Garmin GFC 500 Maintenance Manual
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Garmin GFC 500 Maintenance Manual

Autopilot with envelope stability and protection, part 23 aml stc, includes instructions for continued airworthiness for stc sa01866wi
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See also: Manual
GFC 500
Autopilot with Envelope Stability
And Protection
Part 23 AML STC Maintenance Manual
Includes Instructions for Continued Airworthiness
for STC SA01866WI
190-02291-01
2017
Revision 1

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  • Page 1 GFC 500 Autopilot with Envelope Stability And Protection Part 23 AML STC Maintenance Manual Includes Instructions for Continued Airworthiness for STC SA01866WI 190-02291-01 2017 Revision 1...
  • Page 2 Garmin. Garmin hereby grants permission to download a single copy of this manual and of any revision to this manual onto a hard drive or other electronic storage medium to be viewed and...
  • Page 3 All information depicted in screen shots, including software file names, versions and part numbers, is subject to change and may not be up to date. GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page ii 190-02291-01...

  • Page 4: Table Of Contents

    Connector Layout ......................20 6. EQUIPMENT REMOVAL & INSTALLATION ..............21 GMC 507 ........................21 GSA 28 Servos ......................23 7. GFC 500 LRU REPLACEMENT/CONFIGURATION & TESTING ........24 GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page iii 190-02291-01 Revision 1...
  • Page 5 GFC 500 System Configuration ..................25 9. GFC 500 RETURN TO SERVICE PROCEDURE ...............26 Yaw Offset and Pitch/Roll Offset Calibration ..............26 Pre-Flight Test (PFT)....................26 Normal Mode Tests ......................27 GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page iv 190-02291-01 Revision 1...
  • Page 6 Figure 2-5 – Electrical Bonding Preparation – Terminal Lug ............9 Figure 6-1 – GMC 507 Installation with rack ................22 Figure 6-2 – GMC 507 Installation without rack .................22 GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page v 190-02291-01...
  • Page 7 Table 2-2 – Electrical Bonding ....................8 Table 4-1 – Maintenance Intervals ....................14 Table 4-2 – Visual Inspection Procedure ...................15 Table 4-3 – Lightning Strike Inspection Procedure ..............16 GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page vi 190-02291-01 Revision 1...

  • Page 8: Introduction

    (ICA) for the GFC 500 Autopilot with Envelope Stability and Protection as installed under Supplemental Type Certificate (STC) SA01866WI. 1.2 Applicability This document applies to all Part 23 aircraft equipped with the GFC 500 installed under AML STC SA01866WI. Modification of an aircraft by STC SA01866WI obligates the aircraft operator to include the maintenance information provided by this document in the operator’s Aircraft Maintenance...

  • Page 9: Definitions/Abbreviations

    Instrument Landing System LRU: Line Replaceable Unit OBS: Omni-Bearing Selector PFT: Pre-Flight Test SAE: Society of Automotive Engineers STC: Supplemental Type Certificate VOR: VHF Omnidirectional Radio GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 2 190-02291-01 Revision 1...

  • Page 10: Units Of Measure

    The documents listed in Table 1-1 are required by this maintenance manual to perform maintenance on the GFC 500 Autopilot. It is the responsibility of the owner/operator to ensure that the latest versions of these documents are used during operation, servicing or maintenance of the airplane.

  • Page 11: Revision And Distribution

    1.7 Revision and Distribution This document is required for maintaining the continued airworthiness of the GFC 500 Autopilot. When this document is revised, every page will be revised to indicate current revision level. Garmin Dealers may obtain the latest revision of this document on the Garmin Dealer Resource Center website.

  • Page 12: System Description

    The GSA 28 is limited to a maximum of 60 in-lbs of torque. GFC 500 Autopilot systems may have up to three servos (pitch, roll, and pitch trim). The pitch trim servo is optional and may not be available on all airframes. Most installations will use bridle cables attached to the primary flight control cables using clamps.

  • Page 13: Gfc 500 Interface Summary

    2.2 GFC 500 Interface Summary The following figure provides a high-level summary of the GFC 500 autopilot system. The G5 is required to be installed by STC SA01818WI. The minimum system requires the G5 in the attitude indicator position. Figure 2-2 – GFC 500 System Overview...

  • Page 14: Power Requirements

    2.3 Power Requirements Table 2-1 below summarizes the power requirements for the GFC 500 LRUs. Table 2-1 – Power Requirements Characteristics Specifications Average Current Draw @ 14 VDC 0.11 A Max Current Draw @ 14 VDC 0.20 A GMC 507 Average Current Draw @ 28 VDC 0.06 A...

  • Page 15: Figure 2-3 - Electrical Bonding Preparation - Nut Plate

    Figure 2-3, Figure 2-4, and Figure 2-5. Figure 2-3 – Electrical Bonding Preparation – Nut Plate Figure 2-4 – Electrical Bonding Preparation – Bolt/Nut Joint GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 8 190-02291-01...

