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Garmin GFC 500, Maintenance Manual

The Garmin GFC 500 is a state-of-the-art aviation autopilot system that enhances aircraft control and safety. With advanced features and precise functionality, this user-friendly system allows pilots to download a free manual from manualshive.com for complete guidance on installation, operation, and troubleshooting, ensuring a seamless flying experience.

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GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual 

Page 1 

190-02291-01 

Revision 1 

1.  Introduction 

1.1  Content, Scope, Purpose 

This document provides maintenance instructions and Instructions for Continued Airworthiness 
(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 
Manual and the operator’s Aircraft Scheduled Maintenance Program. 

 

1.3  Organization 

The following outline briefly describes the organization of this manual: 

Section 2: System Description 

Provides a complete description of the type design change associated with installing the GFC 
500 Autopilot.  Also provides an interface summary, power requirements, and instructions on 
electrical bonding. 

Section 3: Control and Operation

 

Provides brief instructions on controls and operation. 

Section 4: Instructions for Continued Airworthiness

   

Provides maintenance instructions for continued airworthiness of the GFC 500 Autopilot. 

Section 5: Troubleshooting

 

Provides troubleshooting information to aid in diagnosing and resolving potential problems with 
the GFC 500 Autopilot. 

Section 6: Equipment Removal & Replacement    

 

Gives instructions for the removal and replacement of GFC 500 Autopilot equipment. 

Section 7: GFC 500 LRU Replacement/Configuration & Testing

 

Gives instructions for loading software, configuring, and testing of GFC 500 Autopilot 
equipment. 

Section 8: GFC 500 Software Load and Configuration Procedures

 

Gives instructions for loading software and configuring the GFC 500 Autopilot. 

Section 9: GFC 500 Return to Service Procedure

 

Specifies return-to-service procedures to be performed upon completion of maintenance of the 
GFC 500 Autopilot. 

Summary of Contents for GFC 500

Page 1: ...190 02291 01 2017 Revision 1 GFC 500 Autopilot with Envelope Stability And Protection Part 23 AML STC Maintenance Manual Includes Instructions for Continued Airworthiness for STC SA01866WI ...

Page 2: ...ectronic or printed copy of this manual or revision must contain the complete text of this copyright notice and provided further that any unauthorized commercial distribution of this manual or any revision hereto is strictly prohibited Garmin International Inc 1200 E 151st Street Olathe KS 66062 USA Telephone 913 397 8200 www garmin com Garmin Europe Ltd Liberty House Bulls Copse Road Hounsdown Bu...

Page 3: ...ceding statement is required to be included on any and all reproductions in whole or in part of this manual This product its packaging and its components contain chemicals known to the State of California to cause cancer birth defects or reproductive harm This Notice is being provided in accordance with California s Proposition 65 If you have any questions or would like additional information plea...

Page 4: ... 7 2 4 Electrical Bonding 7 3 CONTROL AND OPERATION 10 3 1 GMC 507 10 3 2 Autopilot Disconnect Trim Interrupt Switch 10 3 3 Trim Switch 10 3 4 Go Around GA Switch 10 4 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 11 4 1 Airworthiness Limitations 11 4 2 Servicing Information 12 4 3 Maintenance Intervals 14 4 4 Visual Inspection 15 4 5 Electrical Bonding Test 16 4 6 Disconnect Tone and Sonalert Test 17 ...

Page 5: ...07 24 7 2 GSA 28 Servo 24 8 GFC 500 SOFTWARE LOAD AND CONFIGURATION PROCEDURES 25 8 1 GMC 507 and GSA 28 Software Loading 25 8 2 GFC 500 System Configuration 25 9 GFC 500 RETURN TO SERVICE PROCEDURE 26 9 1 Yaw Offset and Pitch Roll Offset Calibration 26 9 2 Pre Flight Test PFT 26 9 3 Normal Mode Tests 27 ...

Page 6: ...AGE Figure 2 1 GMC 507 5 Figure 2 2 GFC 500 System Overview 6 Figure 2 3 Electrical Bonding Preparation Nut Plate 8 Figure 2 4 Electrical Bonding Preparation Bolt Nut Joint 8 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 ...

