step 3. If not performing the Avidyne Release 7 upgrade at this time, go to step 2.L.(10). MK400-34-01 March 9, 2009 Page 21 (10) Reinstall the Avidyne EX5000 MFD into right side of the instrument panel, and connect the P530 connector. (11) Install the Avidyne EXP5000 PFD, connecting the 3 electrical connectors on the back. Connect the quick-connect fittings of the pitot and static lines on the back of the PFD. NOTE: Connect the blue pitot tube to the top fitting on the back of the PFD and connect the clear static tube to the lower quick connect fitting on the back of the PFD. (12) Tighten the four locking mechanisms for the Avidyne PFD and the MFD. (13) If performing the Garmin GNS 430W upgrade at this time, go to Step 4), If not performing the Garmin GNS 430W upgrade at this time, go to Step 2.L.(14). (14) Install the two Garmin GNS 430W GPS/WAAS Navigation units in the radio trays. (15) Install the glare shield assembly. Connect the lighting wires at the 3 pin Molex connector and attach to the glare shield. Make sure that the front edge of the glare shield is properly secured into the three clips near the defroster vent and attach the three screws into the mounting arms above the instrument panel. (16) (For the Model 400 airplanes only.) If not previously performed: Install and reconnect both the left and right batteries at this stage, before proceeding with the remaining steps. Install the battery box cover. Refer to step 2.L.(31) below. (17) Install the padded carpeting in the aft baggage shelf. Reinstall the aft interior cushion on the aft bulkhead. (18) Reinstall the baggage netting that divides the baggage compartment from the aft baggage shelf. Tighten the two bolts that secure this net into the floor. Secure any loose edges of the padded carpeting underneath the edge of the oxygen fill port surround. (19) Reinstall the cargo net on the floor of the forward baggage area. (20) Install the aft overhead upholstered console. (21) Install the right crew upholstered door surround panel on the right crew door frame. (22) Reinstall the forward overhead console assembly. (23) (For Model 400 airplanes only.) Reconnect the oxygen hose and reconnect any oxygen bonding straps that were disconnected when the forward overhead console assembly was removed. (Refer to the 400 AMM) (24) Reconnect all the overhead wire harnesses and connect the compass lighting wire when installing the forward overhead. (25) Reinstall all the interior upholstery panels along the right side of the airplane, including the front section surrounding the stick grip, the aft section near the passenger’s seat, and the elevator push tube cover along the right side in the baggage compartment. (26) Reinstall the right door tread and hardware. (27) Install the right front seat assembly. MK400-34-01 March 9, 2009 Page 22 (28) There are two square washer plates that are mounted between the rear seat back bar and the fuselage attach points (except on some early serial number airplanes). Place the square washer plates in position. Reinstall the rear seat back bar over the square washers, then place the snap pins in their positions on the outboard ends of the bar. (29) Reinstall the rear sear backs and their associated snap pins into the seat back bar. (30) Reinstall the rear passenger seat backs and bottom seat cushions. (31) Reconnect the airplane batteries and airplane electrical power. (a) Remove the maintenance warning tags from the batteries and the ground power receptacle. (b) Reconnect both the left and right airplane batteries to the electrical system. (Refer to the appropriate 350/400 AMM for further details.) NOTE: Be careful that both batteries are connected to the proper polarity cables. (c) Reinstall the battery cover access panel. (32) Go to Step 5 and perform the Operational Checkout and Return to Service procedures. 3. Perform the Avidyne EXP5000 Primary Flight Display (PFD) and EX5000 Multi-Function Display (MFD) Release 7 upgrades as follows: NOTE: If available, the technician should reference the instructions contained in the Avidyne Reference Documents. NOTE: The installer may sign off the ‘Avidyne PFD and MFD Release 7 Upgrades’ section of this document separately from the remaining Sections of this document. A. If not previously removed, remove the Avidyne EXP5000 PFD from the airplane and return the unit to the Avidyne factory for the required hardware and software upgrades. NOTE: The return of the PFD to the Avidyne Factory must be scheduled and coordinated through an authorized Avidyne Service Center in advance. Contact Avidyne Product Support at Telephone (888) 723-7592, or Fax (781) 402-7599 for more information. There may be a substantial lead time for scheduling this upgrade and the turn around time required for Avidyne to perform the Release 7 upgrades. Plan accordingly. NOTE: The Avidyne EX5000 MFD does not need to be returned to the Avidyne factory for upgrades. B. Following completion of the EXP5000 PFD upgrades by the Avidyne factory, install the PFD in the airplane as follows: (1) Install the Avidyne EXP5000 PFD, connecting the 3 electrical connectors on the back. Connect the quick-connect fittings of the pitot and static lines on the back of the PFD. NOTE: Connect the blue pitot tube, to the top fitting on the back of the PFD, and connect the clear static tube to the lower quick connect fitting to the back of the PFD. (2) Tighten the four locking mechanisms for the Avidyne PFD. MK400-34-01 March 9, 2009 Page 23 (3) Install the Avidyne EX5000 MFD into the right side of the instrument panel and connect the P530 connector. (4) Tighten the four locking mechanisms for the Avidyne MFD. C. Perform the Avidyne EXP5000 PFD configuration as follows: (1) Ensure that the batteries have been reconnected and the airplane power is restored. (2) Make sure that all circuit breakers are engaged. (3) Connect the appropriate 14 or 28 Volt Ground Power Source to the airplane and then turn on the Ground Power. (4) Put the Left and Right Battery Master Switches to the ON position. Put the Crosstie Switch to the ON position. (5) The PFD should begin powering up. The system will begin its normal start up sequence. (6) Access the System pages of the PFD to configure the unit for airplane specific settings. To access the System Pages: (a) Simultaneously press and hold the top left button (L1), and the third button down from top left (L3), until the countdown timer in the lower left corner of the display indicates zero. The System Page is displayed when the timer reaches zero. NOTE: The ON/OFF switches on the Garmin GNS430W units must be set to the OFF position, or the Avionics Master switch must be set to OFF, to successfully access the System pages on the PFD. (7) The tabs at the bottom of the page indicate the available System Setup and Information Pages, which can be accessed by turning the left knob. The tab for the current page is highlighted with a green border. (8) (Table 2.) Operate the controls on the PFD to navigate through the tabbed pages across the bottom of the screen. Each tab represents a page of configurable settings that must be properly configured for the unit to function correctly. Refer to the table