FORM: 2391 DRAWING NO: ICA-525-27-00005 Cessna Aircraft Company P.O Box 7704 WICHITA, KS 67277 ENGINEERING DRAWING AND PART LIST SIGNATURE AUTHORIZATION Originals Electronically Signed in the VPM System ================================================================================ REVISION: ICA-525-27-00005 ICA --- PKG: 0000113572 ================================================================================ ORIGINATOR (DRM) Brice Logan (APPROVE 11/22/2017 15:08:15) MAINTENANCE_ENG (ALL) Stephen Taylor (APPROVE 11/22/2017 13:53:46) ICA_COORDINATOR (ALL) Jason Peterson (APPROVE 11/22/2017 15:10:04) PROJECT (525 SERIES) Neil Hague (APPROVE 11/22/2017 14:03:23) AIRWORTHINESS (ALL) Chad Groene (APPROVE 11/22/2017 14:54:36) ODA ICA admin (ALL) Doug Carpenter (APPROVE 11/22/2017 14:30:41) ICA_COORDINATOR (ALL) Jason Peterson (APPROVE 11/22/2017 15:11:10) RELEASE (ALL) Stephanie Haymond (APPROVE 11/22/2017 15:15:59)
TEXTRON AVIATION INC. AIRCRAFT DIVISION WICHITA, KANSAS 67277 AUTOPILOT CLAMP BLOCK IMPROVEMENT ICA Supplement MODEL NO: 525 SUPPLEMENT NO: ICA-525-27-00005 SUPPLEMENT DATE: 11/22/2017 TEXTRON AVIATION INC. Form 2261 Rev 1
TEXTRON AVIATION INC. AIRCRAFT DIVISION WICHITA, KANSAS 67277 REVISIONS ICA-525-27-00005 Rev: - Date: Nov 22/2017 ICA Summary Pages 1-6 Manuals Affected Description Title Maintenance Manual 22-10-25 pages 401-408 GARMIN RUDDER AUTOPILOT SERVO ASSEMBLY - REMOVAL/INSTALLATION This section contains the revised procedures for installation of the autopilot clamp blocks. Maintenance Manual 22-10-35 pages 401-405 GARMIN ELEVATOR AUTOPILOT SERVO ASSEMBLY - REMOVAL/INSTALLATION This section contains the revised procedures for installation of the autopilot clamp blocks. Maintenance Manual 27-30-05 pages 201-214 ELEVATOR AND TAB SYSTEM CONTROL CABLES - MAINTENANCE PRACTICES This section contains the revised procedures for installation of the autopilot clamp blocks. Maintenance Manual 27-30-10 pages 401-420 ELEVATOR AND TAB SYSTEM COMPONENTS - REMOVAL/INSTALLATION This section contains the revised procedures for installation of the autopilot clamp blocks. Appendix A: Illustrated Parts Catalog Appendix B: Wiring Diagram Manual NOT USED See Attached Parts Table NOTE 1: This change to clamp block installation and torque speciication has also revised procedures for torque speciications of clamp blocks introduced in Airplanes -0871 thru -0971. Clamp blocks installed on Airplanes -0871 thru -0971 was 25 inch pounds to 40 inch pounds and is NOW 30 inch pounds to 40 inch pounds to match new design. 1. Export Compliance A. This publication contains technical data and is subject to U.S. export regulations. This information has been exported from the United States in accordance with export administration regulations. Diversion contrary to U.S. law is prohibited. ECCN: 9E991 2. Revision Bars A. Revision bars in this ICA supplement identify new ICAs and/or changes to the current ICAs in the released maintenance manual. New ICAs that are not in the current maintenance manual will have a revision bar from top to bottom along the left margin. ICAs that are in the current maintenance manual and have information added, deleted or revised will have a revision bar(s) in the left margin adjacent to the added, deleted or revised information. New or changed illustrations will have a change bar for the entire length of the page. 3. Page Numbering A. The page number system for ICA included in this supplement have three-element numbers that are separated by dashes. The three-element number is found at the bottom right corner of the page, left of the page number. The date is found below the page number. Page 1 of 6 Nov 22/2017 TEXTRON AVIATION INC.
TEXTRON AVIATION INC. AIRCRAFT DIVISION WICHITA, KANSAS 67277 B. When the chapter/system element number is followed with zeros in the section/subsystem and subject/unit element number (28-00-00), the information is applicable to the entire system. C. When the section/subsystem element number is followed with zeros in the subject/unit element number (28-21-00), the information is applicable to the subsystems in the system. D. The subject/unit element number is used to identify information applicable to units in the subsystems. The subject/unit element number continues in sequence from the number -01- with the number of subsystem units in which maintenance information is necessary. E. All system/subsystem/unit (chapter/section/subject) maintenance data is separated into speciied types of information: Description and Operation, Troubleshooting, Maintenance Practices, etc. Blocks of page numbers that are in sequence are used to identify the type of information: (1) Description and Operation or Troubleshooting information may not be included if the procedure is easy. When subtopics are short, they may be put together into the Maintenance Practices section. Maintenance Practices can have a mix of subtopics that includes information to service, remove, install, adjust, test, clean, paint or do approved repairs. (2) Longer procedures that are not as easy to do may be included in a speciied section. Page 1 through 99 - Description and Operation Page 101 through 199 - Troubleshooting Page 201 through 299 - Maintenance Practices Page 301 through 399 - Servicing Page 401 through 499 - Removal/Installation Page 501 through 599 - Adjustment/Test Page 601 through 699 - Inspection/Check Page 701 through 799 - Cleaning/Painting Page 801 through 899 - Approved Repairs F. A typical page number: G. Illustrations use the same igure numbers as the page block in which they appear. For example, Figure 202 would be the second igure in a Maintenance Practices section. Page 2 of 6 Nov 22/2017 TEXTRON AVIATION INC.
