March 31, 1978

AV78-6
SUBJECT: AUTOPILOT SYSTEM MALFUNCTION
AVIONICS APPLICABILITY: All 400B Autopilots and IFCS Systems
Installed in 1976 through 1978 Cessna
310, 340 and 400 Series Aircraft and
1977 and 1978 Model 210 Series Aircraft

(See REMARKS for specific aircraft)

The possibility exists that the pitch control actuator in 400B Autopilots
and IFCS systems in 210, 310, 340 and 400 Series Cessna aircraft, as well
as the roll actuator in the 210 aircraft, may fail to disengage when the
Autopilot disengage switch is actuated by the pilot.
The control force required by the pilot under this condition may be higher
than normal and although this additional force is not excessive, the condition
is undesirable.

This failure of the Autopilot to disengage results from damaged actuator

relay contacts caused by surge currents. The attached ARC Bulletin #206
provides instructions for modifying the actuators to protect the relay against
surge current damage, and should be accomplished at the earliest opportunity.

Until the affected actuators have been modified in accordance with the attached
Bulletin, it is recommended that prior to the next flight the Autopilot be
disabled as described below.

1) On 300 and 400 Series Aircraft, the Autopilot Computer (COMP.)

and Actuator (ACT.) circuit breakers should be pulled.

2) On Model 210 Series Aircraft, the actuator can be disabled

by disconnecting the connectors at the roll and pitch actuator.

If inspection of the K1 relay, as described in procedures 1 on page 2 of the

Bulletin, reveals that a new relay is required, the relay (part number
38381-0006) can be obtained through the Cessna Dealer Organization at a
suggested list price of $12.72 (M) each.

continued . ...

COPYRIGHT © 1978
CESSNA AIRCRAFT COMPANY

THERE ARE MORE CESSNAS FLYING THAN ANY OTHER MAKE

AV78-6
Page 2

Full parts credit plus a labor allowance will be paid for modifying
the 400B Autopilot/IFCS units provided the work is accomplished and
your Cessna Dealer submits a credit claim by the following dates.
Domestic ....... October 31, 1978
International. .... December 31, 1978

REMARKS:

Aircraft requiring modification of the 400B Autopilot and IFCS systems

are the serials listed below which were delivered from Cessna, Wichita
prior to April 1, 1978.

Model

210/T210 21061574 thru 21062583

P210 P2100001 thru P2100010

310R 310R0501 thru 310R1302

310R1304 thru 310R1315
310R1317 and 310R1318

340A 340A0001 thru 340A0458

340A0460 thru 340A0466
340A0468, 340A0470 thru 340A0483

402B 402B1001 thru 402B1331

402B1233 thru 402B1338

404 404-0001 thru 404-0218

404-0220 thru 404-0222

414 414-0801 thru 414A0032

414A0034 thru 414A0038
414A0040 thru 414A0047

421 421C0001 thru 421C0479

421C0481 thru 421C0488

**** **

(Owner Notification System - No. 2)

ALL PRICES SUBJECT TO CHANGE WITHOUT NOTICE

CESSNA AIRCRAFT COMPANY

SPECIAL NOTE TO CESSNA
ZONES AND DEALERS
ATTACHMENT TO
AV78-6

PARTS INFORMATION:

Relays, ARC P/N 38381-0006, are available from the Cessna Service
Parts Center.

CREDIT INFORMATION:

Full parts credit plus a labor allowance as shown in the Removal and
Installation Manual (part number D5433-13) for the applicable aircraft
model and 2 man hours for modification (bench labor) will be paid
provided the work is completed and a claim submitted by the dates shown
in this Service Letter. Reference Policy Information and Procedures
Manual, Section F-32.
 TAKE YOUR CESSNA HOME
FOR SERVICE AT THE SIGN
SERVICE LETTER
MARKETING DIVISION * CESSNA AIRCRAFT COMPANY · WICHITA. KANSAS 67201
AVIATION S MOST
COMPLETE
OF THE CESSNA SHIELD LINE OF AVIONICS

July 24, 1978

AV78-6
(Supplement #1)

SUBJECT: AUTOPILOT SYSTEM MALFUNCTION

AVIONICS APPLICABILITY: All 400B Autopilots and IFCS Systems

Installed in 1976 through 1978 Cessna
310, 340 and 400 Series Aircraft and
1977 and 1978 Model 210 Series Aircraft

Attached is an amendment to FESB No. 206 (AV78-6) which authorizes

the use of a supplemental relay in the PA-495A-2 actuator.

(Owner Notification System - No. 1)

CESSNA AIRCRAFT COMPANY

COPYRIGHT © 1978
CESSNA AIRCRAFT COMPANY

THERE ARE MORE CESSNAS FLYING THAN ANY OTHER MAKE

ARC FIELD ENGINEERING SERVICE BULLETIN
ARC Service Agencies March 23, 1978 206
To: Date No.

PA-495A-2 Actuator, P/N 45850-(*), Modification to Reduce Turn-On

Subject:
Surge Current Damage and to Improve Performance of Relay K1.