and set the configurable items in the PFD to match the settings and values listed in the table. Make sure that all the settings have been updated correctly. For additional specific information on configuring each page, the technician must refer to the Avidyne Entegra PFD Installation Manual. (9) Following completion of the configuration setup, save the configuration settings. Press the soft key labeled ‘Back to PFD”. The PFD will revert back to the Main PFD Flight screen. (10) Remove power from the unit by pulling the Left PFD and Right PFD circuit breakers. Allow the unit to remain off for one minute, then close both the PFD circuit breakers to power the unit back up. Allow the PFD to initialize. D. Following completion of the Avidyne EXP5000 PFD upgrades, upgrade the Avidyne EX5000 MFD as follows: MK400-34-01 March 9, 2009 Page 24 NOTE: Avidyne will send the PFD back with a kit, which contains the necessary elements to perform a field upgrade of the EX5000 MFD software. The kit contains a utility for doing a Save and Restore of the configuration settings, a software card in CF format to upgrade the operating software, a USB Flash Drive for doing the Save and Restore operation, a revised Avidyne Release 7 Pilot’s Guide for the Entegra EX5000 MFD, and Avidyne Service Bulletin number 60100004-077 or 601-00004-78 for performing the Release 7 software upgrade for the EX5000 MFD. NOTE: In order to install the upgrades to the Avidyne EX5000 MFD, airplane electrical power must be able to be applied to the avionics bus and the MFD during the installation of the Release 7 software upgrades. The power to the MFD will need to be cycled on and off several times during the course of the procedure. The MFD will need to be removed from the instrument panel mounts during the installation of the Release 7 upgrades and should remain connected to the P530 connector during the procedure. If the Release 7 upgrades are being performed by a Service Center which has the proper equipment to power the EX5000 MFD on a test bench, then this note does not apply. The installer should follow the instructions supplied with Avidyne Service Bulletins 601-00004-077 or 601-00004-078 for specific procedures on upgrading the EX5000 MFD to Release 7 software. (1) Loosen the four mounting screws on the Avidyne MFD and remove the unit only far enough to access the small cover plate with four screws on top of the unit. Do not disconnect the P530 electrical connector. (2) Ensure that the batteries have been reconnected and the airplane power is restored. Connect the appropriate 14 or 28 Volt Ground Power Source to the airplane, then turn on the Ground Power. (3) Make sure that all circuit breakers are engaged. (4) Put the Left and Right Battery Master Switches to the ON position. Put the Crosstie Switch to the ON position. To cycle power to the MFD as described in the Avidyne Instructions below, put the Avionics Master Switch in the On or Off positions as required. (5) Follow the Specific instructions supplied with Avidyne Service Bulletins 601-00004077 or 601-00004-078 to perform the field upgrade of the MFD to Release 7 software. (6) Install the Avidyne EX5000 MFD into right side of the instrument panel. Tighten the four locking mechanisms for the Avidyne MFD. E. Following completion of the Avidyne EX5000 MFD Release 7 upgrades, perform a final configuration and check of the Avidyne EX5000 Multi-Function Display configuration options as follows: NOTE: Even after restoring the original configuration settings of the MFD with the Save and Restore utility that was part of the Release 7 Software upgrade kit, the installer should still proceed with the steps below to verify that all the settings are correct. The Save and Restore captures most of the settings, but does not capture all the settings in the MFD. Pay particular attention to the settings for the XM Radio, Engine Instruments, and the Checklist options. Make sure that these settings are double checked per the steps below. Make corrections in the configuration to any settings that do not match those shown in Tables 3 and 4. (1) If not already done, connect the appropriate 14 or 28 Volt Ground Power Source to the airplane, then turn on the Ground Power. MK400-34-01 March 9, 2009 Page 25 (2) Put the Left and Right Battery Master Switches to the ON position. Put the Crosstie Switch to the ON position. (3) Put the Avionics Master switch to the ON position. NOTE: To support the different sensor options available on the Model 350 and 400, the installer must configure the EX5000 MFD for the correct installed options and select the correct port configuration. Table 3 lists sensor options and their associated port configurations. The installer must determine the applicable airplane configuration. (4) To access the MFD maintenance configuration pages, proceed as follows: (a) The MFD will begin its normal start up sequence. Press any button when prompted with “Press any bezel key to continue.” (b) Rotate the left knob clockwise until the AUX page at the bottom of the screen is displayed. (c) Simultaneously press and hold buttons L1 (top left) and L3 (3rd down on the left) until the blue Maintenance Mode Page displays. (d) The MFD Maintenance Mode page contains sub-configuration pages for each available EX5000 feature option. On each of the sub-configuration pages, the following controls are used to change the available configuration options: Select Knob – (Left Knob) Rotate to change the highlighted parameter box. Change Knob – (Right Knob) Rotate to select a parameter to modify from the highlighted box. Save – (Soft Key) Stores any setup changes made since entering the page and return to the Maintenance Mode Main page. Cancel – (Soft Key) Return to the Maintenance Mode Main page without saving changes. NOTE: (Tables 3 and 4.) On the main maintenance configuration pages of the MFD, there will be soft keys that represent a page of configurable settings that must be properly configured for the unit to function correctly. After making configuration changes, check that all the settings have been updated correctly. For additional specific information on configuring each page, refer to the Avidyne Entegra EX5000 MFD Installation Manual. (5) (Table 3.) Operate the controls on the MFD to configure the settings and values for each configurable item to match the settings and values shown in Table 3. (6) (Table 4.) Determine the installed Transponder and Traffic configuration options for the specific airplane. Modify the Avidyne MFD configuration settings for the various installed Transponder and Traffic system options to match the appropriate values in Table 4. (7) After making changes to each setup page, press SAVE to save your changes and return to the main menu. Changes in the setup pages do not take effect until the MFD has been restarted. From the Maintenance Mode Page, press RESTART SYSTEM. (8) If no changes were made, press BACK TO MAP to exit the Maintenance Mode. MK400-34-01 March 9, 2009 Page 26 (9) Put the Left and Right Battery Master Switches, Crosstie Switch, and the Avionics Master Switch in the OFF position. Make sure that all circuit breakers are engaged. (10) Turn off and disconnect the Ground Power Unit from the airplane. (11) If the Avidyne Release 7 upgrade was performed at the same time as the Antenna Wedge Block installation and Antenna Replacement, go to Step 2.L.