TEXTRON AVIATION INC. AIRCRAFT DIVISION WICHITA, KANSAS 67277 4. Supplement Revisions A. Revisions to this supplement may be accomplished if changes to this supplement are required after release of the original issue and prior to incorporation into the manuals listed in the REVISIONS table. B. All revisions to this supplement will have changes identiied in detail in the revision block(s) above. C. All pages in this ICA supplement will have the same date and are valid as of the date shown. 5. ICA Incorporation into Applicable Manuals Most ICA supplements will be incorporated in the next available revision to the manuals listed above and should be used in conjunction with those manuals until the next available revision is released. A. The ICA Supplement List located in the Introduction section of each manual listed in the REVISIONS table will indicate the incorporation status as of the release date of the published revision. B. The manual revision level of the supplement incorporation will be listed in the "Manual Incorporation Status" column in the ICA Supplement List, when those ICAs associated with that manual have been incorporated. After ICAs are incorporated, the manual that they are incorporated in must now be used for those ICAs instead of the supplement. Based on revision cycle times for the affected manuals, MM ICAs, WDM ICAs, etc. in this supplement may be incorporated in the manuals at different times. There will not be a revision to this supplement to indicate incorporation in the manuals. Users are required to check the ICA Supplement List for each manual affected to determine incorporation status. C. This supplement will be completely superseded by the manuals listed in the REVISIONS table when it has been incorporated in all of the manuals. Page 3 of 6 Nov 22/2017 TEXTRON AVIATION INC.
TEXTRON AVIATION INC. AIRCRAFT DIVISION WICHITA, KANSAS 67277 1. Purpose INTRODUCTION A. The purpose of this Supplement is to provide the maintenance technician with the information necessary to ensure the correct functionality and performance of the AUTOPILOT CLAMP BLOCK IMPROVEMENT on the Cessna Model 525 (M2) until this information gets incorporated into the next revision to the manuals listed in the "REVISIONS" section of this supplement. B. This ICA supplement is designed to satisfy the requirements of 14 CFR 23.1529 "Instructions for Continued Airworthiness" associated with this installation. This document is a supplement to the Model 525 (0685 and -0800 and On) Maintenance Manual and will be incorporated in the next revision to the manual. C. When this information is incorporated in the next revision to the manuals listed in the "REVISIONS" section, those manuals shall take precedence over this supplemental document. Refer to the "ICA Supplement List" in the "Introduction" section of the respective manual for the status of all applicable ICA Supplements. D. Revisions to this supplement may occur if there is a change to any of the ICAs in this supplement prior to incorporation into all of the affected manuals. This document must be placed with the aircraft operator's Technical Library CD-ROM or Model 525 (0685 and -0800 and On) Maintenance Manual and incorporated into the operator's scheduled maintenance program. 2. Effectivity A. These Instructions for Continued Airworthiness (ICA) are effective for the following aircraft model and serialization. Model Beginning Effectivity Ending Effectivity 525 (M2) -0972 and On 3. Complete ICA Documents A. The following document(s), in conjunction with this supplement, constitute the Instructions for Continued Airworthiness for the AUTOPILOT CLAMP BLOCK IMPROVEMENT on the Cessna Model 525 (M2). All items must be available to the operator at initial delivery. (1) Model 525 (0685 and 0800 and On) Maintenance Manual 4. System Components A. Refer to Appendix A: Illustrated Parts Catalog Page 4 of 6 Nov 22/2017 TEXTRON AVIATION INC.
TEXTRON AVIATION INC. AIRCRAFT DIVISION WICHITA, KANSAS 67277 LIST OF INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 1. Model 525 (0685 and 0800 and On) Maintenance Manual A. Chapter 22 Auto Flight (1) ATA 22-10-25 Garmin Rudder Autopilot Servo Assembly - Removal/Installation (2) ATA 22-10-35 Garmin Elevator Autopilot Servo Assembly - Removal/Installation B. Chapter 27 Flight Contols (1) ATA 27-30-05 Elevator and Tab System Control Cables - Maintenance Practices (2) ATA 27-30-10 Elevator and Tab System Components- Removal/Installation Page 5 of 6 Nov 22/2017 TEXTRON AVIATION INC.
TEXTRON AVIATION INC. AIRCRAFT DIVISION WICHITA, KANSAS 67277 1. Continuous Inspection Program INSPECTION PROGRAM AND AIRWORTHINESS LIMITATIONS A. This ICA Supplement does not affect the current inspection program. 2. Airworthiness Limitations A. Cessna Aircraft Company Model 525 (0685 and 0800 and On) Maintenance Manual, Chapter 4, Airworthiness Limitations, contains the system and airframe limitations for the Model 525 (M2). The Airworthiness Limitations section is FAA-approved and speciies maintenance required under Section 43.16 and 91.403 of Title 14 Code of Federal Regulations, unless an alternative program has been FAA approved. (1) There are no new (or additional) airworthiness limitations associated with this equipment and/or installation. Page 6 of 6 Nov 22/2017 TEXTRON AVIATION INC.