EFFECTIVITY

All PA-495A-2 Actuators, P/N 45850-(*), earlier than S/N 3690.

NOTE

The PA-495A-2 is used as the pitch actuator in

all AF-550A and IF-550A installations. It is
also used as the roll actuator in installations
in Cessna Series 210 Aircraft.

PRIORITY

This modification eliminates the possibility of turn-on surge current damage to relay
K1 which could result in the relay being welded "on". It must be accomplished at the
earliest opportunity on all PA-495A-2 actuators earlier than serial number 3690 to
allow the affected autopilots to be returned to service.

GENERAL

When the AF-550A Autopilot or IF-550A IFCS is engaged, high surge currents are
required to charge up filter components in the actuator. It has been discovered
that these surge currents can cause a transfer of material between contacts of
relay K1, especially contacts 9 and 10, creating the possibility of a "welded
contact" problem. This modification relocates the connections to the relay
contacts to allow direct filter charging and to eliminate the imposition of
high surge currents on the relay contacts.

PARTS INFORMATION

Although no parts changes are required for implementing MOD 1 in a PA-495A-2,

a replacement relay K1, P/N 38381-0006 may be required, and is available through
the Cessna Dealer Organization.

AIRCRART RADIO AND CONTROL

DIVISION OF Cessna AIRCRAFT COMPANY BOONTON, N.J. 07005

Telephone (201) 334-1800 Cable ARC RADIO

Page 2 FIELD ENGINEERING SERVICE BULLETIN No. 206

REFERENCES

For general disassembly information, assembly board and parts location, and a
schematic diagram of the original relay contact connections, refer to the 400B
Series Navomatic Autopilot (Type AF-550A) or 300B, 400B, 800B Series Integrated
Flight Control Systems (Type IF-550A) Service/Parts Manual. For a schematic
diagram of the relocated relay K1 connections, see Figure 1 of this bulletin.
Wiring changes to Assembly A1 are shown in Figures 2 and 3.

PROCEDURE

To modify a PA-495A-2 Actuator, disassemble the unit as required to provide

access to both sides of Assembly A1 (Index No. 36, Figure 7-26 of the service/
parts manuals), and proceed as follows:

1. Remove and inspect the original K1 relay. If proper operation of

the relay is not verified, replace the relay (50, Figure 7-26).

2. Remove and discard the white/black wire connected between

terminal A1E10 and terminal A2E9. (The terminal numbers
are printed on the assembly boards.)

3. Examine component side of board being modified to determine

level number for printed pattern used on the component side
of the board. (Pattern number is printed in a large circle
on the board under A1C5. One end of A1C5 may have to be
unsoldered, the cable tie clipped, and the capacitor lifted
up to be able to see the number.)

4. See Figure 2 of this bulletin and select appropriate modifica-

tion detail (A, B, or C) for board being modified. Modify
component side printed wiring as shown.

5. Restore A1C5, but do not replace cable tie.

6. Examine flow solder side of board to determine level number for

printed pattern used on flow solder side. (Pattern number is
printed in a large circle on the board and may not be the same
number as for the component side.)

7. See Figure 3A, 3B, or 3C, as appropriate, for printed pattern

being modified. Modify printed wiring as shown on the appropriate
illustration. Use No. 20 AWG, solid tinned copper wire (ARC P/N
08819-0020, or equivalent) and protective sleeving (ARC P/N 08800-
0032, or equivalent) for the jumpers.

8. Replace cable tie on A1C5, using tie to secure longer jumpers on

flow solder side, as applicable.

9. Install relay K1, or replacement relay, as required.

Page 3 FIELD ENGINEERING SERVICE BULLETIN No. 206

PROCEDURE (Continued)

10. Reassemble actuator and identify it as MOD 1.

CAUTION

To prevent arcing, make sure bench power

is OFF before connecting the actuator to
the bench test setup. Also, when connecting
or disconnecting the actuator in the aircraft,
make sure the master switch is off and any
external power source is disconnected.

11. Verify operation of the actuator.

NOTE; Publication of this FESB does not alter ARC's right to make changes
in its equipment without obligation to incorporate such changes in
previously delivered equipment.
 Al

E2

E4

K1

Figure 1. PA-495A-2 Actuator, Part of Schematic Diagram of Assembly A1

to Show Reconnection of Relay K1 (MOD 1)
 A. MODIFICATION FOR PATTERN NO. 1

B. MODIFICATION FOR PATTERN NO. 2

C. MODIFICATION FOR PATTERNS NO. 3, 4, OR 5

Figure 2. PA-495A-2 Actuator, Assembly A1, Printed Wiring Changes

on Component Side of Board (MOD 1)
 2

Procedure: 1. Remove original jumpers X and Y.

2. Cut printed wiring 6 places, A - F
3. Add jumpers 1 - 8
Procedure: 1. Cut printed wiring 8 places, A - H
2. Add jumpers 1 - 9
D

Procedure: 1. Cut printed wiring 7 places, A - G

2. Add jumpers 1 - 8