(15), If the Avidyne Release 7 software upgrades was not performed at the same time as the Antenna Wedge Block installation, go to Step 4. MK400-34-01 March 9, 2009 Page 27 Avidyne PFD Airplane Specific Configuration settings MK400-34-01 March 9, 2009 Page 28 Avidyne MFD Airplane Specific Configuration Settings MK400-34-01 March 9, 2009 Page 29 Supplemental Configuration Changes for Installed Traffic / Transponder Options 4. Perform the Garmin GNS 430W WAAS GPS Navigation Unit Upgrade as follows: NOTE: Both of the Garmin GNS 430 GPS Navigator units need to be replaced with the Model GNS 430W WAAS GPS Navigation units. The upgrades to the new GNS 430W WAAS GPS Navigation units must be accomplished through a Garmin Authorized Service Center. The original units that are installed in the airplane will be sent to Garmin for a core credit, and Garmin will replace them with two GNS 430W GPS WAAS Navigator units. Contact a Garmin authorized Service Center to schedule and pre-arrange the replacement of the units. Contact Garmin at Telephone (800) 800-1020, or Fax (913) 397-8282 for additional information. Both GPS units must be upgraded so that all GPS equipment is at the same hardware and software levels. There will be a fee from Garmin to upgrade each of the units to GNS 430W models. NOTE: The technician performing the upgrade should reference all instructions contained in the Garmin Reference Documents listed at the beginning of these instructions. NOTE: The technician may sign off the Garmin GNS 430W Upgrades section of this modification kit separately from the remaining portions of this modification kit. See note at the beginning of this modification kit regarding authorized service facilities. MK400-34-01 March 9, 2009 Page 30 NOTE: If the Avidyne Release 7 Upgrade, the antenna wedge block installation and antenna replacement, and the Garmin GNS 430W WAAS GPS Navigation Unit upgrades were performed at separate times, the final maintenance facility that completes the last of the three tasks will be responsible for all the final post-installation testing, checkout, and return to service actions for the WAAS installation on the airplane. A. If not previously removed, remove the two GNS 430 units from the radio rack. Be sure to record the serial numbers of the old units. Return the units back to Garmin for a core credit. B. Record the serial numbers of the two new GNS 430W units and install the two new Garmin GNS 430W units into the radio tray. Use the locking mechanism to lock the units into the radio trays. C. The new GNS 430W units will come with two new data cards per unit. The data cards can generally be found in a red envelope contained with the paperwork package for each GNS 430W unit. Insert the Supplemental Terrain and Obstacle database cards into the right slots of the GNS 430W units. Insert the Jeppesen Aviation database cards into the left slots of the GNS 430W units. D. Perform the Initial Configuration Procedures for the Garmin GNS 430W #1 (top unit) and GNS 430W #2 (bottom unit) as follows: (1) Ensure the batteries have been reconnected. (2) Make sure that all circuit breakers are engaged. (3) Connect the appropriate 14 or 28 Volt Ground Power Unit to the airplane, then turn on the Ground Power Unit. (4) Put the Left and Right Battery Master Switches to the ON position. Put the Crosstie Switch to the ON position. (5) Ensure the Avionics Master switch is set to the OFF position. (6) Simultaneously press and hold the ENT keys on both the Garmin GNS430W units. While holding the ENT keys on both units, set the Avionics Master Switch to the ON position. (7) Release the ENT key when each display activates. (8) After the initial database pages appear, press the ENT key two times to enter the configuration pages. (9) The first page displayed is the MAIN ARINC 429 CONFIG page. (10) While in the configuration mode, make sure the cursor is off, and rotate the small right knob (CRSR) to change to the desired configuration pages. (11) To change data on the selected configuration page, press the small right knob (CRSR) to turn on the cursor. (12) Turn the large right knob to move the cursor between data fields. (13) Turn the large or small right knob as required to change a field that the cursor is highlighting. (14) Once you have made the desired selection, press the ENT key to accept the entry. MK400-34-01 March 9, 2009 Page 31 (15) Operate the controls on the GNS 430W #1 GPS unit to configure the unit to match the settings shown in the Table 5. (16) Operate the controls on the GNS 430W #2 GPS unit to configure the unit to match the settings shown in the Table 6. (17) Operate the controls on both GNS 430W units. Modify the configuration settings on both the GNS 430W units to match the configuration settings for the various installed Traffic and Transponder options shown in Table 4. NOTE: For configuration changes to take effect on the GNS430W units, the Cursor mode must first be exited in each configuration page before moving to the next page. The cursor mode can be exited by pressing the small CRSR knob on the right side of the display. After exiting the cursor mode and completing required configuration changes, the unit must be reset for the final changes to take effect. This is accomplished by powering the unit off and then back on. (18) Put the Left and Right Battery Master Switches, Crosstie Switch, and the Avionics Master Switch in the OFF position. Make sure that all circuit breakers are engaged. (19) Turn off and disconnect the Ground Power Unit from the airplane. (20) If the Garmin GNS 430W WAAS GPS Navigation Unit upgrade was performed at the same time as the Antenna Wedge Block Installation and Antenna Replacement, go to step 2.L.(15). If the Garmin GNS 430W WAAS GPS Navigation Unit upgrade was not performed at the same time as the Antenna Wedge Block installation and Antenna Replacement, go to step 5. MK400-34-01 March 9, 2009 Page 32 Garmin GNS 430W #1 – Airframe Specific Configuration Settings MK400-34-01 March 9, 2009 Page 33 Garmin GNS 430W #2 – Airframe Specific Configuration Settings MK400-34-01 March 9, 2009 Page 34 5. Perform the Operational Checkout and Return to Service procedures as follows: NOTE: The following ground checks and calibrations should be conducted by an appropriately qualified technician who is familiar with the basic functionality of the Garmin and Avidyne avionics and has familiarity with the operation of all the controls. It is beyond the scope of these instructions to provide training for detailed operation and testing of this equipment. The testing instructions provided here provide streamlined instructions for completing the Post Installation Testing of the WAAS upgrades on the Model 350 and 400 airplanes. For further detailed instructions on the operation and testing of this equipment, the technician should refer to the appropriate 350 or 400 AMM and the manufacturer’s operation or installation manuals for the specific Garmin or Avidyne avionics