1. General GARMIN RUDDER AUTOPILOT SERVO ASSEMBLY - REMOVAL/INSTALLATION A. This section gives the removal and installation procedures for the Garmin Rudder Autopilot Servo Assembly. The Garmin Rudder Autopilot Servo Assembly includes the Garmin GSA 80 Rudder Autopilot Servo Actuator and the Garmin GSM 86 Rudder Autopilot Servo Gear Box. For a general description of the rudder autopilot function, refer to Auto Flight - General. For more detailed Garmin GSM 86 maintenance data refer to the GSM 86 Servo Gear Box Installation Manual P/N 190-00303-83 found in the Supplier publication List. 2. Tools and Equipment A. Refer to Chapter 22, Auto Flight - General Tools and Equipment. 3. Garmin GSA 80 Rudder Autopilot Servo Actuator (Motor) Removal/Installation A. Remove the Rudder Autopilot Servo Actuator (Motor) (Refer to Figure 401). (1) Remove the electrical power from the airplane. (2) Disengage the Automatic Flight Control System (AFCS) circuit breaker on the right circuit breaker panel in the cockpit. (3) Open the tailcone baggage compartment door. Refer to Chapter 6, Dimensions and Areas - Description and Operation. (4) Remove aft baggage compartment panel 321AL to get access to the rudder autopilot servo actuator. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (5) Disconnect the electrical connector (JT310) from the rudder autopilot servo actuator electrical connector. (6) Remove the bolts and the washers that attach the rudder autopilot servo actuator to the rudder autopilot servo gear box. (7) Remove the rudder autopilot servo actuator from the rudder autopilot servo gear box and the airplane. (8) If necessary, use a clean, lint-free cloth and remove unwanted grease buildup from the rudder autopilot servo actuator output gear. (9) If the rudder autopilot servo actuator is not going to be installed immediately, put covers over the openings to keep the rudder autopilot servo gear box and rudder autopilot servo actuator clean. B. Install the Rudder Autopilot Servo Actuator (Motor) (Refer to Figure 401). (1) Remove the protective covers from the rudder autopilot servo gear box and rudder autopilot servo actuator openings. (2) Apply a thin layer of Aeroshell 33MS grease or an equivalent to the rudder autopilot servo actuator output gear. Refer to Chapter 22, Auto Flight - General. (3) Put the rudder autopilot servo actuator in it's correct position on the rudder autopilot servo gear box. (4) Align the splines on the rudder autopilot servo actuator shaft with the splines in the rudder autopilot servo gear box. (5) Starting with two opposite corner bolts, tighten all bolts until 0.01 to 0.03 Inches (0.25 to 0.76 mm) from fully seated. (6) Verify that the rudder autopilot servo actuator is still slightly loose relative to the rudder autopilot servo gear box, ensuring there is still relative movement between the two units. (7) Starting with two opposite corner bolts, torque all bolts from 25.00 to 40.00 inch-pounds (2.82 N-m to 4.51 N-m). Refer to Chapter 20, Torque Data - Maintenance Practices. (8) Connect the electrical connector (JT310) to the rudder autopilot servo actuator electrical connector. (9) Engage the AFCS circuit breaker on the right circuit breaker panel in the cockpit. 22-10-25 Page 401
(10) If a new rudder autopilot servo actuator has been installed, do the G3000 Baseline Software/ Coniguration Installation. Refer to Chapter 34, Garmin Integrated Avionics System - Adjustment/Test. For more data applicable to the Model 525 G3000 software and coniguration uploading procedures, refer to Section 6 and Section 8 of the Garmin G3000 Integrated Avionics System Line Maintenance Manual, P/N 190-01579-00, found in the Introduction, Supplier Publication List. (11) Do the Garmin GFC 700 AFCS Operational Test, Yaw Axis Check. Refer to Chapter 22, Garmin GFC 700 AFCS - Adjustment/Test. (12) Install the aft baggage compartment panel 321AL. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (13) Close the tailcone baggage compartment door. Refer to Chapter 6, Dimensions and Areas - Description and Operation. 4. Garmin GSM 86 Rudder Autopilot Servo Gear Box (Mount) and Cables Removal/Installation A. Remove the Rudder Autopilot Servo Gear Box (Mount) and Cables. (Refer to Figure 401). (1) Remove the electrical power from the airplane. (2) Disengage the AFCS circuit breaker on the right circuit breaker panel in the cockpit. (3) Open the tailcone baggage compartment door. Refer to Chapter 6, Dimensions and Areas - Description and Operation. (4) Remove aft baggage compartment panel 321AL to get access to the rudder autopilot servo motor. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (5) Remove the rudder autopilot servo actuator. Refer to, Garmin GSA 80 Rudder Autopilot Servo Actuator (Motor) Removal/Installation in this section. (6) For Airplanes -0685 and -0800 and On, do the steps that follow: (a) Remove the clips from the turnbuckle that connects the rudder upper autopilot cable to the aft rudder autopilot cable. Refer to Chapter 20, Safetying - Maintenance Practices. (b) Loosen the turnbuckle to release the cable tension. (c) (d) Remove the rudder upper autopilot cable from the turnbuckle. For Airplanes -0685 and -0800 thru -0870 that have NOT incorporating SB525-27-24, put a mark on the rudder left aft cable that shows the clamp block position for the attachment of the rudder lower autopilot cable to the rudder left aft cable. 11.4 +0.50 or -0.50 Inches (289.56 +12.70 or -12.70 mm) from the center of the rudder autopilot servo gear box. (e) Loosen the clamp block screws and nuts. Airplanes -0685, and -0800 thru -0870 NOT incorporating SB525-27-24 use a clamp block that is attached with screws and nuts. (f) For Airplanes -0685 and -0800 thru -0870 Incorporating SB525-27-24 and Airplanes -0871 and On, remove eyebolt and cable. (g) Remove the clips from the turnbuckle that connects the rudder upper autopilot cable to the aft rudder autopilot cable. Refer to Chapter 20, Safetying - Maintenance Practices. (h) Loosen the turnbuckle to release the cable tension. (i) Remove the rudder upper autopilot cable from the turnbuckle. (j) Remove the bolt, washer, nut, and cotter pin from the fork end terminal that connect the left aft rudder cable to the rudder lower autopilot cable and left middle rudder cable. (k) Remove the lower rudder autopilot cable from the left aft rudder cable. (l) Remove the lower autopilot rudder cable from the left aft rudder cable. (7) Remove the bolts that attach the rudder autopilot servo gear box to the bracket. (8) Remove the rudder autopilot servo gear box and the cables from the airplane. (9) If the rudder autopilot servo gear box is to be replaced remove the cable as follows: (a) Remove the screws and the washers that attach the capstan cover to the cable guard pins. 1 Remove the capstan cover from the pins. 22-10-25 Page 402