  • Page 16: Figure 2-5 - Electrical Bonding Preparation - Terminal Lug

    Additional guidance can be found in SAE ARP 1870 Section 5. For a more detailed procedure, refer to SAE ARP 1870 Sections 5.1 and 5.5. GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 9 190-02291-01...

  • Page 17: Control And Operation

    3.3 Trim Switch If the GFC 500 Autopilot includes a pitch trim servo, a TRIM switch is provided on the pilot’s flight controls to allow for manual electric control of the pitch trim system. If the autopilot is engaged and the TRIM switch is pressed, the autopilot will disengage.

  • Page 19: Servicing Information

    4.2 Servicing Information Servicing of the GFC 500 Autopilot equipment is ‘on condition’. In the event of system failure, troubleshoot the GFC 500 Autopilot in accordance with Section 5. 4.2.1 On Condition Servicing ‘On Condition’ replacement and/or servicing should occur when an item exhibits conditions, symptoms, and/or abnormalities defined in Section 5 of this manual.
  • Page 20 4.2.2 Required Tools The following tools are needed to perform maintenance tasks on GFC 500 Autopilot equipment: • Calibrated Milliohm meter with Kelvin probes, OR o Agilent 34410A Ammeter or equivalent o Fluke 187 Voltmeter or equivalent o Variable DC Power Supply capable of providing 1 amp current •...

  • Page 21: Maintenance Intervals

    Removal and Replacement On Condition Controller With aircraft Servos, Servo Control manufacturer’s Cables and associated Visual Inspection Table 4-2 required primary hardware control cable checks GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 14 190-02291-01 Revision 1...

  • Page 22: Visual Inspection

    For continuous travel servos only, visually inspect the condition of the idler pulley, shaft, washer, and E-ring, to ensure no corrosion, chafing, cracks, or other defects exist. GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 15 190-02291-01...

  • Page 23: Electrical Bonding Test

    4.5.1 Requirements All GFC 500 equipment must be installed. For the GMC 507, the tests are performed with the connectors connected. For the GSA 28, tests are conducted with the connector disconnected.

  • Page 24: Disconnect Tone And Sonalert Test

    If a sonalert is connected, verify that the autopilot disconnect tone plays through the sonalert. NOTE: The normal autopilot disconnect sonalert tone is a continuous 2000 Hz tone that plays for approximately 3 seconds. GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 17 190-02291-01...

  • Page 25: Troubleshooting

    ICA, p/n 190-01112-11. 5.1 GFC 500 Failure Messages During operation of the GFC 500 Autopilot, the G5 may annunciate a failure or fault that is specific to the GFC 500 Autopilot. Contact Garmin Technical Support for assistance in troubleshooting the problem.
  • Page 26 Install Manual Addendum (190-02291-XX), the following troubleshooting steps may be used to help identify the cause. 1. Verify that the GFC 500 system is configured as shown on the model-specific Install Manual Addendum (190-02291-XX) 2. Verify that the trim servo is installed as shown on the model-specific Install Manual...

  • Page 27: Gfc 500 Interconnect Drawings

    GFC 500 Interconnect Drawings For GFC 500 interconnect drawings reference Garmin document 190-02291-00. Connector Layout For GFC 500 LRU connector layout reference Garmin document 190-02291-00. GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 20 190-02291-01 Revision 1...

  • Page 28: Equipment Removal & Installation

    6.1 GMC 507 Removal: 1. De-energize the GFC 500 system by pulling the AUTOPILOT circuit breaker. 2. Insert a 3/32” hex drive tool into the left and right access holes. 3. Turn the hex drive tool counterclockwise until the tool stops.

  • Page 29: Figure 6-1 - Gmc 507 Installation With Rack

    Figure 6-1 – GMC 507 Installation with rack Figure 6-2 – GMC 507 Installation without rack GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 22 190-02291-01 Revision 1...

  • Page 30: Gsa 28 Servos

    3. Reconnect the electrical connector (1P281 for Roll, 2P281 for Pitch, or 3P281 for Pitch Trim, as applicable) to the mating connector on the servo. 4. Perform a functional check of the GSA 28 per Section 7.2 GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 23 190-02291-01...

  • Page 31: Gfc 500 Lru Replacement/Configuration & Testing

    7. GFC 500 LRU Replacement/Configuration & Testing This section provides procedures to be followed after any GFC 500 LRU is replaced. At the beginning of each LRU section, instructions are given to guide the technician for various removal/replacement scenarios. These instructions define necessary procedures to be followed for situations where original equipment was reinstalled as well as for situations where new equipment (new serial number) is installed.

  • Page 32: Gfc 500 Software Load And Configuration Procedures

    Part 23 AML STC Maintenance Manual including ICA, p/n 190-01112-11 if the G5 was replaced. 8.2 GFC 500 System Configuration For configuration items not related to the GFC 500 Automatic Flight Control System, refer to the Garmin G5 Electronic Flight Instrument Part 23 AML STC Maintenance Manual including ICA, p/n 190-01112-11.