equipment. A. Pitot-Static Leak Check. (For airplanes in which only the PFD was removed.) Perform a pitotstatic leak check anytime the pitot-static ports are disconnected and then reconnected to the PFD. Perform the pitot-static leak check in accordance with the Model 350 or 400 AMM and FAR 91.411 PARA (a) (2). The maximum allowable leak rate for the static system is 100 FPM. NOTE: IRU Calibration. For the EXP5000 PFD units with Release 7 hardware and software upgrades, a post-installation IRU (Inertial Reference Unit) Calibration is not required as was required on earlier software versions of the PFD. B. Turn on the airplane power as follows: (1) Ensure the batteries have been reconnected and the airplane power is restored. (2) Make sure that all circuit breakers are engaged. (3) Connect the appropriate 14 or 28 Volt Ground Power Source to the airplane, then turn on the Ground Power. (4) Put the Left and Right Battery Master Switches to the ON position. Put the Crosstie Switch to the ON position. (5) Put the Avionics Master switch in the ON position. C. PFD Post Installation Check. (1) Pull the Left and Right PFD circuit breakers. Wait momentarily, then re-engage both the PFD circuit breakers. (2) When the splash screen comes up on the PFD during power up, a text box will appear inside the splash screen that indicates the airplane type and model. Make sure that the indication is ‘LC41-550-FG’ if the airplane is a Model 400 or ‘LC42-550-FG’ if the airplane is a model 350. Allow the PFD to continue powering up. NOTE: It is critical that this step be performed. The PFD must be configured for the proper airplane model. If the PFD is configured with the wrong model, incorrect airspeed and engine limitations will be displayed. MK400-34-01 March 9, 2009 Page 35 (3) Verify the accuracy and integrity of the Airspeed and Altitude information displayed on the PFD. Make sure that there are no red Xs displayed on the Airspeed, Altimeter, or VSI tapes on the PFD. D. (Table 7.) GPS Navigation Switching Integration Test. To begin the check, press the NAV button on the PFD until GPS1 displays. Check that the GNS-430W #1 CDI button displays ‘GPS.’ As you press the buttons listed in the sequence in the table below, check that the PFD - NAV button and the GNS-430W CDI button displays the expected values in the sequence indicated in the table. NOTE: Failure of the actions to display the expected result at the proper time is an indication that the PFD or GPS units are not properly configured. TABLE 7 ACTION Step/ Sequence 1 2 3 4 5 6 7 8 EXPECTED RESULT Unit - Button to Press PFD NAV GNS-430W #1 CDI GNS-430W #1 CDI PFD NAV PFD NAV GNS-430W #2 CDI GNS-430W #2 NAV PFD NAV Avidyne PFD NAV Button Indicates GNS 430W CDI Button Indicates GPS1 GPS VLOC1 VLOC GPS1 GPS VLOC1 VLOC GPS2 GPS VLOC2 VLOC GPS 2 GPS VLOC2 VLOC GNS 430W Unit Reference GNS430W #1 GNS430W #2 GPS Navigation Switching Integration Test E. Display of Self-Test Data. (1) Set the Avionics Master Switch to the OFF position. Wait 10 seconds. Set the Avionics Master switch to the ON position. (2) Power up the PFD, MFD, both GNS 430W units, the autopilot, and all other avionics in normal operating mode. (3) (Table 8.) Following normal power-up of the GNS 430W units. Press the ENT key once to display the ‘Instrument Panel Self-Test’ page. Do not press the ‘ENT’ button twice, or the Self-Test Page will be skipped. While the GNS430W unit is displaying the Instrument Panel Self-Test page, the unit will provide a stream of valid navigation data information, which is transmitted to the PFD, MFD, and autopilot. Observe that the parameters in Table 8 are correctly displayed on the PFD and MFD as applicable. MK400-34-01 March 9, 2009 Page 36 (4) On the MFD, turn the left knob until the cursor is set to the AUX page. Press the NAV SRC soft key on the left side of the screen until the selected GPS NAV SRC indicates ‘GPS 1’. Turn the left knob back to the MAP tab at the bottom of the screen. (5) Verify that the EX5000 MFD Waypoint data blocks displays the correct information based on Table 8, as applicable. (6) On the MFD, repeat steps 5.E.(1) through 5.E.(5) for the GPS 2, by selecting the GPS 2 as the NAV SRC on the MFD. (7) (Table 8.) PFD: With the GNS 430W units in the ‘Instrument Panel Self-Test’ page (Step 5.E.(3)) verify that the EXP5000 PFD displays the correct information shown in Table 8, as applicable. Press the NAV button on the PFD to toggle between the GPS 1 and GPS 2. In the NAV data blocks on the PFD and on the CDI / glide-slope displays on the PFD, observe that the self test parameters in Table 8 are correctly displayed where applicable. TABLE 8 Instrument CDI VDI HDI Annunciators Bearing to WPT (RMI) DTK Distance To Go Time To Go Active Waypoint Groundspeed Self-Test Value Half-scale left deflection, TO indicator Half-scale up Half-scale left MSG, WPT, GPS INTEG displayed on PFD. 135° 150° 10 NM 4 min. GARMN 150 Kts. Valid Data Self Test (8) Repeat the procedure in step 5.E.(7) for the GNS 430W #2, by selecting GPS2 as the NAV Source on the PFD NAV Button. (9) Heading/OAT: With the GNS 430W units in the ‘Instrument Panel Self-Test’ page or locked onto the satellites, and with the PFD showing valid heading information, observe that the heading shown on the map page of the MFD is the same as the heading displayed on the PFD. NOTE: In the absence of valid data from the PFD and GPS units, the MFD will display last known track information in the heading bar at the top of the MFD, rather than a valid heading. Make sure that it is actually heading, not track data, which is viewed at the top of the screen. The indicator triangle next to the heading bar on the MFD should change from a ‘T’ for track to an ‘H’ for heading after the GPS units acquire the satellites and the PFD is displaying valid data. (10) Make sure that the Outside Air Temperature (OAT) information that is displayed on the MFD is the same as the temperature information displayed on the PFD. MK400-34-01 March 9, 2009 Page 37 F. Bezel Lighting: Adjust the airplane Upper Panel Dimming bus rheostat. Verify that the MFD bezel and PFD Bezel lighting operation matches the operation of the rest of the upper panel cockpit instrument lighting. G. Engine Instrumentation: To test the engine instrumentation, turn the left knob on the MFD to the ENGINE tab at the bottom of the screen. The engine page will display. Verify that the ambient Manifold Pressure is correctly displayed, and that the page is displaying the correct voltages for the left and right buses. Observe that there are no engine instruments X’ed out. NOTE: On the Model 350 airplanes only, the engine instrument cluster should display 5 primary round instruments with no oil temperature shown. On the model 400 airplanes only, six round instruments should be displayed on the engine page with the oil temperature shown on the sixth instrument. H. Error Messages: Test to make sure that there are no failure messages displayed on the MFD, PFD, or either of the Garmin GNS 430W units. Some initial startup messages will inherently appear and must be acknowledged. Clear all initial messages before determining the validity of displayed error messages. I. ELT: Check the ELT remote switch function. Tune the VHF COM to 121.5 MHz, then briefly set the ELT remote switch located in the right knee bolster to the ON position. Listen through the cabin speaker or the headsets for 3 audible sweeps of the ELT and verify that the red light flashes on the remote switch. Immediately thereafter, turn the remote switch back to the ARM position. NOTE: Per FCC regulations, the ELT system should only be checked during the first five (5) minutes of the hour. J. GPS Signal Acquisition Check: (1) Turn on the GNS 430W units. Upon acknowledgement of the Instrument Panel Self-Test Page, press the ‘ENT’ button twice to access the Satellite Status Page. Verify that each GPS unit is displaying a number of satellites. The GPS Status should indicate “3D Differential’ for the type of Navigation quality the GPS is receiving and should ideally have 68 satellites in view. (2) If the unit is unable to acquire satellites, relocate the airplane away from any obstructions that might be shading GPS reception. If the reception does not improve, check the GPS antenna installations. NOTE: After installation of the GNS 430W, the initial acquisition of position can take up to 20 minutes. Subsequent acquisitions should not take more than 2 or 3 minutes. (3) On the position page, verify that the displayed latitude / longitude information agrees with a known reference position. K. Receiver / Transmitter Operation: Tune the #1 GNS 430W unit to a local VHF COM frequency, select COM 1 on the GMA 340 Audio panel. Verify the receiver output produces a clear and understandable audio output. Verify the transmitter functions properly by contacting another station and getting a report of reliable communications. Repeat the procedure for the #2 GNS 430W unit. MK400-34-01 March 9, 2009 Page 38 L. VHF COM Interference Check: (1) The following tests should be conducted with all installed avionics turned on. Once the Signal Acquisition Test has been completed successfully, test the COM 1 and COM 2 radios to make sure that the communication radio transmissions do not adversely interfere with the reception and performance of the GPS navigation systems, and that there is no harmful interference with the installed IFR avionics systems during radio transmissions. NOTE: The interference check must be completed on all IFR installations. (2) Enter a valid GPS waypoint into the flight plan of each GPS unit. (3) On each GNS 430W unit, view the Satellite Status Page and verify that at least 6-8 satellites have been acquired. (4) Verify that the GPS units are sending valid data to the HSI indication on the PFD, that there are no red Xs displayed on the HSI portion of the PFD, and that the CDI indication of the HSI is properly displayed when the NAV button on the PFD is selected to the GPS 1 or GPS 2 modes. (5) Select 121.150 MHz on the COM transceiver to be tested. Set the NAV button on the PFD to GPS 1. Set the Audio Panel to COM 1. (6) Transmit for a period of 30 seconds. (7) Verify that the GPS CDI indication on the PFD does not move or display any red Xs. (8) Repeat steps 5.L.(3) through 5.L.(7) for the following frequencies: • 121.150 MHz • 121.175 MHz • 121.200 MHz • 121.225 MHz • 121.250 MHz • 131.200 MHz • 131.225 MHz • 131.250 MHz • 131.275 MHz • 131.300 MHz • 131.325 MHz • 131.350 MHz (9) On the Audio Panel, Select COM 2 transmitter, set the NAV button on the PFD to indicate GPS 2, and repeat procedure 5.L. for the #2 COM transmitter. (10) If the GPS “NAV” flag repeatedly comes into view (red X on the HSI) during any of these tests, contact Cessna Customer Service at (316) 517-5800 or FAX (316) 517-7271 for assistance. M. Autopilot Ground Test and VHF Navigation Radio Checkout: NOTE: Refer to the airplane POH or the avionics equipment manufactures manuals for detailed procedures on the operation of the Garmin VHF navigation radios (GNS430W), the Avidyne PFD, and associated test equipment. (1) Turn the Autopilot Master switch, at the top of the instrument panel, to the OFF position. The message bar across the top of the PFD should indicate a message, which reads ‘Communication with the Autopilot has failed’. MK400-34-01 March 9, 2009 Page 39 (2) Set the Autopilot Master switch to the AP/FD position. The autopilot will enter a self test mode. The message bar at the top of the PFD should display all autopilot mode settings, which are simultaneously displayed on the autopilot computer. After the autopilot completes its self test, the autopilot and the PFD will indicate ‘AP RDY’. (3) Set the on/off switch on both GNS430W units to the OFF position, then back to ON. Press the ‘ENT’ button only once until the ‘Instrument Panel Self Test Page’ displays. Do not press the ENT button twice, or this step will be skipped. (4) On the face of the STEC 55X autopilot computer, press the NAV button twice to enter the GPSS mode. The GPSS annunciation should flash on the autopilot and the PFD. After a couple of seconds, the GPSS annunciation should quit flashing and remain on steady. (5) With the GPSS mode engaged on the autopilot, make sure that the autopilot engages in the roll mode. With the GPSS engaged, the pilot’s control stick should begin moving to the right for 5 seconds, then stop for approximately 5 seconds, and will continue to repeat this cycle. NOTE: The GNS430W units must be in the ‘Instrument Panel Self-Test Page’ and the GPSS annunciation on the Autopilot must be on steady for the GPSS self test mode to operate properly. (6) Press the ALT button on the autopilot computer. The stick should be engaged in the pitch mode and there should be no fore and aft movement of the control stick. (7) The Flight Director Command bars on the PFD should be visible and active. Observe that the Flight Director on the PFD is following the action of the control stick. (8) Press the AP DISC button on the control stick. The autopilot should disengage from the control sticks and an aural chime should sound, indicating that the autopilot has disconnected. (9) Press the HDG and ALT buttons on the autopilot and repeat 5.M.(8) using the AP DISC button on the right control stick. (10) Press the ENT button twice on each GNS 430W unit to cycle past the ‘Instrument Panel Self Test Page’. (11) Press the VS button on the PFD. Turn the control knobs to set the VS value on the PFD to +1000 fpm. (12) On the autopilot computer press the HDG button, then press the VS button. (13) The VS annunciation should appear on PFD. The flight director on the PFD should appear in a pitch up attitude and the control stick should engage in both the roll and pitch modes. The control stick should begin moving aft, indicating a pitch up command from the autopilot computer. Press the HDG BUG button on the PFD and operate the HDG BUG control knob on the PFD to positions left and right of the airplane heading. The flight director and the control stick should follow the left and right movement of the heading bug operation. (14) Press the HDG BUG control knob on the PFD to center the HDG BUG. The control stick should return to neutral. (15) Press the ALT PRE button on the PFD. Use the control knobs on the PFD to set the Altitude Pre-selector to an altitude