(b) (c) (d) Remove the cable guard pins from the rudder autopilot servo gear box. Record how the cable is installed on the capstan drum. Remove the cable from the capstan drum. 1 If the servo gearbox capstan has retaining clips, the swaged ball end of the cable can be removed by sliding the ball past the clip while pressing the retaining clip with a lat screwdriver or similar tool. Refer to, Figure 402. B. Install the Rudder Autopilot Servo Gear Box (Mount) and Cables. (Refer to Figure 401). (1) If the rudder autopilot servo gear box has been replaced install the cables as follows: (a) Install cables on the rudder autopilot servo gear box capstan drum as recorded. CAUTION: Make sure the ball is fully seated in the capstan. (b) Install the cable guard pins in the positions A, C, F, and J on the rudder autopilot servo gear box. (c) Put the capstan cover in its position on the cable guard pins. (d) Install but do not tighten the capstan cover screws and washers. (e) Start with two opposite screws, torque all the screws from 8.00 to 12.00 inch-pounds (0.90 N-m to 1.35 N-m). Refer to Chapter 20, Torque Data - Maintenance Practices. (2) Put the rudder autopilot servo gear box and the cables in their position at the rudder autopilot servo gear box bracket assembly. (a) Start with two opposite bolts, torque all the bolts from 25.00 to 40.00 inch-pounds (2.82 N-m to 4.51 N-m). Refer to Chapter 20, Torque Data - Maintenance Practices. (3) For Airplanes -0685 and -0800 thru -0870 that have NOT incorporated SB525-27-24, do the steps that follow: (a) Put the lower rudder autopilot cable in the clamp block. (b) Make sure the clamp block is aligned at the mark on the left aft rudder cable. 14.50 +0.50 or -0.50 Inches (368.30 +12.70 or -12.70 mm) from the center of the rudder autopilot servo gear box. (c) Tighten the clamp block nuts from 12.00 to 15.00 inch-pounds (1.35 N-m to 1.69 N-m). Refer to Chapter 20, Torque Data - Maintenance Practices. (d) Install the rudder upper autopilot cable to the turnbuckle that connects the upper rudder autopilot cable to the upper aft rudder autopilot cable. (4) For Airplanes -0685 and -0800 thru -0870 Incorporating SB525-27-24 and airplanes -0871 and On, do the steps that follow: (a) Install the bolt, washer, nut and cotter pin to the fork end terminal that connects the left aft rudder cable to the rudder lower autopilot cable and left middle rudder cable. (b) Install the rudder upper autopilot cable to the turnbuckle that connects the upper rudder autopilot cable to the upper aft rudder autopilot cable. (5) Install the rudder autopilot servo actuator. Refer to, Garmin GSA 80 Rudder Autopilot Servo Actuator (Motor) Removal/Installation in this section. (6) Tighten the rudder servo cable turnbuckle to the correct cable tension. Refer to Chapter 27, Rudder and Tab System - Adjustment/Test, Figure 502. (7) Install the clips on the turnbuckle. Refer to Chapter 20, Safetying - Maintenance Practices. (8) Engage the AFCS circuit breaker on the right circuit breaker panel in the cockpit. (9) If the rudder autopilot servo gear box and the rudder autopilot servo actuator were replaced new as an assembly, do the G3000 Baseline Software/Coniguration Installation. Refer to Chapter 34, Garmin Integrated Avionics System - Adjustment/Test. For more data applicable to the Model 525 G3000 software and coniguration uploading procedures, refer to Section 6 and Section 8 of the Garmin G3000 Integrated Avionics System Line Maintenance Manual, P/N 190-01579-00, found in the Introduction, Supplier Publication List. (10) Do the Garmin GFC 700 AFCS Operational Test, Yaw Axis Check. Refer to Chapter 22, Garmin GFC 700 AFCS - Adjustment/Test. 22-10-25 Page 403
(11) Install the aft baggage compartment panel 321AL. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (12) Close the tailcone baggage compartment door. Refer to Chapter 6, Dimensions and Areas - Description and Operation. 22-10-25 Page 404
Garmin Rudder Autopilot Servo Assembly Figure 401 (Sheet 1) 22-10-25 Page 405
Garmin Rudder Autopilot Servo Assembly Figure 401 (Sheet 2) 22-10-25 Page 406
Garmin Rudder Autopilot Servo Assembly Figure 401 (Sheet 3) 22-10-25 Page 407
Swaged Ball from 3/32" Spiral Wrap Capstan Figure 402 (Sheet 1) 22-10-25 Page 408
1. General GARMIN ELEVATOR AUTOPILOT SERVO ASSEMBLY - REMOVAL/INSTALLATION A. This section gives the removal and installation procedures for the Garmin Elevator Autopilot Servo Assembly. The Garmin Elevator Autopilot Servo Assembly includes the Garmin GSA 81 Elevator Autopilot Servo Actuator and the Garmin GSM 86 Elevator Autopilot Servo Gear Box. For a general description of the elevator autopilot function, refer to Auto Flight - General. For more detailed maintenance data, refer to the GSM 86 Servo Gear Box Installation Manual P/N 190-00303-83 found in the Supplier publication List. 2. Tools and Equipment A. Refer to Chapter 22, Auto Flight - General Tools and Equipment. 3. Garmin GSA 81 Elevator Autopilot Servo Actuator (Motor) Removal/Installation A. Remove the Elevator Autopilot Servo Actuator (Motor) (Refer to Figure 401). (1) Remove the electrical power from the airplane. (2) Disengage the Automatic Flight Control System (AFCS) circuit breaker on the right circuit breaker panel in the cockpit. (3) Open the tailcone baggage compartment door. Refer to Chapter 6, Dimensions and Areas - Description and Operation. (4) Remove aft baggage compartment panel 321AL to get access to the elevator autopilot servo actuator. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (5) Disconnect the electrical connector (JT311) from the elevator autopilot servo actuator electrical connector. (6) Remove the bolts and the washers that attach the elevator autopilot servo actuator to the elevator autopilot servo gear box. (7) Remove the elevator autopilot servo actuator from the elevator autopilot servo gear box and the airplane. (8) If necessary, use a clean, lint-free cloth and remove unwanted grease buildup from the elevator autopilot servo actuator output gear. (9) If the elevator autopilot servo actuator is not going to be installed immediately, put covers over the openings to keep the elevator autopilot servo gear box and elevator autopilot servo actuator clean. B. Install the Elevator Autopilot Servo Actuator (Motor) (Refer to Figure 401). (1) Remove the protective covers from the elevator autopilot servo gear box and elevator autopilot servo actuator openings. (2) Apply a thin layer of Aeroshell 33MS grease or an equivalent to the elevator autopilot servo actuator output gear. Refer to Chapter 22, Auto Flight - General. (3) Put the elevator autopilot servo actuator in it's correct position on the elevator autopilot servo gear box. (4) Align the splines on the elevator autopilot servo actuator shaft with the splines in the elevator autopilot servo gear box. (5) Starting with two opposite corner bolts, tighten all bolts until 0.01 to 0.03 Inches (0.25 to 0.76 mm) from fully seated. (6) Verify that the rudder autopilot servo actuator is still slightly loose relative to the rudder autopilot servo gear box, ensuring there is still relative movement between the two units. (7) Starting with two opposite corner bolts, torque all bolts from 25.00 to 40.00 inch-pounds (2.82 N-m to 4.51 N-m). Refer to Chapter 20, Torque Data - Maintenance Practices. (8) Connect the electrical connector (JT311) to the elevator autopilot servo actuator electrical connector. (9) Engage the AFCS circuit breaker on the right circuit breaker panel in the cockpit. 22-10-35 Page 401
(10) If a new elevator autopilot servo actuator has been installed, do the G3000 Baseline Software/ Coniguration Installation. Refer to Chapter 34, Garmin Integrated Avionics System - Adjustment/Test. For more data applicable to the Model 525 G3000 software and coniguration uploading procedures, refer to Section 6 and Section 8 of the Garmin G3000 Integrated Avionics System Line Maintenance Manual, P/N 190-01579-00, found in the Introduction, Supplier Publication List. (11) Do the Garmin GFC 700 AFCS Operational Test, Pitch Axis Check. Refer to Chapter 22, Garmin GFC 700 AFCS - Adjustment/Test. (12) Install aft baggage compartment panel 321AL. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (13) Close the tailcone baggage compartment door. Refer to Chapter 6, Dimensions and Areas - Description and Operation. 4. Garmin GSM 86 Elevator Autopilot Servo Gear Box (Mount) and Cables Removal/Installation A. Remove the Elevator Autopilot Servo Gear Box (Mount) and Cables (Refer to Figure 401). (1) Remove the electrical power from the airplane. (2) Disengage the AFCS circuit breaker on the right circuit breaker panel in the cockpit. (3) Open the tailcone baggage compartment door. Refer to Chapter 6, Dimensions and Areas - Description and Operation. (4) Remove aft baggage compartment panel 321AL to get access to the elevator autopilot servo mount and cable. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (5) Remove the elevator autopilot servo actuator. Refer to, Garmin GSA 81 Elevator Autopilot Servo Actuator (Motor) Removal/Installation in this section. (6) For Airplanes -0685 and -0800 and On, do the steps that follow: (a) Remove the clips from the turnbuckle that connects the elevator upper autopilot cable to the upper elevator aft autopilot cable. Refer to Chapter 20, Safetying - Maintenance Practices. (b) Loosen the turnbuckle to release the cable tension. (c) (d) Remove the elevator upper autopilot cable from the turnbuckle. Put a mark on the elevator left aft cable that shows the clamp block position for the attachment of the elevator lower autopilot cable to the elevator left aft cable. 11.4 +0.50 or -0.50 Inches (289.56 +12.70 or -12.70 mm) from the center of the elevator autopilot servo gear box. (e) Loosen the clamp block screws/nuts. Airplanes -0685, and -0800 thru -0870 use a clamp block that is attached with screws and nuts. Airplanes -0871 and On use a clamp block that is attached with screws on threaded clamp block half. (f) Remove the elevator lower autopilot cable from the elevator left aft cable. (7) Remove the bolts that attach the elevator autopilot servo gear box to the bracket. (8) Remove the elevator autopilot servo gear box and the cables from the airplane. (9) If the elevator autopilot servo gear box is to be replaced remove the cable as follows: (a) Remove the screws and the washers that attach the capstan cover to the cable guard pins. 1 Remove the capstan cover from the pins. (b) Remove the cable guard pins from the elevator autopilot servo gear box. (c) Record how the cable is installed on the capstan drum. (d) Remove the cable from the capstan drum. 1 If the servo gearbox capstan has retaining clips, the swaged ball end of the cable can be removed by sliding the ball past the clip while pressing the retaining clip with a lat screwdriver or similar tool. Refer to, Figure 402. 22-10-35 Page 402
B. Install the Elevator Autopilot Servo Gear Box (Refer to Figure 401). (1) If the elevator autopilot servo gear box has been replaced install the cables as follows: (a) Install cables on the elevator autopilot servo gear box capstan drum as recorded. CAUTION: Make sure the ball is fully seated in the capstan. (b) Install the cable guard pins in the positions A, C, F, and J on the elevator autopilot servo gear box. (c) Put the capstan cover in its position on the cable guard pins. (d) Install but do not tighten the capstan cover screws and washers. (e) Start with two opposite screws, torque all the screws from 8.00 to 12.00 inch-pounds (0.90 N-m to 1.35 N-m). Refer to Chapter 20, Torque Data - Maintenance Practices. (2) Put the elevator autopilot servo gear box and the cables in their position at the elevator autopilot servo gear box bracket assembly. (a) Start with two opposite bolts, torque all the bolts from 25.00 to 40.00 inch-pounds (2.82 N-m to 4.51 N-m). Refer to Chapter 20, Torque Data - Maintenance Practices. (3) Put the elevator lower autopilot cable in the clamp block. (4) Make sure the clamp block is aligned at the mark on the elevator left aft cable. 