MODEL 400/400A MAINTENANCE MANUAL

List of Effective Pages

CH-SE-SU PAGE DATE
56-LOEP 1 Oct 01/14
56-CONTENTS 1 and 2 Oct 01/14
56-00-00 1 thru 4 Apr 01/08
201 thru 203 Oct 01/14
56-10-00 1 and 2 Jan 18/02
201 thru 223 Oct 01/14
56-20-00 1 and 2 Jan 18/02
201 thru 209 Jan 18/02

C27 Page 1
56-LOEP Oct 01/14
REV34, 4/20/07

BEECHJET 400/400A MAINTENANCE MANUAL

CHAPTER 56 - WINDOWS
TABLE OF CONTENTS

SUBJECT PAGE
56-00-00

Windows - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Cockpit Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Cabin Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Special Tools and Recommended Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Windows - Maintenance Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
Flight Compartment Side Windows and Cabin Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
Scratch Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
Scratch Removal (Optional Method) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
Scratch Depth Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203

56-10-00

Cockpit - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Windshield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Side Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Cockpit - Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
Windshield Antistatic Coating and Tab Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
Antistatic Tab Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
Windshield Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
Installation of P/N 45AS31001-11 or -12 Windshields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
Installation of Rubber Gasket on Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
Sealing the Windshield in the Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
Installation of Windshield Retainers and Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
Finishing Windshield Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
Installation of P/N 45AS31001-13, -14, -21, -22, -23 or -24 Windshields . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
Installation of Rubber Gasket on Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
Sealing the Windshield in the Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
Installation of Windshield Retainers and Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
Application of Aluminum Tape Over Windshield Protector Uncured Fillet Seal . . . . . . . . . . . . . . . . . . . .214
Finishing Windshield Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Side Window Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
Side Window Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
Windshield Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Side Window Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Windshield and Side Window - Rubber Gasket Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219

Page 1
C27 56-CONTENTS Oct 1/14
 BEECHJET 400/400A MAINTENANCE MANUAL

CHAPTER 56 - WINDOWS
TABLE OF CONTENTS (CONTINUED)

SUBJECT PAGE
56-20-00

Cabin - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Cabin Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tinted Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Polarized Windows (RJ-39 and After and RK-1 and After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cabin - Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Window Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Window Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Window Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Polarized Windows Removal (RJ-39 and After and RK-1 and After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Polarized Windows Disassembly (RJ-39 and After and RK-1 thru RK-52) . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Polarized Windows Assembly (RJ-39 and After and RK-1 thru RK-52). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Polarized Windows Disassembly (RK-53 and After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Polarized Windows Assembly (RK-53 and After). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Polarized Windows Installation (RJ-39 and After and RK-1 and After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Replacement of Polarized Window Knobs and Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Tinted Window Removal (RJ-39 and After and RK-1 and After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Tinted Window Installation (RJ-39 and After and RK-1 and After). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Page 2
Oct 1/14 56-CONTENTS C27
 MODEL 400/400A MAINTENANCE MANUAL

200200200

WINDOWS - MAINTENANCE PRACTICES

REPLACEMENT CRITERIA
WINDSHIELD

WARNING: The following criteria define the in-use limits of acceptable damage. Failure to observe these
standards could jeopardize the airworthiness of the windshield.
Delamination

Delamination is separation of the acrylic sheet from the vinyl layer. Delamination of the windshield is acceptable
within certain limitations. Vision must not be impaired and the windshield must pass an operational check. Refer to
Chapter 30-40-00.

Cracks

To determine the location of a crack, view the silver bus bar at the top and bottom of the windshield from inside the
airplane. If the crack is beyond the bus bar, then it is in the outer glass ply. If the crack is in the interlayer, it will
appear to be against the bus bar. Side to side head movement will not cause any change in the perceived location
of the crack relative to the bus bar. If the crack is in one of the stretched acrylic plies it will appear to be inboard of
the bus bar. Placing a dot on the inboard surface of the windshield with a pen and then viewing the windshield at a
45º angle will assist in judging how deep into the windshield the crack is located. A crack through both stretched
acrylic plies will appear to be almost an inch wide.

If a crack occurs in the outer face ply or the interlayer, pressurized flight may be continued if vision is not seriously
impaired and the heating system is not affected. However, if the crack is in the outer face ply, windshield
replacement is recommended as soon as a replacement is available.

If a crack occurs in one of the stretched acrylic plies, only nonpressurized flight is permissible.

If a crack occurs through both of the stretched acrylic plies, no flight is permissible.

Scratches

Outer face ply scratches are acceptable as long as vision is not seriously affected. No repair is possible because
the electrically conductive antistatic coating will be compromised.

Inside surface scratches can be polished out. A minimum inner ply thickness of 0.315 in. (8.0 mm) must be
maintained after repair.

Electrical Defects

Arcing does not affect the structural integrity of the windshield but the heating system may become inoperative.
Continued arcing may result in face ply cracking.

The heating element resistance shall not exceed 0.81 ohms between terminals 3 and 4 or 1.2 ohms between
terminals 4 and 5.

Failure of a sensing element will not require removal of the windshield because a second element is in reserve.
However, if both elements fail the windshield should be removed.

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 MODEL 400/400A MAINTENANCE MANUAL

FLIGHT COMPARTMENT SIDE WINDOWS AND CABIN WINDOWS

Delamination (Cockpit Side Windows)

Separation of acrylic sheet from vinyl layer. If cloudiness appears, if vision is impaired or moisture is trapped
between the laminations, the window must be replaced.

Delamination (Cabin Windows)

No delamination is permissible.

Discoloration

Strength of the window is not affected. If vision is impaired, replace window.

Crazing

Deformities in the acrylic sheet surface. Strength of the window is not affected. Window should be replaced if vision
is affected. Crazing is usually caused by use of unapproved cleaning material. Crazing less than 0.010 in. (0.254
mm) in depth may be repaired the same as scratches. Crazing equal to or exceeding 0.010 in. (0.254 mm) in depth
require window replacement.

Gouges/Scratches

Marks on the window surface. All scratches, gouges or nicks equal to, or exceeding 0.010 in. (0.254 mm) in depth
require window replacement. Scratches, gouges, or nicks less than 0.010 in. (0.254 mm) in depth and having sharp
enough edges to catch the fingernail, should be locally rounded out and buffed.

Cracks

Any cracks/breaks that extend the full thickness of the acrylic sheet. Cracks will affect the strength, so the window
must be replaced.

SCRATCH REMOVAL
This section specifies the necessary materials and processes stipulated in MIL-PRF-25690 for polishing the acrylic
window surfaces which have scratches, abrasions and soiled spots.