that is at least 1000 ft higher than field elevation. MK400-34-01 March 9, 2009 Page 40 (16) On the Autopilot, press the HDG button, and then simultaneously press the ALT and VS buttons. The HDG, ALT, and VS modes should appear across the top of the PFD and the flight director and control stick should pitch up to follow the pitch commands from the Altitude Pre-selector function of the PFD. (17) Change the ALT PRE value on the PFD to a value that is 500 – 1000 feet less than the airport elevation. Then simultaneously press the ALT and VS buttons on the autopilot computer. The flight director and the control stick should move in a pitch down direction. (18) Turn the Autopilot Master switch to the FD ONLY position. The autopilot computer should remain on in the mode selected. The autopilot will disengage from the control sticks, a chime will sound, and the flight director command bars must remain present and in view on the PFD. NOTE: If not already accomplished, Cessna Service Letter SL-05-004B ‘Flight Director’, Steps 5-8, must be complied with on Cessna model 350 Airplane serial numbers 42002 through 42062 for this function to work properly. (19) Press the AP DISC button on the control stick to disconnect the autopilot. NOTE: The following steps test the operation of both the VHF navigation radios and the NAV coupling of the PFD to the autopilot computer. (20) Tune the NAV 1 radio to a frequency that is not an active local VOR station. Set the NAV button on the PFD to indicate VLOC 1. Press the NAV button on the autopilot once, until the autopilot mode annunciation indicates NAV. (21) Turn the OBS course selector knob on the PFD HSI until the NAV course pointer is centered on the airplane heading line on the HSI. The autopilot should be engaged in roll mode, and the control stick should remain nearly motionless. Turn the OBS knob on the PFD to positions left and right of the airplane heading. The control stick should follow the position of the OBS course pointer. (22) Press the AP DISC button on the pilot’s control stick. (23) Leave the Autopilot Master Switch in the AP/FD position. (24) Press the NAV button on the PFD to select VLOC 1 mode. Tune the NAV 1 VHF navigation radio to the appropriate VOR frequency to be used for testing. Press the NAV button on the autopilot computer. (25) Check the VOR reception with ground test equipment or a local VOR station. Make sure that the accuracy of the VOR displayed on the PFD CDI is within the limits of FAA Regulation 91.171. (26) Set the selected test radial on the test equipment to match the airplane heading. (27) Turn the OBS Course Selector knob on the PFD HSI to match the airplane heading. (28) The roll motion of the control stick should be nearly motionless when the CDI is centered at the selected course on the HSI and the selected course is set to the airplane heading. (29) Operate the test equipment to change the test radial 5-10 degrees left and right of the selected course. The autopilot (control stick) and the flight director should follow the tracking of the CDI. MK400-34-01 March 9, 2009 Page 41 (30) Verify the audio Ident and Morse code ID functions of each NAV radio. (31) Engage the autopilot computer in NAV and ALT modes. (32) Change the test equipment to the ILS or LOC/GS modes. Tune an ILS frequency to be used for testing on the NAV 1 radio. NOTE: When an ILS frequency is entered into the active window of the NAV 1 radio, the autopilot should automatically enter the APR mode, in addition to the NAV and ALT modes already selected. (33) Operate the controls of the test equipment to center the CDI needle left and right, then set the position of the VDI (glide-slope) needle to be in the full up position on the PFD. (34) After the VDI needle is in the full up position for more than 10 seconds, the GS annunciation on the autopilot computer should begin flashing. Slowly use the test equipment to position the VDI needle back to the center position. As the VDI comes back to center, the GS annunciation on the autopilot computer should come on steady and the ALT annunciation should extinguish. The autopilot will now begin tracking the glide slope indicator on the PFD. (35) Operate the localizer and glide slope controls on the test equipment. Make sure that the CDI, the VDI (glide slope), and the movement of the control stick and the flight director tracks the operation of the test equipment. (36) Repeat Steps 5.M.(20) through 5.M.(35) for the NAV 2 Radio. N. Ryan / Avidyne – TCAD / TAS Traffic System Interface Check: (For airplanes equipped with the Ryan TCAD 9900BX or Avidyne TAS 620 Traffic Advisory System only.) (1) Move the airplane outside and verify that the traffic system displays local traffic. The Ryan/Avidyne traffic systems should show traffic in the vicinity of the airport and in the appropriate quadrants on the PFD or GPS 2 displays. Refer to the Pilots Operating Handbook to determine proper operation of the different available Ryan or Avidyne traffic systems. (2) Make sure that local traffic is displayed on the Traffic pages of both the MFD and the #2 (lower) GNS 430W GPS unit. O. TIS Traffic Information System Check: (For airplanes equipped with a Garmin GTX330 Transponder only.) NOTE: Refer to the Pilots Operating Handbook for determining proper operation of the TIS traffic option. The TIS traffic system is only available if the airplane is equipped with a Garmin GTX 330 Mode S transponder, and service will only be available in select FAA approach radar coverage areas. For airplanes equipped with Garmin GTX 327 transponders, the TIS option is not available. (1) To test the TIS traffic option: select the Traffic page on the #1 (top) Garmin GNS 430W unit and turn on the GTX 330 transponder. If the airplane is located within a select radar coverage area, the available traffic will display on the traffic page of the #1 GNS 430W unit. If the airplane is outside the coverage area, the Traffic page on the #1 GNS 430W unit will display a message in the center of the screen which reads ‘NO TRFC AVAILABLE’. MK400-34-01 March 9, 2009 Page 42 NOTE: For airplanes equipped with both TIS and the 9900BX or TAS 620 systems, the #1 GNS 430W units is configured to display TIS traffic, and the # 2 GNS 430W unit and the MFD are configured to display TCAD/TAS type traffic. For airplanes which are equipped with a GTX 330 transponder and are NOT equipped with 9900BX or TAS 620 systems, the TIS traffic information should also be displayed on the Traffic page of the MFD and should be tested on the MFD in the same manner as on the GNS430W. P. Stormscope Interface Check: (For Model 350 airplanes with a L3 Communications WX-500 Stormscope installed only.) (1) Turn the left knob to the Lightning page on the Avidyne MFD. (2) Verify that LIGHTNING FAILED message is not displayed. NOTE: An initial Lighting Failed message may appear on the MFD after initial startup of the avionics. Clear any initial messages before determining the validity of subsequent failure messages. (3) Access the Lightning configuration page in the MFD maintenance mode pages as follows: (a) To access the MFD maintenance configuration pages, proceed as follows: (b) The MFD will begin