11.4 +0.50 or -0.50 Inches (289.56 +12.70 or -12.70 mm) from the center of the elevator autopilot servo gear box. Airplanes -0685, and -0800 thru -0870 use a clamp block that is attached with screws and nuts. Airplanes -0871 and On use a clamp block that is attached with screws on threaded clamp block half. (a) Airplanes -0685 and -0800 thru -0870, tighten the clamp block nuts from 12.00 and 15.00 inch-pounds (1.35 N-m to 1.69 N-m). (b) Airplanes -0871 and On, tighten the clamp block nuts from 30-40 inch pounds (3.39 N-m to 4.51 N-m) (c) Install the elevator upper autopilot cable to the turnbuckle that connects the elevator upper autopilot cable to the upper elevator aft autopilot cable. (5) Install the elevator autopilot servo actuator. Refer to, Garmin GSA 81 Elevator Autopilot Servo Actuator (Motor) Removal/Installation in this section. (6) Tighten the elevator autopilot servo cable turnbuckle to the correct cable tension. Refer to Elevator and Tab System Control Cables - Adjustment/Test, Figure 502. (7) Install the clips on the turnbuckle. Refer to Chapter 20, Safetying - Maintenance Practices. (8) Engage the AFCS circuit breaker on the right circuit breaker panel in the cockpit. (9) If the elevator autopilot servo gear box and the elevator autopilot servo actuator were replaced new as an assembly, do the G3000 Baseline Software/Coniguration Installation. Refer to Chapter 34, Garmin Integrated Avionics System - Adjustment/Test. For more data applicable to the Model 525 G3000 software and coniguration uploading procedures, refer to Section 6 and Section 8 of the Garmin G3000 Integrated Avionics System Line Maintenance Manual, P/N 190-01579-00, found in the Introduction, Supplier Publication List. (10) Do the Garmin GFC 700 AFCS Operational Test, Pitch Axis Check. Refer to Chapter 22, Garmin GFC 700 AFCS - Adjustment/Test. (11) Install aft baggage compartment panel 321AL. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (12) Close the tailcone baggage compartment door. Refer to Chapter 6, Dimensions and Areas - Description and Operation. 22-10-35 Page 403
Garmin Elevator Autopilot Servo Assembly Figure 401 (Sheet 1) 22-10-35 Page 404
Swaged Ball from 3/32" Spiral Wrap Capstan Figure 402 (Sheet 1) 22-10-35 Page 405
1. General ELEVATOR AND TAB SYSTEM CONTROL CABLES - MAINTENANCE PRACTICES A. Refer to Elevator and Tab System Components - Removal/Installation for elevator and tab components not covered in this section. B. Refer to Chapter 55, Elevator - Removal/Installation for removal, installation and maintenance of the elevator. 2. Tools and Equipment A. For a list of necessary tools and equipment, refer to Flight Controls - General. 3. Elevator Forward Control Cables Removal/Installation A. Remove the Forward Control Cables (Refer to Figure 201). (1) Remove the pilot and copilot seats. Refer to Chapter 25, Crew Seats - Maintenance Practices. (2) Remove panels 241BTC, 252ATC, 252BTC, 252CTC, 252DTC, 252GC, and 251FL to get access to the forward control cables. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (3) Remove the aft evaporator to get access to the pressure seals on the aft pressure bulkhead. Refer to Chapter 21, Cooling System - Maintenance Practices. (4) Remove screws, washers and nuts attaching the upper left fairlead to the forward control cables at FS 208.67 and FS 249.16, and remove the fairleads. (5) Enter aft baggage compartment. (6) Remove panels 321A, 321AZ, 321BB, 321CB, 321DC and 321FC to get access to the forward control cables. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (7) Remove the clips and loosen the turnbuckle for the elevator autopilot servo cable. Refer to Chapter 22, Garmin Elevator Autopilot Servo Assembly - Removal/Installation. (8) Remove the clips and disconnect the forward control cable turnbuckles at FS 339.55 and FS 355.74 from the aft control cables. (9) Remove the guard pins from the pulley brackets at FS 131.50 and FS 147.00 in the cabin and FS 313.44 in the tailcone. (10) Remove the spring retainers and the pressure seals at the aft pressure bulkhead (FS 285.00). (11) Remove the fairlead halves from the cable tubes for the forward elevator control cables at the control lock slide assembly. Refer to Control Lock System - Maintenance Practices. (12) Remove the nuts, washers and screws attaching the forward control cables to the forward elevator sector at FS 126.00. (13) Pull the cables forward and remove the control cables from airplane. (14) If a removed cable will be replaced with a new cable, record the distance of the swaged ball from the forward ball end on the cable. This distance measurement will be used to locate the ball on the new cable before it is installed. B. Install the Elevator Forward Control Cables (Refer to Figure 201). The left forward control cable is approximately 17 inches (0.43 m) longer than the right forward control cable. The ball ends of the left and right forward control cables are not typical. (1) If a new forward elevator control cable is installed, put the swage ball at the recorded distance from the forward ball end on the cable. The recorded distance was measured during the last step of the removal of the initial cable. (a) Use a 1/8 inch (3.18 mm) cable die to swage the ball in position. 27-30-05 Page 201
Elevator Control Cables Installation Figure 201 (Sheet 1) 27-30-05 Page 202
Elevator Control Cables Installation Figure 201 (Sheet 2) 27-30-05 Page 203
Elevator Control Cables Installation Figure 201 (Sheet 3) 27-30-05 Page 204
(2) Attach the left forward control cable to forward sector at FS 126.00 with a screw, washer and nut. (3) Route the left forward control cable aft through the forward pulley (FS 131.50), control lock, fairleads (FS 208.67 and FS 249.16) and the aft pressure bulkhead. (4) Attach the right forward control cable to the forward sector at FS 126.00 with a screw, washer and nut. (5) Route the right forward control cable aft through the forward pulley (FS 131.50), control lock, fairleads (FS 208.67 and FS 249.16) and aft pressure bulkhead. (6) Mark the forward control cables where the cable contacts the aft pressure bulkhead. (7) Withdraw the forward control cables 12 inches (30 cm) into cabin. (8) Locate the mark made earlier on the forward control cables, and lubricate them with 5565450-28 grease 6 inches (0.15 m) on both sides of the mark. (9) Install the fairlead halves to the cable tubes for the forward elevator control cables at the control lock slide assembly. Refer to Control Lock System - Maintenance Practices. (10) Install the pressure seals in the aft pressure bulkhead using spring retainers. (11) In the tailcone, route the forward control cables through pulleys at FS 313.44 and connect to the mating control cable turnbuckles. (12) Install the guard pins in the pulley brackets at FS 131.50 and FS 147.00 in the cabin, and FS 313.44 in the tailcone. (13) Install fairleads, screws, washers and nuts at FS 208.67 and FS 249.16. (14) Adjust control cables for correct rigging. Refer to Control Cables Adjustment. (15) Install the aft evaporator. Refer to Chapter 21, Cooling System - Maintenance Practices. (16) Install panels 241BTC, 252ATC, 252BTC, 252CTC, 252DTC, 252GC, and 251FL, and 525GR. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (17) Install tailcone baggage panels 321A, 321AZ, 321BB, 321CB, 321DC and 321FC. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (18) Install the pilot and copilot seats. Refer to Chapter 25, Crew Seats - Maintenance Practices. 4. Elevator Aft Control Cables Removal/Installation A. Remove Elevator Aft Control Cables (Refer to Figure 201). (1) Remove panels 340ATC, 340BL, 340BR, 340CR, 340CL, 340DL and 340ER to get access to the aft control cables. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (2) Remove aft evaporator. Refer to Chapter 21, Cooling System - Maintenance Practices. (3) Open the aft baggage compartment door. (4) Remove tailcone baggage panels 321CB, 321BC, 321DC, 321FC and 321GC to get access to the aft control cables. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (5) Remove the clips and loosen the autopilot elevator servo cable turnbuckle on the left aft control cable. (6) Remove the clips and disconnect the aft control cable turnbuckles (FS 339.55 and FS 355.74) to release the aft control cables from the forward control cables. (7) On airplanes 0685, -0800 thru -0870 with clamp block connection: (a) Put a mark at the two clamp blocks to show the correct position on the elevator trim cables. (b) Remove the screws, washers, and nuts that attach the clamp blocks to the elevator trim servo cables and the elevator trim cables. (c) Remove the clamp blocks from the cables. (8) Airplanes -0871 and On with clamp block connection, do the steps that follow: (a) Put a mark at the two clamp blocks to show the correct position on the elevator trim cables. (b) Remove the screws that attach the clamp blocks to the elevator trim servo cables and the elevator trim cables. (c) Remove the clamp blocks from the cables. (9) On airplanes -0685, -0800 and On, with eyebolt connection: (a) Remove bolt, washer, nut, and cotter key from the elevator trim cables. (10) Remove the bolts and the washers that attach the fairleads and the retainers to the vertical stabilizer ribs at VFS 79.50 and VFS 105.60. (a) Remove the fairleads and the retainers from the airplane. 27-30-05 Page 205
(11) Remove the guard pins attaching the aft control cables pulley brackets at FS 387.00 and FS 424.07. (12) Remove the nuts, washers and screws attaching the aft control cables to the elevator aft sector. (13) Withdraw the cables and remove from the airplane. B. Install Elevator Aft Control Cables (Refer to Figure 201). The right aft control cable is 17 inches (0.43 m) longer than the left aft control cable. The ball ends of the left and right aft control cables are not typical. (1) Attach the left aft control cable to the left forward cable turnbuckle. Do not tighten turnbuckle. (2) Route the cable aft through the pulleys (FS 387.00 and FS 424.07) to the aft elevator sector. (3) Attach the control cable to the aft sector assembly using a screw, washer and nut. (4) Attach the right aft control cable to the aft elevator sector with a screw, washer and nut. (5) Route the right aft control cable forward through the pulleys (FS 424.07 and FS 387.00) to the right forward control cable turnbuckle. (6) Connect the right forward control cable and the right aft control cables at the turnbuckle (FS 339.55). (7) Airplanes -0685 and -0800 thru -0870 with clamp block connection do the steps that follow: CAUTION: The clamp blocks and the nuts must be installed in the correct position to make sure that they do not catch on the adjacent cables or structure. Damage to the cables or the structure can occur if the cables or the nuts are not installed in the correct position. (a) Put the elevator auto pilot servo cables and the clamp blocks in their recorded position on the elevator trim cables. (b) Install clamp block screws and nuts. (c) Torque the clamp block nuts to 12-15 inch pounds (1.35 N-m to 1.69 N-m). (8) Airplanes -0871 and On with clamp block connection, do the steps that follow: (a) Put the elevator autopilot servo cables and the clamp blocks in their recorded position on the elevator trim cables. (b) Make sure lush side of clamp block is installed to provide the largest amount of clearance between the control cables. (c) Install clamp block screws and torque to 30-40 inch pounds (3.39 N-m to 4.51 N-m). (9) On airplanes -0685, and -0800 and On, with eyebolt connection: (a) Install bolt, washer, nut, and cotter key to the elevator trim cables. (10) Install the guard pins in the pulley brackets at FS 387.00 and FS 424.07. (11) Put the fairleads and the retainers in their position on the vertical stabilizer ribs at VFS 79.50 and VFS 105.60. The fairlead and the retainer bolt holes are larger than the bolts to help move them to make sure that they do not touch the control cables. (a) Install the bolts and the washers. The bolts will be removed and have sealant applied to the threads after the inal adjustment of the cables. (12) Adjust the trim system for correct rigging. Refer to Elevator and Tab System Control Cables - Adjustment/Test, Elevator Trim Cables Rigging (13) Remove one of the bolts and the washers that attach the fairleads and the retainers to the vertical stabilizer ribs at VFS 79.50 and VFS 105.60. 27-30-05 Page 206