NOTE: Scratches or abrasions in the windshield glass outer surface are not to be repaired. The maximum depth in
the repair of scratches (abrasions) in acrylic surfaces is 0.010 in. (0.254 mm). Perform the SCRATCH
DEPTH MEASUREMENT procedure.
The following procedure or the SCRATCH REMOVAL (OPTIONAL METHOD) procedure must be complied with on
both the critical and noncritical areas.

a. Clean the window surface in accordance with the appropriate procedure. Refer to Chapter 12-20-00.

b. Polish the surface by hand sanding in a circular motion of approximately 6.0 in. (152 mm) in diameter, using
sandpaper (10, Chart 2, 56-00-00) wrapped over a wood or rubber core sanding block.

c. Periodically check the scratch removal by flushing with water and wiping by hand to remove the particles, then
visually inspect.

d. Use a clean water-dampened flannel cloth to remove excess water from the surface.

e. Repeat Steps b. thru d. until the scratches are reduced to less than 0.003 in. (0.076 mm).

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 MODEL 400/400A MAINTENANCE MANUAL

f. The scratches remaining may be removed using a water-moistened flannel cloth and applying polishing
compound (5, Chart 2, 56-00-00) in a circular motion.

g. Polish the entire window area.

h. Flush the surface with water and wipe by hand to remove all particles and polishing compound. Dry the surface
with a clean water moistened flannel cloth. Any residual oil and/or soiled spots may be removed with solvent
(1, Chart 2, 56-00-00).

i. If the window has insufficient transparency, proceed with the following steps:

1. Water-hone using a water-moistened flannel cloth with a small amount of polishing compound. Flush the
surface with water and dry with a clean water-moistened flannel cloth.

2. Clean the entire surface with a clean flannel cloth soaked with solvent.

3. Polish the surface with a glass cleaner (7, Chart 2, 56-00-00), then wipe dry with a clean flannel cloth.

SCRATCH REMOVAL (OPTIONAL METHOD)

NOTE: Scratches or abrasions in the windshield glass outer surface are not to be repaired. The maximum depth in
the repair of scratches (abrasions) in acrylic surfaces is 0.010 in. (0.254 mm). Perform the SCRATCH
DEPTH MEASUREMENT procedure.
The following procedure or the SCRATCH REMOVAL procedure must be complied with on both the critical and
noncritical areas.

Clean window using materials found in the Acrylic Restoration Kit (29, Chart 2, 56-00-00).

a. Apply CTP 40 solution using the hard pad supplied in kit.

b. Clean window using Anti-Static Cleaner.

c. Apply CTP 20 using a soft pad.

d. Clean window using Anti-Static Cleaner.

SCRATCH DEPTH MEASUREMENT

The depth of a window scratch may be determined either by a comparison with a standard sample, by the use of an
optical micrometer (1, Chart 1, 56-00-00) or by the use of a depth gauge (4, Chart 1, 56-00-00). When using an
optical micrometer or depth gauge, use the procedures recommended by the manufacturer.

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 MODEL 400/400A MAINTENANCE MANUAL

200200200

COCKPIT - MAINTENANCE PRACTICES

The windshield and side windows are part of the pressurized structure and care must be taken during maintenance.
Maintenance practices and procedures are the same for the left and right windshields and side windows. The
windshields and side windows are removed from inside the cockpit. The window attachment screws are installed
from the outside of the airplane. Access to the electrical terminal block for the windshield anti-ice is from inside the
cockpit at the bottom of the windshield. When a windshield is changed, the windshield anti-ice system must be
functionally checked. Refer to Chapter 30-40-00.

WINDSHIELD ANTISTATIC COATING AND TAB INSPECTION

The electrically heated windshields are to be inspected as outlined in the following steps:

NOTE: A volt-ohmmeter (2, Chart 1, 56-00-00) capable of reading in excess of 100 megohms will be required for
the following inspection.

a. Turn off all electrical power.

CAUTION: To prevent damage to the windshield, always follow instructions specified under WINDSHIELD
CLEANING procedures in Chapter 12-20-00.

b. Clean the exterior of the windshield glass with isopropyl alcohol (21, Chart 2, 56-00-00). Refer to Chapter
12-20-00.

c. Perform the SHROUD INDICATOR PANEL REMOVAL procedure in Chapter 31-10-00.

d. Disconnect the airplane's electrical system ground wire (22) from post 4 of the ground terminal (23) on the
windshield and connect a ground wire that will extend from the windshield ground terminal (23), out through the
entrance door and around to the front of the windshield (Ref. Figure 201, Detail F).

e. Set volt-ohmmeter (2, Chart 1, 56-00-00) range dial on 100 megohms and adjust the needle reading to zero.

f. Attach one volt-ohmmeter test lead to the ground wire that is connected to the windshield ground terminal (23).
Attach the other volt-ohmmeter test lead to a copper mesh pad (26, Chart 2, 56-00-00).

g. Contact the windshield glass with the copper mesh pad. Check the volt-ohmmeter reading. If the volt-ohmmeter
reading is 100 megohms or less, but more than 0 ohms, in at least 10 different locations, no further action is
required. Disconnect the test ground wire from the windshield ground terminal (23) and connect the airplane's
electrical system ground (22).
NOTE: Resistance between the windshield antistatic coating (25) and the windshield ground terminal (23) should
range from 5 to 100 megohms. A continuity reading is desirable.

h. If the volt-ohmmeter reading is more than 100 megohms, proceed with the following steps:
NOTE: Do not remove the windshield (5) from the airplane as a result of this inspection. Contact the Technical
Support Department of Beechcraft Corporation for consultation.

i. If some of the readings were more than 100 megohms, draw a diagram noting the locations of the excessive
readings and contact the Technical Support Department of Beechcraft Corporation for consultation.

j. If all the volt-ohmmeter readings were more than 100 megohms, perform the following antistatic tab inspection
steps:

1. Remove the volt-ohmmeter test lead from the copper mesh pad.

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 MODEL 400/400A MAINTENANCE MANUAL

2. Place the volt-ohmmeter test lead on the windshield glass within 0.50 in. (12.7 mm) of the fiberglass cover
tab (13). Do not press down on the fiberglass cover tab (13) during this inspection.

3. If the volt-ohmmeter reading is 10 megohms or less as the lead is drawn around the antistatic tab, the
antistatic tab is providing sufficient electrical continuity between the windshield ground terminal (23) and the
antistatic coating (25) on the windshield glass. If the ohmmeter reading is more than 10 megohms, continue
with the following steps:
NOTE: During the following test, make sure that the hands and body are completely insulated from the airplane,
windshield and meter probes.