its normal start up sequence. Press any button when prompted with “Press any bezel key to continue.” (c) Rotate the left knob clockwise until the AUX page at the bottom of the screen is displayed. (d) Simultaneously press and hold buttons L1 (top left) and L3 (3rd down on the left) for at least five seconds, until the blue Maintenance Mode Page displays. (e) Press the configuration soft key for the lightning page. (4) While in the Lightning configuration page on the MFD, press the ‘Lightning Strike Test’ softkey. (5) The MFD will switch to the MAP page and should display a single strike at the 15 mile range and 45 degrees relative bearing. Q. XM Weather Broadcast: (For airplanes equipped with the optional XM Weather system only.) The XM broadcast satellite network transmits signals that are received by an XM data-link receiver on the airplane. The information is displayed on the MFD. NOTE: For detailed information about the operation of the XM Weather Datalink system and information about XM customer account activation, see the Entegra EX5000 Pilot’s Guide. (1) Bring the airplane to an area on the ramp with as few obstacles to line-of-sight viewing of the southern horizon as possible. (2) Turn the left knob to select the Trip page on the MFD. Press the Display soft key until XM Broadcast (down-pointing arrow) Status page is selected. (a) The XM Broadcast Status page will display the 8-character XM Receiver ID. MK400-34-01 March 9, 2009 Page 43 (b) If the XM Service level reports anything other than ‘Aviator’, contact the airplane owner to have the account renewed at XM radio. Make a note of the Receiver ID for the airplane owner, who will need it when contacting XM Radio at (800) 985-9200 to reactivate the account. (c) If the Broadcast Receiver is working, and the airplane is in view of at least one XM satellite, the Signal Quality should be “Good”, or “Marginal”. If the Signal Quality is reported as “Weak”, or “None”, reposition the airplane as required. NOTE: After turning on the avionics systems in the airplane, it may take up to 30 minutes for all the blocks of valid XM data to be received and displayed. (3) Enter a destination waypoint such as ‘KRDM’ into the GPS, and turn to the Trip page on the MFD. Press the Display button on the trip page of the MFD to cycle through various XM valid data information such as METARS, TAF’s, WINDS ALOFT, etc. Make sure that valid data is displayed on these pages. (4) Make sure that the METAR (textual meteorological report) for the destination waypoint is displayed on the MFD and that the graphical weather data for en-route weather is displayed as an overlay on the map. R. Primary Flight Display (PFD) Magnetometer Calibration: NOTE: For calibrating the magnetometer function of the PFD, an approved handheld magnetic sight compass will be required. Two technicians are required for performing the procedure. One in the airplane to monitor procedure and push required line select keys on the PFD, and one handheld sight compass operator outside of the airplane to precisely align the airplane to each of 12 calibration points. Avidyne suggests using an approved compass rose for this procedure. (1) Make sure that the calibration procedure is done in a known magnetically clean area at least 200 feet from metal structures of any kind and not above areas that may have underground fuel tanks or steel rebar in the concrete ramp. Make sure the airplane doors are closed, flaps are in retracted position, and that the airplane is reasonably level. NOTE: If you stop the calibration process (for example: by exiting the Magnetometer Calibration Page or shutting off power to the PFD) before completion, you will lose the stored calibration parameters. You will need to restart the calibration process over from the beginning. (2) Make sure that all circuit breakers are engaged. (3) Put the Left and Right battery Master Switches to the ON position. (4) Put the Avionics Master switch to the OFF position. NOTE: Consider attaching an external power cart until ready to actually perform the calibration, unless you are performing this calibration with the engine running and alternators on. All other airplane equipment should be operating. NOTE: Leave the Avionics Master Switch in the OFF position while performing the magnetometer calibration to conserve battery power if the engine is not being operated while performing the magnetometer calibration. MK400-34-01 March 9, 2009 Page 44 (5) Allow the PFD to align for approximately 3 minutes, until the ADAHRS warm-up window disappears. Wait in the aligned state for an additional 5-10 minutes. (6) Simultaneously press and hold the top left button (L1) and the third button down from top left (L3), on the PFD, until the countdown timer in the lower left corner of the display indicates zero. The System Page is displayed when the timer reaches zero. NOTE: When accessing the System page on the PFD, both Garmin GNS430W units must be turned off. If the GNS430W units are in the ‘Instrument Panel Self Test Page,’ the PFD Maintenance Mode can not be accessed. (7) The tabs at the bottom of the page indicate the available System Pages, which you can access by turning the left knob. The tab for the current page is highlighted with a green border. (8) Scroll the left knob to the Calibration tab. Press the PERFORM MAG CAL button. A Magnetometer Calibration Page will display on the first line: “Align to 360° magnetic, then press calibrate heading.” (9) Manually move or taxi the airplane to each calibration point. The handheld sight compass operator outside of the airplane should sight each heading from about 20 feet in front of the airplane by aligning the sight on the handheld compass to the nose and up the vertical stabilizer for precise alignment at each of the 12 headings to be calibrated (every 30 degrees). Manually align or taxi the airplane such that the centerline of the airplane is on magnetic north (360° ± 1° or less) heading as indicated by the handheld sight compass operator. It is critical that you take the time you need to fine-tune each calibration point. (10) Follow the prompts on the Magnetometer Calibration Page. Align the centerline of the airplane on consecutive 30° headings (12 total calibration points) as indicated by the handheld sight compass operator, by manually repositioning or taxiing the airplane as required. At each of the alignment points, press the CALIBRATE HEADING button and wait until “DONE” displays. (11) Follow the directions of the Magnetometer Calibration Page until the procedure is complete. NOTE: If any of the 12 calibration points display FAILED, rather than DONE, press the REDO PREVIOUS button to “undo” the previous step and repeat the calibration point. (12) After the last heading point of 330° is calibrated, the PFD will display the following message: “Mag Cal Complete: Return to PFD. Cycle Power”. After this message appears, press the ‘Back to PFD.’ Button. NOTE: At the last heading calibration point (330°), it may take up to a minute for “Done” to display. (13) Wait approximately 30 seconds and then power down the PFD screen by pulling the Left PFD and Right PFD circuit breakers. Wait 30 seconds. (14) Reset both the left PFD and the right PFD circuit breakers. Wait for the PFD to completely initialize – approximately 3 minutes. (15) Align the centerline of the airplane with consecutive 90° headings (90, 180, 270, 360) as indicated by the handheld sight compass. Verify that the PFD heading display is within ± 4° of the handheld sight compass. The calibration is now complete. MK400-34-01 March 9, 2009 Page 45 S. Update the airplane Weight and Balance and Installed Equipment List records in the POH and the airplane maintenance records as according to Table 9: NOTE: The total weight change following all installations is less than 1.0 lbs, which is considered a negligible weight and balance change. DESCRIPTION REMOVED: TABLE 9 SERIAL NUMBER WEIGHT Garmin GA 56 GPS Antenna P/N 011-00134-00 0.36 Garmin GA 56 GPS Antenna P/N 011-00134-00 Garmin GNS 430 P/N 011-00280-00 Garmin GNS 430 P/N 011-00280-00 Subtotals ! 0.36 5.30 5.30 11.32 Orbcomm Weather (If installed on top of Cabin.) XM Weather Antenna, (If installed under Glare shield) XM Weather Antenna, (If installed under on top of Cabin) 0.52 Subtotals ! INSTALLED: Garmin GNS 430W P/N 011-00160-10 Garmin GNS 430W P/N 011-00160-10 Garmin GA 37 / GPS/WAAS, XM Antenna,01300245-00, Garmin GA 35 GPS/WAAS Antenna, 013-0023500. Subtotals ! ARM 226.4 0 226.4 0 79.00 79.00 188.0 0 MOMENT 81.50 81.50 418.70 418.70 1000.40 97.76 0.26 77.47 20.14 185.5 0.26 0 48.23 Add individual optional items to Removed Subtotal as required. 5.10 5.10 79.00 79.00 402.90 402.90 0.50 226.40 113.20 0.47 11.17 185.50 87.19 1006.19 Weight and Balance information T. Garmin GNS 430W Airplane Flight Manual Supplement (AFMS): (1) An Airplane Flight Manual Supplement (AFMS) for the Garmin GNS430W must be completed and included in the Supplements section of the Cessna 350 or 400 POH. (2) To obtain the required AFMS for the GNS430W units, contact Garmin or a Garmin Dealer, and request the latest version of the Garmin Airplane Flight Manual Supplement for the Garmin 400W Series GPS-WAAS Navigation System, Document 190-00356-03. (3) Several sections of the AFMS must be filled out manually with detailed information about the specific autopilot installation. These sections are listed below. The AFMS does not need further FAA approval. It should just be inserted in the Supplements section of the new POH once the entries below are made. MK400-34-01 March 9, 2009 Page 46 " " " Cover Page: Manually enter the Make, Model, Registration, and Serial Number of the airplane. Section 2.7 Autopilot Coupling: Mark the check box labeled “(a) No Limitations for Autopilot Coupling”. Section 4.3 Coupling the Autopilot during Approaches: Mark the check box labeled “(2) this installation supports a seamless transition from digital GPSS to Analog guidance for the autopilot…” U. The Cockpit Reference Guides (CRG) for the Garmin GNS 430W units and the Avidyne Release 7 Software for the PFD and the MFD will be included with the documentation that is returned with each of these units. Insert a copy of the CRG into the airplane and remove any earlier versions of these documents. V. Make a logbook entry in the airplane maintenance records indicating each installation upgrade that was performed in accordance with this Modification Kit for that particular procedure. Once all three installation upgrade procedures have been completed, a logbook entry can be made stating ‘Complete compliance has been accomplished in accordance with this Modification Kit. MK400-34-01 March 9, 2009 Page 47 Figure 1 - GA37 and GA35 Antenna Coax Routing MK400-34-01 March 9, 2009 Page 48 Figure 2 – Coax Cable Modifications Figure 3 - Tie Block Mounting Detail MK400-34-01 March 9, 2009 Page 49 Amphenol Number Connector Type Hex Crimp Data Stripping Dimensions, inches Cavity for Contact Cavity for Outer Ferrule a b 31-2373 TNC Plug .068 .213 .593 .250 31-2381 TNC Angle Plug .068 .213 .578 .328 c .15 6 .12 5 Step 1 - Strip cable jacket, braid, and dielectric to dimensions in table above. All cuts are to be sharp and square. Important: Do not nick braid, dielectric, and center conductor. Slide outer ferrule onto cable as shown. Figure 4 – Coax Connector Assembly Instructions (Sheet 1) MK400-34-01 March 9, 2009 Page 50 Step 2 - Flare slightly end of cable braid as shown to facilitate insertion of inner ferrule. Important: Do not comb out braid. Place contact on cable center conductor so that it butts against cable dielectric. Crimp contact in place using Die Set Cavity indicated in table above. Step 3 - Install cable assembly into body assembly so that inner ferrule portion slides under braid. Push cable assembly forward until contact snaps into place in insulator. Slide outer ferrule over braid and up against connector body. Crimp outer ferrule using Die Set Cavity in table above. Figure 4 – Coax Connector Assembly Instructions (Sheet 2) MK400-34-01 March 9, 2009 Page 51 Figure 5 - Antenna Box Modification MK400-34-01 March 9, 2009 Page 52 Figure 6 - Drill Template for Antenna Box MK400-34-01 March 9, 2009 Page 53 Figure 7 - GA 37 Antenna Installation MK400-34-01 March 9, 2009 Page 54 Figure 8 - GA 37 Orientation MK400-34-01 March 9, 2009 Page 55 Figure 9 - Wedge Location Detail MK400-34-01 March 9, 2009 Page 56 Figure 10 - Wedge block and GA35 Assembly Detail. MK400-34-01 March 9, 2009 Page 57 Figure 11 - Wedge block location reference. MK400-34-01 March 9, 2009 Page 58 Figure 12 – 14° Degree Wedge Block (molded wedge shown) Figure 14 – Footprint of Wedge Marked on Masking Figure 13 –Masked off, Foot print marked on masking. Figure 15 – Masking Removed only under Footprint. FIGURE 16 NOTE: The location of the brackets may vary. The connector hole may need to be repositioned slightly. Once the fore and aft position of the hole location is determined, the technician should mark the hole location on the inside of the fuselage, as close to the lateral centerline as possible. Drill the pilot hole from inside the fuselage. Figure 16 – Location of air-conditioning duct brackets and center connector hole as viewed from inside the fuselage. MK400-34-01 March 9, 2009 Be aware that the bond seam that connects the two fuselage halves together inside the cabin is not precisely the centerline of the airplane. It is acceptable to drill trough the concave areas of the bond seam if required. Page 59 Figure 17 – Removal of the paint, under the footprint to expose lightning mesh Figure 19 – Wedge Block bonded on with Jeffco Adhesive. Notice Adhesive Squeeze Figure 21 – Completed Installation of the GA 37 WAAS – XM Antenna MK400-34-01 March 9, 2009 Figure 18 - Appearance of mesh exposed down to bare metal with a glossy Figure 20 – Completed installation of the GA 35 WAAS Antenna and Wedge. Figure 22 – Previously installed Orbcomm or XM Antenna. Page 60 Figure 23 – Location of XM Antenna under glare shield. To be removed. Figure 24 – Detailed view of XM antenna location under glare shield. This antenna and hardware will be Figure 25 – Alternate LB53404406 Wedge Block Figure 26 – 7781 Glass Cloth Repair Ply Lay-ups MK400-34-01 March 9, 2009 Page 61 Figure 27 – Exterior Skin Fuselage Sanding Dimensions and Preparation for Repair. MK400-34-01 March 9, 2009 Page 62