Page 7: ...S TABLE PAGE Table 1 1 Required Documents 3 Table 1 2 Garmin Reference Documents 3 Table 1 3 Other Reference Documents 3 Table 2 1 Power Requirements 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 ...

Page 8: ...design change associated with installing the GFC 500 Autopilot Also provides an interface summary power requirements and instructions on electrical bonding Section 3 Control and Operation Provides brief instructions on controls and operation Section 4 Instructions for Continued Airworthiness Provides maintenance instructions for continued airworthiness of the GFC 500 Autopilot Section 5 Troublesho...

Page 9: ...ion Indicator CFR Code of Federal Regulations CWS Control Wheel Steering DDM Difference in Depth of Modulation DTK Desired Track ESP Electronic Stability and Protection FAA Federal Aviation Administration GPS Global Positioning System ICA Instructions for Continued Airworthiness ILS Instrument Landing System LRU Line Replaceable Unit OBS Omni Bearing Selector PFT Pre Flight Test SAE Society of Aut...

Page 10: ...anual 190 02291 XX GFC 500 Autopilot with Electronic Stability and Protection Part 23 AML STC Model Specific Installation Manual Addendum 190 01112 12 G5 Electronic Flight Instrument Pilot s Guide for Certified Aircraft The documents listed in Table 1 2 are recommended to be available during the performance of maintenance activities Table 1 2 Garmin Reference Documents Document Number Title 190 01...

Page 11: ...operators may obtain the latest revision of this document from the https fly garmin com Support page or by contacting a Garmin dealer contacting Garmin Product Support at 913 397 8200 toll free 866 739 5687 or using around the world contact information on https fly garmin com A Garmin Service Bulletin describing the revision to this document will be sent to Garmin dealers if the revision is determ...

Page 12: ...s a brushless DC motor This brushless DC motor has an inherent safety feature in that it cannot drive by itself and requires software commutation to run The brushless DC motor also has a lower backdrive friction than brushed motor or steppers motors 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 tr...

Page 13: ...1 Revision 1 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: ...C 0 20 A Max Current Draw 28 VDC 0 90 A 2 4 Electrical Bonding For the purposes of this STC aircraft ground reference definitions vary according to airframe type as defined in Table 2 2 Refer to the periodic test and reconditioned resistance values corresponding to these ground reference definitions when performing the equipment bonding tests in Section 4 5 The periodic test value is the value all...

Page 15: ...for Untreated or Bare Dissimilar Metals The correct material finish is important when mating untreated or bare dissimilar metals Materials should be galvanically compatible When corrosion protection is removed to make an electrical bond any exposed area after the bond is completed should be protected again Additional guidance can be found in SAE ARP 1870 Section 5 Typical electrical bonding prepar...

Page 16: ... been necessary to remove any high resistance protective coating the area from which the coating has been removed should be refinished with the same finish as is on the rest of the part within 24 hours In cases where the parts come in with certain areas spot faced or if there is no finish on the part bare metal apply conformal coating over the bond joint and hardware per MIL I 46058 or clear lacqu...

Page 17: ... autopilot system and to interrupt the electric pitch trim 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 3 4 Go Around GA Switch A GO AROUND switch is provided for engage...

Page 18: ......

Page 19: ...s manual Replacement and or servicing should be made only after the technician troubleshoots the system to the extent determined necessary by using the guidance in this manual along with common avionics maintenance practices The remainder of this document is organized in the following fashion Section 4 3 lists maintenance requirements related to the GFC 500 Autopilot Section 6 gives instructions r...

Page 20: ...alent o Variable DC Power Supply capable of providing 1 amp current 3 32 Hex tool Calibrated VHF NAV COM ILS ramp tester or equivalent Calibrated pitot static ramp tester Outdoor line of site to GPS satellite signals or GPS indoor repeater Headset microphone Ground Power Unit Calibrated Flight Control Cable Tension Meter or equivalent Calibrated torque wrench capable of measuring 0 70 in lbs Stand...

Page 21: ... 507 if installed without rack GSA 28 mounting brackets and any associated bonding components 4 5 Following removal and replacement of the racks or brackets AND Every 2000 flight hours or ten years whichever is first Equipment Bonding Visual Inspection suspected lightning strike Inspection of bonding Components Table 4 3 At any suspected or actual lightning strike GFC 500 Equipment Visual Inspecti...