4. Connect the volt-ohmmeter test leads to the copper mesh pads. Place one copper mesh pad within 0.50 in.
(12.7 mm) of the fiberglass cover tab (13). Place the other copper mesh pad in 10 different locations on the
windshield (5) and note the resistance readings. If the 10 resistance readings are 100 megohms or less,
repair the fiberglass cover tab (13). Refer to ANTISTATIC TAB REPAIR procedure.

k. Perform the SHROUD INDICATOR PANEL INSTALLATION procedure in Chapter 31-10-00.

ANTISTATIC TAB REPAIR

a. To repair the fiberglass cover tab (13), remove the protector (4) and dimpled washers (18) (Ref. Figure 201,
Detail F) that are attached with screws in position 43 through 63 (Ref. Figure 201, Detail B).

b. Fabricate a wedge from 0.50 in. (12.7 mm) or thicker stretched acrylic or plexiglass. Using the wedge, scrape
the sealant off of the windshield (5).

c. Using masking tape (14) mask off an area around the fiberglass cover tab (13). The area should be large enough
to protect the glass and contain excessive sealant flow.

d. Using the plastic wedge fabricated in Step b., gently pry the fiberglass cover tab (13) away from the windshield
(5) surface. Do not disconnect the fiberglass cover tab (13).

e. Fold the fiberglass cover tab (13) back over the windshield frame skin (26) and tape it down out of the work area.

f. Using the plastic wedge fabricated in Step b., pry the copper tab away from the windshield (5) surface. Do not
break or sever the copper braid (24) attaching the copper tab. Tape the tab out of the work area.

g. Gently scrape the sealant from the windshield surface with the plastic wedge fabricated in Step b.

h. Remove any residual sealant by rubbing the area with a soft cloth dampened with solvent (18, Chart 2,
56-00-00). The glass may exhibit some straining that cannot be removed; however, it is not detrimental to the
tape bond.

i. Using a 40-watt pencil-type soldering iron (3, Chart 1, 56-00-00), melt the solder attaching the copper tab to the
braided wire and separate the wire from the tab.

j. Cut a piece of copper foil tape (23, Chart 2, 56-00-00) 0.50 in. (12.7 mm) in length.

k. Remove the copper foil tape backing, being careful not to contaminate the adhesive with body oils or dirt. Place
the copper foil tape over the area originally used for tab bonding. Rub the copper foil tape down to the surface
of the windshield (5) with the plastic wedge fabricated in Step b.

l. Position a section of wire solder on the center of the copper foil tape (installed in the previous step). Apply the
tip of the 40-watt pencil-type soldering iron to the solder just long enough to melt a puddle of solder with a
maximum diameter of 0.125 in. (3.175 mm). Remove the soldering iron and the solder simultaneously.

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 MODEL 400/400A MAINTENANCE MANUAL

m. Using tweezers or some other suitable tool, hold the copper braid (24) to the top of the solder spot. Apply the
tip of the 40-watt pencil-type soldering iron to the copper braid (24) at the solder spot. Remove the soldering
iron as soon as the solder has blended with the copper braid (24).

n. Remove any excess flux with a cotton swab dampened with solvent (18, Chart 2, 56-00-00). Wipe the interior
of the taped-off area with isopropyl alcohol (21, Chart 2, 56-00-00).
CAUTION: Use only minimal amounts of methyl propyl ketone and isopropyl alcohol, as either could destroy the
adhesive bond of the copper foil tape.

o. Thoroughly clean the bond surface of the fiberglass cover tab (13) with isopropyl alcohol (21, Chart 2, 56-00-00).
Using a cotton swab, apply a moderate coat of primer (24, Chart 2, 56-00-00) to the bond surface of the
fiberglass cover tab (13). Allow the primer to dry for approximately two minutes.

p. Apply a 0.0625 to 0.125 in. (1.59 mm to 3.175 mm) thick layer of electric grade silicone rubber (25, Chart 2,
56-00-00) over the copper tab and inner boundaries of the taped off area.

q. Fold the fiberglass cover tab (13) back to its original position and tape it in place. Apply sufficient pressure to
the fiberglass cover tab with the tape to make sure of a weather-proof seal. Allow the sealant (25, Chart 2,
56-00-00) to cure for 24 hours before removing the tape.

r. Remove excessive sealant flow from the tape by gently rubbing it with the plastic wedge, fabricated in Step b.
After the excessive sealant has been removed, remove the tape.

s. Clean the windshield (5) and frame (20), removing all sealant. Apply a parting agent (30) film tape (15, Chart 2,
56-00-00), sealant (19, Chart 2, 56-00-00) then install the protector (4) and dimpled washers (18) (Ref. Figure
201, Detail G). Tighten screws (19) 10 to 15 in.-lbs (1.13 to 1.69 N.m) plus the friction torque of the self-locking
nuts.

WINDSHIELD REMOVAL
a. Turn the BATTERY switch OFF and disengage the appropriate circuit breaker(s). Attach a caution tag to the
circuit breaker panel noting that maintenance is in progress.

b. Remove interior trim adjacent to the windshield. Refer to Chapter 25-10-00.

c. Perform the SHROUD INDICATOR PANEL REMOVAL procedure in Chapter 31-10-00.

d. Disconnect the windshield anti-ice wiring from the electric heating terminal (6). Refer to Chapter 30-40-00. Tag
each wire to aid installation of the windshield (5) (Ref. Figure 201 Detail A).

e. Perform the OVERHEAD SWITCH PANEL REMOVAL procedure in Chapter 31-10-00 (Ref. Figure 201, Details
C and E).

f. Remove nuts (15), washers (16), bolts (17 and 21) and screws (19) from the windshield frame.
NOTE: Retain bolts and screws for installation. On airplanes with NAS517 screws (19), replace them with
NAS560HK3P20 and NAS560HK3P21 stainless steel screws. Note location and length of bolts and screws
to facilitate proper installation.

g. Remove the brackets (14), panel (11), retainers (1, 9 and 10), shims (2 and 8), seal (7) and windshield (5) (Ref.
Figure 201, Details A and D).

h. Remove sealant material from the windshield frame (20) and skin (26) (Ref. Figure 201, Detail F). Refer to
SURFACE PREPARATION procedure in Chapter 20-00-00.