CAUTION: Be careful to not move the fairlead or the retainer from their position on the vertical stabilizer rib. The fairlead and the retainer are installed in a position to make sure that they do not cause an unwanted movement of the cables. (14) Shank seal the bolt with Type X, Class B sealant. Refer to Chapter 20, Fuel, Weather, Pressure, and High-Temperature Sealing - Maintenance Practices. (a) Install the bolt and the washer. (b) Do the steps again for the other bolts. (15) Install the aft evaporator. Refer to Chapter 21, Cooling System - Maintenance Practices. (16) Install panels 321CB, 321BC, 321DC, 321FC and 321GC. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (17) Install panels 340ATC, 340BL, 340BR, 340CR, 340CL, 340DL and 340ER. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. 5. Elevator Forward Trim Cables Removal/Installation The forward trim cables have a chain installed between two cables. The left and right forward trim cables extend from their connecting point with the trim chain below the control pedestal, through pulleys and fairleads, to interconnecting turnbuckles in the tailcone. A. Remove the Forward Trim Cables (Refer to Figure 202). (1) Remove panels 241BTC,, and 252ATC, 252BTC, 252CTC, 252DTC, 252GC, 252GR, and 251FL to get access to the forward trim cables. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (2) Remove vertical stabilizer panels 340BL and 340BR to get access to the aft elevator sector. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (3) Install a #10 rigging pin in the aft elevator sector or put an approved clamp on the elevator horn to the horizontal stabilizer to hold the elevator in a ixed position. (4) Open the tailcone baggage compartment door. Refer to Chapter 6, Dimensions and Areas - Description and Operation. (5) Remove panels 321A, 321CTC, 321DC and 321FC to get access to the forward trim cables in the tailcone. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (6) Install an inclinometer on the left elevator and the left elevator trim tab. (7) Use the pitch trim wheel in the cockpit to manually move the elevator trim tabs 4 degrees (+1 or -1 degree) down from the streamlined position. When the elevator trim tabs are at the 4 degree down from streamline position, the chains will be equal on each side of the trim tab actuator sprockets and the elevator trim sprocket in the pedestal in the cockpit. (8) Disengage PITCH TRIM circuit breaker. (9) Remove the pilot's crew seat. Refer to Chapter 25, Crew Seats - Maintenance Practices. (10) Remove the aft evaporator to get access to the pressure seals on the aft pressure bulkhead. Refer to Chapter 21, Cooling System - Maintenance Practices. (11) Remove screws, washers and nuts attaching the upper left fairlead to the forward control cables at FS 208.67 and FS 249.16, and remove the fairleads. (12) Remove the clips and loosen the turnbuckle for the elevator trim servo cable. Refer to Elevator and Tab System Components - Removal/Installation, Garmin GSM 86 Elevator Trim Servo Gearbox and Cable Removal/Installation. (13) Remove the clips and disconnect the cables at the turnbuckles located in the tailcone. (14) Remove the guard pins from the pulley brackets throughout cable routing. (15) Remove the spring retainers from the pressure seals in the aft pressure bulkhead. (16) Loosen and remove the stop blocks from the forward trim cables. (17) Route the cables forward through the aft pressure bulkhead, through fuselage pulleys to control pedestal. 27-30-05 Page 207
Elevator Forward/Aft Trim Cables Installation Figure 202 (Sheet 1) 27-30-05 Page 208
Elevator Forward/Aft Trim Cables Installation Figure 202 (Sheet 2) 27-30-05 Page 209
Elevator Forward/Aft Trim Cables Installation Figure 202 (Sheet 3) 27-30-05 Page 210
Elevator Forward/Aft Trim Cables Installation Figure 202 (Sheet 4) 27-30-05 Page 211
(18) Remove the spring clips from the connecting links that attach the left and right trim cables to the trim control chain. (a) Remove the connecting links from the trim control chain and cables. B. Install the Forward Trim Cable. The right forward trim cable is approximately 23 inches (0.58 m) longer than the left forward trim cable. (1) Mark the center of the trim cable chain. (2) Put the center mark of the trim chain over the top chain pulley. The top chain pulley is located directly behind the elevator trim wheel. With the elevator tab at the 4 degree down position, the ends of the chain must be within 1 link of equal. (3) Put the connecting links in their position on the left and the right forward elevator trim cables and the elevator trim control chain. (4) Install the spring clips on the connecting link. (5) Route the right half of the trim cable under the upper elevator trim pulley. (a) Install two guard pins to keep the cable on the pulley. (6) Route the left half of the trim cable over the lower elevator trim pulley. (a) Install two guard pins to keep the cable on the pulley. (7) Route the cables aft through the fuselage pulley assemblies and fairleads at FS 208.67 and FS 249.16. (8) Put the forward trim cables through the aft pressure bulkhead seals. (9) Mark the cables at the point where they go through the aft pressure bulkhead. (10) Lubricate forward trim cables using 5565450-28 grease, 12 inches (0.30 m) on both sides of cable mark made earlier. (11) Install aft pressure bulkhead seals with forward trim cables through aft pressure bulkhead. (12) Put spring retainers on the seal to keep seal in place. (13) Install the fairleads at FS 208.67 and FS 249.16 using screws, washers and nuts. (14) Route the forward trim cables upward, along the aft pressure bulkhead to the upper trim cable pulley bracket assembly. (15) Attach the forward trim cable to the aft trim cables at the turnbuckles. (16) Install the guard pins in the tailcone trim cable pulleys. (17) Adjust the trim system for correct rigging. Refer to Elevator and Tab System Control Cables - Adjustment/Test, Elevator Trim Cables Rigging (18) Install the aft evaporator. Refer to Chapter 21, Cooling System - Maintenance Practices. (19) Remove the rigging pin from the aft elevator sector or the clamp from the elevator horn. (20) Remove the inclinometers from the left elevator and trim tab. (21) Install vertical stabilizer panels 340BL and 340BR. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (22) Install 241BTC,, and 252ATC, 252BTC, 252CTC, 252DTC, 252GC, 252GR, and 251FL. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (23) Install panels 321A, 321CTC, 321DC and 321FC. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. (24) Close the tailcone baggage compartment door. Refer to Chapter 6, Dimensions and Areas - Description and Operation. (25) Install the pilot's crew seat. Refer to Chapter 25, Crew Seats - Maintenance Practices. 6. Elevator Aft Trim Cables and Trim Interconnect Cable Removal/Installation A. Remove the Elevator Aft Trim Cables and Trim Interconnect Cable (Refer to Figure 202). (1) Disengage the PITCH TRIM circuit breaker. (2) Remove panels 340ATC, 340BL, 340BR, 340CR, 340CL, 340DL and 340ER. panels 331AB, and 322AB to get access to the vertical stabilizer trim cables. Refer to Chapter 6, Access Plates and Panels Identiication - Description and Operation. 27-30-05 Page 212