  • Page 33: Gfc 500 Return To Service Procedure

    9. GFC 500 Return to Service Procedure The following sections will verify the proper operation of the GFC 500 Autopilot after maintenance has been performed on the system. Operational information regarding the GFC 500 Autopilot can be found in the G5 Electronic Flight Instrument Pilot’s Guide for Certified Aircraft, p/n 190-01112-12.

  • Page 34: Normal Mode Tests

    4. Depending on the aircraft and the control system, the pitch trim may run automatically at any time while the autopilot is engaged. If it gets to the end of its travel, an amber TRIM annunciation may appear. GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 27 190-02291-01...
  • Page 35 11. Ensure that the pitch trim (if installed) begins running in the nose down direction. 12. Rotate the NOSE UP/DN thumbwheel on the GMC 507 DN three clicks. GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 28...
  • Page 36 7. Verify that the Pitch Trim Servo engages and drives the airplane trim system in a Nose Up direction. 8. Release the TRIM switch. GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 29 190-02291-01 Revision 1...
  • Page 37 Install Manual Addendum (190-02291-XX). 18. Press the FD button on the GMC 507. 19. Verify that the flight director command bars are no longer displayed. GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 30 190-02291-01 Revision 1...
  • Page 38 (190-02291-XX). If the elapsed time is not within the specified range, refer to Section 5.2 in this manual. 4. Repeat the test in the opposite direction. GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 31 190-02291-01...
  • Page 39 16. Press the AP DISC/TRIM INT switch to disengage the autopilot. 17. Press the FD button to remove the flight director bars from the G5 GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 32 190-02291-01...
  • Page 40 18. Verify ROL and PIT are displayed on the G5. 19. Press the AP DISC/TRIM INT switch to disengage the autopilot. 20. Press the FD button to remove the flight director bars from the G5 GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 33 190-02291-01...
  • Page 41 14. Apply left LOC deviation on the test set. 15. Verify that the flight director command bars indicate a left turn and that the flight controls turn to the left. GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 34 190-02291-01...
  • Page 42 15. Verify that the flight director command bars indicate a pitch down command and the flight controls respond in a nose down direction. 16. Adjust the air data test set for 140 kts airspeed. GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 35 190-02291-01...
  • Page 43 19. Verify that PIT illuminates in green on the G5 and that the VS bug is removed from the 20. Press the AP DISC/TRIM INT switch to disengage the autopilot. GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 36...
  • Page 44 7. When the altitude reaches 3450 +/- 20 feet, verify that Green ALT flashes for approximately 3 seconds in place of ALTS on the G5 and then displays steady. NOTE: GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 37 190-02291-01...
  • Page 45 13. Press the AP DISC/TRIM INT switch to disengage the autopilot. 14. Press the FD button to remove the flight director bars from the G5. GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 38 190-02291-01...
  • Page 46 This appendix includes the following information: • General installation information • Interfaced equipment • GFC 500 Autopilot configuration log • GFC 500 Autopilot wiring diagrams GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page A-1 190-02291-01 Revision 1...
  • Page 47 Mod Level_________________________________________________________________ GSA 28 Roll Servo Part Number_______________________________________________________________ Serial Number______________________________________________________________ Mod Level_________________________________________________________________ GSA 28 Pitch Trim Servo (if installed) Part Number_______________________________________________________________ Serial Number______________________________________________________________ Mod Level_________________________________________________________________ GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page A-2 190-02291-01 Revision 1...
  • Page 48 Minimum Airspeed Limit Maximum Airspeed Limit Vertical Speed Gain Vertical Acceleration Gain Airspeed Gain Expert Configuration Fine Adjust Amount Fine Adjust Time Airspeed Acceleration Gain GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page A-3 190-02291-01 Revision 1...
  • Page 49 High Airspeed Threshold Fastest Movement Speed Slowest Movement Speed Maximum Run Time AP Disc Input = Open Trim Input Test Trim Movement Expert Configuration GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page A-4 190-02291-01 Revision 1...
  • Page 50 Default ESP Powerup State Enabled ☐Enabled ☐Disabled Auto Engage LVL Mode AFCS Setup Page Disabled Disabled Notes: Note (A) through (D) are used for troubleshooting purposes only. GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page A-5 190-02291-01 Revision 1...
  • Page 51 (H) Set this field to “Enabled for dual G5 installations. Set this field to “Disabled” for G5 ADI-only installations that have an external CDI connected to the navigator. GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page A-6 190-02291-01...
  • Page 52 Record equipment locations and sketch the approximate location of wire routing in or as applicable. Figure A-1 – Equipment Location and Wire Routing – Single Engine Airplane GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page A-7 190-02291-01...
  • Page 53 Figure A-2 – Equipment Location and Wire Routing – Twin Engine Airplane GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page A-8 190-02291-01 Revision 1...

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