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INSTALLATION OF P/N 45AS31001-11 OR -12 WINDSHIELDS

Table 201
Replacement Quantities For One Pilot’s or CoPilot’s Windshield
QUANTITY ITEM PRODUCT OR PART NUMBER
5 Sealant (6 ounce tubes) Refer to item 12, Chart 2, 56-00-00
1 - Roll Tape Refer to item 2, Chart 2, 56-00-00
1 - Quart Adhesive Refer to item 22, Chart 2, 56-00-00
1 - Quart Solvent Refer to item 1, Chart 2, 56-00-00
1 - Quart Metal Cleaning Solvent Refer to item 8, Chart 2, 56-00-00
1 - Package Cheesecloth, Bleached White Refer to item 3, Chart 2, 56-00-00
1 - Pair White Cotton Gloves Refer to item 9, Chart 2, 56-00-00
*66 Stainless Screws Refer to the Model 400/400A IPC or subsequent for
applicable part numbers.
*30 Stainless Screws Refer to the Model 400/400A IPC or subsequent for
applicable part numbers.
*66 Nut Refer to the Model 400/400A IPC or subsequent for
applicable part numbers.
*66 Refer to the Model 400/400A IPC or subsequent for
applicable part numbers.
*80 Washer, Flat Refer to the Model 400/400A IPC or subsequent for
applicable part numbers.
1 Seal Refer to the Model 400/400A IPC or subsequent for
applicable part numbers.
* Replace as required.

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INSTALLATION OF RUBBER GASKET ON WINDSHIELD

a. Lightly scuff sand the periphery of the inboard surface of the windshield (5) and one side of the rubber seal (7)
with 280-grit sandpaper (10, Chart 2, 56-00-00) or scotch-brite (31, Chart 2, 56-00-00) making sure the
glossiness is removed without damaging the rubber seal (Ref. Figure 201).

b. Clean the sanded surfaces with a cloth (3, Chart 2, 56-00-00) dampened, but not dripping, with solvent (1, Chart
2, 56-00-00). Wipe with a clean, dry cloth before the solvent evaporates, repeat this process until the grease or
oil-like films are removed and discoloration on the cloth is not evident.

NOTE: After cleaning the surfaces to be bonded, white cotton gloves (9, Chart 2, 56-00-00) should be worn until
parts are assembled.

c. Apply a thin coat of adhesion promoter (28, Chart 2, 56-00-00) or equivalent to the bonding surface of the rubber
seal (7). Allow the adhesion promoter with a clean white cloth (3, Chart 2, 56-00-00) folded as to make a small
pad without any raw edges showing. Do not use a brush as it is possible to put on too heavy a coat. A heavy
coat means possible adhesion failure. Allow adhesion promoter to cure 15 minutes prior to applying sealant.

d. Apply sealant (22, Chart 2, 56-00-00) to all bonding surfaces of rubber seal (7) and the surfaces of the
windshield (5) that the seal will be fitted against. Use a seam roller to press the seal in place and remove any
voids that may have been created and also creating a continuos squeeze-out around the seal and window.
Remove the excess sealant, leaving a slight amount of squeeze-out sealant showing.

NOTE: Let the bond cure for at least 1 hour before installing the windshield (5) in the airplane.

SEALING THE WINDSHIELD IN THE AIRPLANE

a. Clean the frame with a cloth (3, Chart 2, 56-00-00) dampened, but not dripping, with solvent (8, Chart 2,
56-00-00). Wipe with a clean, dry cloth before the solvent evaporates, repeat this process until the grease or
oil-like films are removed and discoloration on the cloth is not evident.

b. Apply primer (13, Chart 2, 56-00-00) to the windshield frame (20) surface that will contact the sealant. Let the
primer dry for at least 30 minutes (Ref. Figure 201).

c. Clean the outboard periphery of the windshield (5) with a cloth (3, Chart 2, 56-00-00) dampened, but not
dripping, with solvent (1, Chart 2, 56-00-00). Wipe with a clean, dry cloth before the solvent evaporates, repeat
this process until the grease or oil-like films are removed and discoloration on the cloth is not evident.

d. Apply parting agent (30) film tape (15, Chart 2, 56-00-00) to the windshield (Ref. Figure 201, Sheet 2, Detail G).

e. Apply sealant (12, Chart 2, 56-00-00) to the windshield frame (20) surface by means of Semco sealing gun,
wooden spatula or a seam roller wherever possible. Sealant shall cover the entire mating surface and shall be
continuous without voids. Sufficient sealant shall be applied to fill all mismatches of parts, joggles, gaps or voids
and to provide a continuous squeeze-out around the edge of the windshield (5) when the windshield (5) is
positioned. For the seal to be adequate between the windshield (5) and frame (20), it must be continuous and
0.01 to 0.06 in. (0.25 to 1.52 mm) thick.

f. Position the windshield (5) with draw-nut or wing-nut type temporary fasteners, preferably in every hole. Tighten
the temporary fasteners until the exterior surface of the windshield (5) is flush with the surface of the fuselage.
There must be continuous squeeze-out of sealant (12, Chart 2, 56-00-00) around the windshield (5) on both the
interior and exterior surfaces of the airplane.

NOTE: Before the sealant cures, set the alignment of the window by completing Steps g. thru m.

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g. Remove temporary fasteners from inboard edge of windshield.

h. Make sure that the bolt holes in inboard retainer (9), align with the bolt holes in the windshield (5) and frame (20).

i. Remove the inboard retainer (9), and install temporary fasteners in the inboard edge of the windshield.

j. Remove temporary fasteners from the rear edge of the windshield.

k. Make sure that the bolt holes in the rear retainer (1), align with the holes in the windshield (5) and fuselage.

l. Remove the rear retainer (1), and install temporary fasteners in the rear edge of the windshield (5).

m. Fair the squeeze-out on the interior surface of the airplane into the joint to provide a fillet seal. Refer to Chapter
20-00-00.

n. On the exterior surface of the airplane, there will be a groove around the windshield (5), which is now partially
filled with sealant (12, Chart 2, 56-00-00). Before the application time expires, use a sealant gun to finish filling
the groove or gap with the same sealant. Keep the tip of the nozzle pointed into the gap and almost
perpendicular to the line of travel.

o. Fair the sealant into the gap or groove using a sealant fairing tool or wood spatula. Press the tool against the
sealant and move it parallel along the gap, making sure that air is not trapped within the sealant. Any evidence
of voids shall be worked out, removed or repaired. When finished, the sealant shall be flush with the exterior
skin (26) surface (Ref. Figure 201).

NOTE: Allow the sealant to cure for 24 hours.

INSTALLATION OF WINDSHIELD RETAINERS AND PROTECTOR

a. Using masking tape (14, Chart 2, 56-00-00), mask off the surface that the protector (4) is going to fit against
(Ref. Figure 201).

b. Clean the bonding surface of the protector (4), dimpled washers (18) and skin area (26) with a cloth (3, Chart
2, 56-00-00) dampened, but not dripping, with solvent (8, Chart 2, 56-00-00)). Wipe with a clean, dry cloth before
the solvent evaporates, repeat this process until the grease or oil-like films are removed and discoloration on
the cloth is not evident.

c. Apply primer (13, Chart 2, 56-00-00) to the bonding surface of the protector (4), dimpled washers (18) and skin
area (26). Let the primer dry for at least 30 minutes.

d. Clean the bonding surface of the windshield (5) with a cloth (3, Chart 2, 56-00-00) dampened, but not dripping,
with solvent (1, Chart 2, 56-00-00). Wipe with a clean, dry cloth before the solvent evaporates, repeat this
process until the grease or oil-like films are removed and discoloration on the cloth is not evident.

e. Remove the temporary fasteners from the inboard edge of the windshield (5).

f. Position the inboard shims (8) and retainer (9) and mount the retainer (9) on the adjacent airplane structure.

g. Remove the temporary fasteners from the rear edge of the windshield (5).

h. Position the rear shims (2) and retainer (1) and mount the retainer (1) on the adjacent airplane structure.

i. Apply a sufficient amount of sealant (12, Chart 2, 56-00-00) to the bonding surface of the protector so that, when
it's installed with permanent fasteners, there will be a small amount of squeeze-out around the edge of the
protector.

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j. Remove the remaining temporary fasteners from the windshield (5).

k. Place the dimpled washers (18) and protector (4) in position on the windshield (5).

NOTE: On airplanes that used NAS517 screws to attach the windshield (5), replace them with NAS560HK3P20 or
NAS560HK3P21 stainless steel screws.

l. Apply sealant (12, Chart 2, 56-00-00) under all screw heads and install screws (19), washers (16) and nuts (15).
Tighten the screws to a snug fit. Along the bottom edge, install the retainer (10), panel (11) and the brackets
(14).

m. Tighten the screws through the windshield (5) progressively in increments until the final torque is reached. The
final torque is 10 to 15 in.-lbs (1.13 to 1.69 N.m) plus the friction of the self-locking nuts.

n. Apply a fillet seal (28) around both edges of the protector (4) to prevent the entrance of moisture (Ref. Figure
201, Detail G). Use sealant (11, Chart 2, 56-00-00) at the edge of the protector (4) over the windshield (5) and
sealant (27, Chart 2, 56-00-00) at the edge of the protector (4) over the skin (26).

o. Remove the excess sealant and the masking tape before the sealant has gone past its application time.

NOTE: Allow the sealant to cure for 24 hours.

FINISHING WINDSHIELD INSTALLATION

a. Perform the QUICK LEAKAGE CHECK procedure in Chapter 21-30-00.

b. Connect the windshield anti-ice wiring with washers and screws to electric heating terminals (6). (Ref. Figure
201). Refer to Chapter 30-40-00. Torque the screws in terminals 1 and 2 to 8 to 10 in.-lbs (0.90 to 1.13 N.m).
Torque the screws in terminals 3, 4 and 5 to 18 to 20 in.-lbs (2.03 to 2.26 N.m). Apply a torque paint stripe to all
terminal connections.

c. Perform the SHROUD INDICATOR PANEL INSTALLATION procedure in Chapter 31-10-00.

d. Perform the OVERHEAD SWITCH PANEL INSTALLATION procedure in Chapter 31-10-00.

e. Install the interior trim. Refer to Chapter 25-10-00.

f. Clean the windshields. Refer to WINDSHIELD CLEANING (RJ-1 AND AFTER AND RK-1 THRU RK-242
WITHOUT KIT 128-5405 INSTALLED; RK-243 AND AFTER) procedure in Chapter 12-20-00.

g. Perform POLISHING WINDOWS procedure in Chapter 12-20-00.

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2 12 4
4
1 2
9 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
1
8 16 37 3
15
1 38
A 14
7
3
4 E H 39
13
4
12
C 41
40

B 11 42
6
43
3 10
13 44
9
45
4 46
8
47
B 7
48

This Page Intentionally Left Blank

6
G 50
49
F
5

4 52
51
D
53 1. REAR RETAINER
3 2. REAR SHIM (2)
54 3. LARGE WASHER RETAINER
55 4. PROTECTOR
2 14
6 56 5. WINDSHIELD
1 57
2 1 6. ELECTRIC HEATING TERMINAL
58
7. SEAL
10 59
60 8. INBOARD SHIM (2)
11 66 61
3 9. INBOARD RETAINER
65 63 62 10. FRONT RETAINER
64
11. PANEL
D 12. CLIP
13. FIBERGLASS COVER TAB
DETAIL B 14. BRACKET
15. NUT
F LEFT SIDE SHOWN 16. WASHER
C VIEWED FROM FRONT OF AIRPLANE 17. AN3-6A INBOARD RETAINER BOLTS (19)
18. DIMPLED WASHER

E C 19. WINDSHIELD SCREWS

20. FRAME
2 3

I THE SEAL MAY BE CUT AT THESE THREE PLACES 21. AN3-5A REAR RETAINER BOLTS (24)
FOR EASIER INSTALLATION 22. ELECTRICAL SYSTEM GROUND WIRE
23. WINDSHIELD GROUND TERMINAL
2 SCREWS 1 THRU 36 ARE NAS560HK3P21
24. COPPER BRAID
25. ANTISTATIC COATING
3 SCREWS 37 THRU 66 ARE NAS560HK3P20 26. SKIN
DETAIL A 27. FAYING SURFACE SEAL
28. FILLET SEAL
D LEFT WINDSHIELD D 4 INSTALL TWO WASHERS ON ALL SCREWS
23 THRU 36
29. SIDE WINDOW
30. PARTING AGENT (TAPE)
VIEW FROM INSIDE PILOT'S COMPARTMENT LOOKING FORWARD RJ56B
31. SEALANT 991290AB.AI

Windshield Installation
Figure 201 (Sheet 1 of 2)

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 MODEL 400/400A MAINTENANCE MANUAL

RJ56B
970119AB.AI

Windshield Installation
Figure 201 (Sheet 2 of 2)

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INSTALLATION OF P/N 45AS31001-13, -14, -21, -22, -23 OR -24 WINDSHIELDS

Table 202
Replacement Quantities For One Pilot’s or CoPilot’s Windshield
QUANTITY ITEM PRODUCT OR PART NUMBER
5 Sealant (6 ounce tubes) Refer to item 19, Chart 2, 56-00-00
1 - Roll Tape Refer to item 2, Chart 2, 56-00-00
1- Quart Adhesive Refer to item 22, Chart 2, 56-00-00
1 - Quart Solvent Refer to item 1, Chart 2, 56-00-00
1 - Quart Metal Cleaning Solvent Refer to item 8, Chart 2, 56-00-00
1 - Package Cheesecloth, Bleached White Refer to item 3, Chart 2, 56-00-00
1 - Pair White Cotton Gloves Refer to item 9, Chart 2, 56-00-00
*66 Stainless Screws Refer to the Model 400/400A IPC or subsequent for
applicable part numbers.
*30 Stainless Screws Refer to the Model 400/400A IPC or subsequent for
applicable part numbers.
*66 Nut Refer to the Model 400/400A IPC or subsequent for
applicable part numbers.
*66 Washer, Dimpled Refer to the Model 400/400A IPC or subsequent for
applicable part numbers.
*80 Washer, Flat Refer to the Model 400/400A IPC or subsequent for
applicable part numbers.
1 Seal Refer to the Model 400/400A IPC or subsequent for
applicable part numbers.
* Replace as required.

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 MODEL 400/400A MAINTENANCE MANUAL

INSTALLATION OF RUBBER GASKET ON WINDSHIELD

a. Lightly scuff sand periphery of the inboard surface of the windshield (5) and one side of the rubber seal (7) with
280-grit sandpaper (10, Chart 2, 56-00-00) or scotch-brite (31, Chart 2, 56-00-00) making sure the glossiness
is removed without damaging the rubber seal (Ref. Figure 201).

b. Clean the sanded surfaces with a cloth (3, Chart 2, 56-00-00) dampened, but not dripping, with solvent (1, Chart
2, 56-00-00). Wipe with a clean, dry cloth before the solvent evaporates, repeat this process until the grease or
oil-like films are removed and discoloration on the cloth is not evident.

NOTE: After cleaning the surfaces to be bonded, white cotton gloves (9, Chart 2, 56-00-00) should be worn until
parts are assembled.

c. Apply a thin coat of adhesion promoter (28, Chart 2, 56-00-00) or equivalent to the bonding surface of the rubber
seal (7). Allow the adhesion promoter with a clean white cloth (3, Chart 2, 56-00-00) folded as to make a small
pad without any raw edges showing. Do not use a brush as it is possible to put on too heavy a coat. A heavy
coat means possible adhesion failure. Allow adhesion promoter to cure 15 minutes prior to applying sealant.

d. Apply sealant (22, Chart 2, 56-00-00) to all bonding surfaces of rubber seal (7) and the surfaces of the
windshield (5) that the seal will be fitted against. Use a seam roller to press the seal in place and remove any
voids that may have been created and also creating a continuos squeeze-out around the seal and window.
Remove the excess sealant, leaving a slight amount of squeeze-out sealant showing.

NOTE: Let the bond cure for at least 1 hour before installing the windshield (5) in the airplane.

SEALING THE WINDSHIELD IN THE AIRPLANE

a. Clean the frame with a cloth (3, Chart 2, 56-00-00) dampened, but not dripping, with solvent (8, Chart 2,
56-00-00). Wipe with a clean, dry cloth before the solvent evaporates, repeat this process until the grease or
oil-like films are removed and discoloration on the cloth is not evident.

b. Clean the outboard periphery of the windshield (5) with a cloth dampened, but not dripping, with solvent (1, Chart
2, 56-00-00) (Ref. Figure 201). Wipe with a clean, dry cloth before the solvent evaporates, repeat this process
until the grease or oil-like films are removed and discoloration on the cloth is not evident.

c. Apply parting agent (30) film tape (15, Chart 2, 56-00-00) to the windshield (Ref. Figure 201, Detail H).

d. Apply sealant (19, Chart 2, 56-00-00) to the windshield frame (20) surface by means off Semco sealing gun,
wooden spatula or a seam roller wherever possible. Sealant shall cover the entire mating surface and shall be
continuous without voids. Sufficient sealant shall be applied to fill all mismatches of parts, joggles, gaps or voids
and to provide a continuous squeeze-out around the edge of the windshield (5) when the windshield is
positioned.

e. Position the windshield (5) with draw-nut or wing-nut type temporary fasteners, preferably in every hole. Tighten
the temporary fasteners until the exterior surface of the windshield (5) is flush with the surface of the fuselage.
There must be continuous squeeze-out of sealant around the windshield (5) on both the interior and exterior
surfaces of the airplane. For the seal to be adequate between the windshield (5) and frame (20), it must be
continuous and 0.01 to 0.06 in. (0.25 to 1.52 mm) thick.

NOTE: Before the sealant cures, set the alignment of the window by completing Steps f. thru k.

f. Remove temporary fasteners from inboard edge of windshield.

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 MODEL 400/400A MAINTENANCE MANUAL

g. Make sure that the bolt holes in the inboard retainer (9) align with the bolt holes in the windshield (5) and frame
(20).

h. Remove the inboard retainer (9), and install temporary fasteners in the inboard edge of the windshield.

i. Remove temporary fasteners from the rear edge of the windshield.

j. Make sure that the bolt holes in the rear retainer (1) align with the holes in the windshield (5) and fuselage.

k. Remove the rear retainer (1), and install temporary fasteners in the rear edge of the windshield (5).

l. Fair the squeeze-out on the interior surface of the airplane into the joint to provide a fillet seal (Ref. Chapter
20-00-00).

m. On the exterior surface of the airplane, there will be a groove around the windshield (5), which is now partially
filled with sealant (19, Chart 2, 56-00-00). Before the application time expires, use a sealant gun to finish filling
the groove or gap with the same sealant. Keep the tip of the nozzle pointed into the gap and almost
perpendicular to the line of travel.

n. Fair the sealant into the gap or groove using a sealant fairing tool or wood spatula. Press the tool against the
sealant and move it parallel along the gap, making sure that air is not trapped within the sealant. Any evidence
of voids shall be worked out, removed or repaired. When finished, the sealant shall be flush with the exterior
skin (26) surface.

NOTE: Allow the sealant to cure for 24 hours.

INSTALLATION OF WINDSHIELD RETAINERS AND PROTECTOR

a. Using masking tape (14, Chart 2, 56-00-00) mask off the surface that the protector (4) is going to fit against (Ref.
Figure 201, Detail G).

b. Clean the bonding surface of the protector (4), dimpled washers (18) and skin area (26) with a cloth (3, Chart
2, 56-00-00) dampened, but not dripping, with solvent (8, Chart 2, 56-00-00). Wipe with a clean, dry cloth before
the solvent evaporates, repeat this process until the grease or oil-like films are removed and discoloration on
the cloth is not evident.

c. Clean the bonding surface of the windshield (5) with a cloth dampened, but not dripping, with solvent (1, Chart
2, 56-00-00). Wipe with a clean, dry cloth before the solvent evaporates, repeat this process until the grease or
oil-like films are removed and discoloration on the cloth is not evident.

d. Remove the temporary fasteners from the inboard edge of the windshield (5).

e. Position the inboard shims (8) and retainer (9) and mount the retainer on the adjacent airplane structure.

f. Remove the temporary fasteners from the rear edge of the windshield (5).

g. Position the rear shims (2) and retainer (1) and mount the retainer on the adjacent airplane structure.

h. Apply a sufficient amount of sealant (19, Chart 2, 56-00-00) to the bonding surface of the protector (4) so that,
when it is installed with permanent fasteners, there will be a small amount of squeeze-out around the edge of
the protector (4).

i. Remove the remaining temporary fasteners from the windshield (5).

j. Place the dimpled washers (18) and protector (4) in position on the windshield (5).

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NOTE: On airplanes that used NAS517 screws to attach the windshield, replace them with NAS560HK3P20 or
NAS560HK3P21 stainless steel screws.

k. Apply sealant under all screw heads and install screws (19), washers (16) and nuts (15). Tighten the screws to
a snug fit. Along the bottom edge, install the retainer (10), panel (11) and the brackets (14).

l. Tighten the screws through the windshield (5) progressively in increments until the final torque is reached. The
final torque is 10 to 15 in.-lbs (1.13 to 1.70 N.m) plus the friction of the self-locking nuts.

m. Immediately after the retainer (10) is installed and before the application time has expired on the sealant, apply
extra sealant (19, Chart 2, 56-00-00) to the masked area around the periphery of the protector (4). Force the
sealant into the retainer and almost perpendicular to the line of travel. Sealant shall be faired back into the
retainer using sealant fairing tools or equivalent. The tool shall be pressed against the sealant and moved
parallel to the retainers being sure that air is not trapped within the sealant. Any evidence of air bubbles shall
be removed and repaired.

n. Remove the excess sealant and the masking tape before the sealant has gone past its application time.

NOTE: Allow the sealant to cure for 24 hours.

The following procedure must only be accomplished when the windshield protector fillet sealant is not fully
cured prior to the airplane’s scheduled dispatch.

APPLICATION OF ALUMINUM TAPE OVER WINDSHIELD PROTECTOR UNCURED FILLET SEAL

a. Using a clean, soft cloth dampened with a 50/50 solution of isopropyl alcohol (21, Chart 2, 56-00-00) and water,
clean the windshield protectors and the outer perimeter of the affected windshield. Do not disturb the windshield
fillet seal. Thoroughly dry the affected area after cleaning.

b. Apply film tape (15, Chart 2, 56-00-00) over the protector fillet sealant. It is permissible to trim the width of the
film tape to match the width of the fillet seal.

c. Apply aluminum tape (30, Chart 2, 56-00-00) over the film tape and onto the windshield and windshield
protector. The aluminum tape should extend 1/2 inch beyond each edge of the fillet seal onto the windshield and
windshield protector.

d. Using a roller, roll this 1/2 inch section of aluminum tape to make sure of a secure bond between the tape and
windshield/protector.

NOTE: The airplane may be dispatched immediately after aluminum tape application. Defer any polishing of the
windshield protector until the aluminum tape is removed.

e. Remove the aluminum tape after 10 days, then polish the windshield protector.

FINISHING WINDSHIELD INSTALLATION

a. Perform the QUICK LEAKAGE CHECK procedure in Chapter 21-30-00.

b. Connect the windshield anti-ice wiring with washers and screws to electric heating terminals (6). Refer to
Chapter 30-40-00. Torque the screws in terminals 1 and 2 to 8 to 10 in.-lbs (0.90 to 1.13 N.m). Torque the screws
in terminals 3, 4 and 5 to 18 to 20 in.-lbs (2.03 to 2.26 N.m). Apply a torque paint stripe to all terminal
connections.

c. Perform SHROUD INDICATOR PANEL INSTALLATION procedure in Chapter 31-10-00.

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 MODEL 400/400A MAINTENANCE MANUAL

d. Perform OVERHEAD SWITCH PANEL INSTALLATION procedure in Chapter 31-10-00.

e. Install the interior trim. Refer to Chapter 25-10-00.

NOTE: For cleaning procedures for P/N 45AS31001-13 and -14 windshield installations, refer to WINDSHIELD
CLEANING (RJ-1 AND AFTER AND RK-1 THRU RK-242 WITHOUT KIT 128-5405 INSTALLED) procedure
in Chapter 12-20-00.
For cleaning procedures for P/N 45AS31001-21 and -22 windshield installations, refer to WINDSHIELD
CLEANING (RJ-1 AND AFTER AND RK-1 THRU RK-242 WITH KIT 128-5405 INSTALLED; RK-243 AND
AFTER) procedure in Chapter 12-20-00.

f. Clean the windshields.

g. Perform POLISHING WINDOWS procedure in Chapter 12-20-00.

SIDE WINDOW REMOVAL

a. Remove interior trim adjacent to the window. Refer to Chapter 25-10-00.

b. Remove nuts (3), washers (2) and screws (1) (Ref. Figure 202).
NOTE: Retain screws (1) for installation. On airplanes with NAS517 screws, replace with NAS560HK3P10 stainless
steel screws.

c. Remove the retainers (4), seal (5) and side window (6).

d. Remove sealant material from window frame (11). Refer to SURFACE PREPARATION procedure in Chapter
20-00-00.

SIDE WINDOW INSTALLATION

a. Clean the side window (6) and frame (11) as follows (Ref. Figure 202):

1. Remove all contaminating films from that surface of the window frame to which sealant will be applied. For
this purpose, use a clean cloth (3, Chart 2, 56-00-00) dampened, but not dripping, with solvent (8, Chart 2,
56-00-00). Clean the surface until the grease or oil-like films are removed and discoloration on the cloth is
not evident.

b. Attach the rubber seal (5) to the retainer (4) as follows:

1. Lightly scuff-sand the periphery of the inboard surface (where it bonds to the rubber seal) of the retainer (4)
and one side of the seal (5) with 280-grit sandpaper (10, Chart 2, 56-00-00).

2. Clean the sanded surfaces with a cloth dampened, but not dripping, with solvent (1, Chart 2, 56-00-00).
Wipe with a clean, dry cloth before the solvent evaporates, repeat this process until the grease or oil-like
films are removed and discoloration on the cloth is not evident.
NOTE: After cleaning the surfaces to be bonded, white cotton gloves (9, Chart 2, 56-00-00) shall be worn until
parts are assembled.

3. Apply a generous coat of sealant (22, Chart 2, 56-00-00) and adhesion promoter (28, Chart 2, 56-00-00) to
the bonding surface of the seal (5) and retainer (4). Allow the sealant at least 20 to 30 minutes to tack before
joining the bonding surfaces. When joining the bonding surfaces, join only a small segment 3 to 6 in. (76.2

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 MODEL 400/400A MAINTENANCE MANUAL

to 152.4 mm) each time and make sure that it is properly aligned before joining the next segment. Once the
surfaces are joined, they cannot be pulled apart, as there is no way to separate the bond without cleaning
the bonding surfaces afterward.

c. After the seal (5) is bonded to the retainer (4), roll the bonded area with a seam roller to make sure of good
adhesion. Allow for a 2 hour dwell time prior to installation.

d. Visually inspect the side window mating surface of the frame (11) for unevenness and damage. Replace the
frame as necessary.

e. Using film tape (15, Chart 2, 56-00-00) apply as parting agent to the surface of the side window (6) just cleaned
(Ref. Figure 202, Detail B).

f. Using sealant (19, Chart 2, 56-00-00) apply a faying surface seal to the side window (6). Use a Semco sealing
gun, wooden spatula or a seam roller wherever possible. Sealant shall cover the entire mating surface with a
continuous coat and be free of voids. Apply enough sealant to adequately fill all voids created by part
mismatches, joggles and gaps. Sufficient sealant shall be applied to provide a slight squeeze-out when the side
window is secured in place.
NOTE: Squeeze-out shall be continuous on the pressurized side of the side window (6). Fair the squeeze-out back
into the joint to provide a fillet seal when the side window is secured.

g. Install the window (6), seal (5) and retainers (4) in position and secure with screws (1), washers (2) and nuts
(3). Tighten all screws (1) through the window (6) progressively in increments to gradually squeeze sealant out
until the final torque is reached. The final torque is 10 to 15 in.-lbs (1.13 to 1.70 N.m) plus the friction torque of the
self-locking nuts.
NOTE: Do not apply additional torque after the sealant has cured.

h. Remove all excess sealant on the outside of the window (6) (Ref. Figure 202, Detail C).

i. Clean and polish the window. Refer to Chapter 12-20-00.

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This Page Intentionally Left Blank

RJ56B
991291AA.AI

Side Window Installation

Figure 202

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 MODEL 400/400A MAINTENANCE MANUAL

WINDSHIELD INSPECTION
a. Visually inspect for loose fasteners.

b. Visually check the windshield for delamination, discoloration, scratches, gouges and cracks.

c. Visually check security of the 45A97010 gasket to make sure it has not migrated from under the retainers. Refer
to Figure 203 to determine gasket serviceability. If the gasket has migrated beyond limits refer to WINDSHIELD
AND SIDE WINDOW - RUBBER GASKET REPAIR.

SIDE WINDOW INSPECTION

a. Visually inspect for loose fasteners.

b. Visually inspect the inner and outer plies for scratches, gouges and cracks.

c. Visually check security of the 45A97010 gasket to make sure it has not migrated from under the retainers. Refer
to Figure 203 to determine gasket serviceability. If the gasket has migrated beyond limits refer to WINDSHIELD
AND SIDE WINDOW - RUBBER GASKET REPAIR.

WINDSHIELD AND SIDE WINDOW - RUBBER GASKET REPAIR

NOTE: If gasket replacement is required the gasket may be replaced in segments so as to not disturb the integrity
of the windshield or side window installation and pressure seal. The retainers associated with the migrating
gasket should be removed one at a time and the appropriate segment of the new gasket material bonded
on the windshield or side window under each retainer.

a. Remove the retainer and shims (if installed) which are installed over the area of the migrating gasket material
by removing the screws, nuts and washers.

b. Carefully remove the debonded gasket. It will be necessary to trim the gasket at the end of each retainer. Refer
to Figure 204 for windshield retainer locations and Figure 205 for side window retainer locations.

c. Clean all surfaces where sealant residue is seen using solvent (1, Chart 2, 56-00-00) and a plastic scraper and
scotch-brite (31, Chart 2, 56-00-00).

d. Lightly scuff sand the periphery of the inboard surface of the windshield and/or side window and one side of the
rubber seal with 280-grit sandpaper (10, Chart 2, 56-00-00) or scotch-brite (31, Chart 2, 56-00-00) making sure
the glossiness is removed without damaging the rubber seal (Ref. Figure 201).

e. Clean the sanded surfaces with a cloth (3, Chart 2, 56-00-00) dampened, but not dripping, with solvent (1, Chart
2, 56-00-00). Wipe with a clean, dry cloth before the solvent evaporates, repeat this process until the grease or
oil-like films are removed and discoloration on the cloth is not evident.

NOTE: After cleaning the surfaces to be bonded, white cotton gloves (9, Chart 2. 56-00-00) should be worn until
parts are assembled.

f. Apply a thin coat of adhesion promoter (28, Chart 2, 56-00-00) or equivalent to the bonding surface of the rubber
seal. Allow the adhesion promoter with a clean white cloth (3, Chart 2, 56-00-00) folded as to make a small pad
without any raw edges showing. Do not use a brush as it is possible to put on too heavy a coat. A heavy coat
means possible adhesion failure. Allow adhesion promoter to cure 15 minutes prior to applying sealant.

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 MODEL 400/400A MAINTENANCE MANUAL

g. Apply sealant (22, Chart 2, 56-00-00) to all bonding surfaces of rubber seal and the surfaces of the windshield
and/or side window that the seal will be fitted against. Use a seam roller to press the seal in place and remove
any voids that may have been created and also creating a continuos squeeze-out around the seal and window.
Remove the excess sealant, leaving a slight amount of squeeze-out sealant showing.

NOTE: Let the bond cure for at least 1 hour before installing the windshield in the airplane.

h. Install the shims and retainers by applying sealant under the screw heads and install screws, washers and nuts.
Tighten the screws to a snug fit.

i. Tighten the screws through the windshield or side window progressively in increments until the final torque is
reached. The final torque is 10 to 15 in. lbs (1.13 to 1.70 N.m) plus the friction of the self-locking nuts.

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 MODEL 400/400A MAINTENANCE MANUAL

MIGRATION PULLED
AWAY FROM FASTENERS
NOT ACCEPTABLE
ACCEPTABLE
MIGRATION

RK56B
074066AA.AI

Gasket Migration Limitation

Figure 203

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 MODEL 400/400A MAINTENANCE MANUAL

ARROWS INDICATE RETAINER JOINT

LOCATIONS WHERE GASKETS MAY BE
TRIMMED FOR SEGMENTED REPLACEMENT

RK56B
074065AA.AI

Windshield Retainer Locations

Figure 204

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 MODEL 400/400A MAINTENANCE MANUAL

ARROWS INDICATE RETAINER

JOINT LOCATIONS WHERE GASKETS
MAY BE TRIMMED FOR SEGMENTED
REPLACEMENT

RK56B
074064AA.AI

Side Window Retainer Location

Figure 205

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