Page 22: ...ound b Inspect all exposed wire harness for chafing damage proper routing of wire bundles and security of attachment in accordance with AC 43 13 1B Chapter 11 Section 8 Paragraph 11 96 Servos Servo Control Cables and associated hardware a Using a flashlight inspect the GSA 28 servos connectors support structure and control cables to ensure that no corrosion chafing cracks or other defects exist b ...

Page 23: ...2 Test Equipment A milliohm meter and Kelvin probes are recommended for this test However an alternate method may be used to provide equivalent results by using the following procedure and a standard voltmeter power supply with adjustable current limit and ammeter The test set up for this alternate method is described below All test equipment used for the bond checks must be calibrated 1 Connect t...

Page 24: ...ning procedure in Section 2 4 GMC 507 case __________ mΩ GSA 28 Roll chassis __________ mΩ GSA 28 Pitch chassis __________ mΩ GSA 28 Pitch Trim chassis __________ mΩ 4 6 Disconnect Tone and Sonalert Test Perform the Disconnect Tone and Sonalert Functional Test at the intervals specified in Table 4 1 1 Apply external electrical power to the aircraft and avionics systems 2 Ensure that the GFC 500 Au...

Page 25: ...gage the following troubleshooting steps may be used to help identify the cause 1 Verify that there are no red X indications present on the G5 Correct any red X indications that may be present Refer to the G5 STC Maintenance Manual Garmin p n 190 01112 11 for further details 2 Check for loose terminals on the circuit breaker connections on the power wire s causing intermittent power connections Al...

Page 26: ...witch not depressed the line should read With the trim switch pressed in the NOSE DOWN direction the line should read Nose Down With the trim switch pressed in the NOSE UP direction the line should read Nose Up 6 Check that the trim servo motor and clutch operate a Restart the G5 ADI in configuration mode b Navigate to the Flight Controls page group c Navigate to the Pitch Trim page d Scroll down ...

Page 27: ... system is rigged in accordance with the applicable Aircraft Maintenance Manual AMM Shop Manual or Service Manual as applicable 5 3 GFC 500 Interconnect Drawings For GFC 500 interconnect drawings reference Garmin document 190 02291 00 5 4 Connector Layout For GFC 500 LRU connector layout reference Garmin document 190 02291 00 ...

Page 28: ...nergize 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 4 Pull the unit from the rack 5 Disconnect the electrical connector P5071 from the GMC 507 Reinstallation NOTE Ensure the position of the GMC 507 retention mechanism is correct by inserting a 3 32 hex...

Page 29: ...GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page 22 190 02291 01 Revision 1 Figure 6 1 GMC 507 Installation with rack Figure 6 2 GMC 507 Installation without rack ...

Page 30: ...emove the servo using the data provided in the appropriate model specific installation manual addendum Refer to the Master Drawing List 005 01264 00 Reinstallation 1 Visually inspect the connectors to ensure there are no bent or damaged pins Repair any damage 2 Reinstall the servo and servo cables using the data provided in the appropriate model specific installation manual addendum Refer to the M...

Page 31: ...7 Installed If a new repaired or exchanged GMC 507 is installed the correct software must be loaded to the unit Refer to Section 8 1 for software loading procedures Continue to the GMC 507 Test Procedure Section 9 2 and 9 3 2 7 2 GSA 28 Servo Original GSA 28 Reinstalled No software loading is required if the removed GSA 28 is re installed This does not include units that were returned for repair a...

Page 32: ...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 NOTE The G5 must be configured in accordance with the Garmin G5 Electronic Instrument Part 23 AML STC Installation Manual prior to configuring the GFC 500 Automatic Flight Control System NOTE To start the G5 in configuration mode hold ...

Page 33: ...aircraft forward motion i e in a canted panel Navigate to the Flight Controls Mode Control Panel Calibrate Yaw Offset page and press the knob 3 Scroll through the yaw offset calibration pages following the instructions on each page to ensure that the system is ready for calibration 4 Select the appropriate value of yaw offset and press the knob 5 When the test is complete select Done to return to ...

Page 34: ...e high low tones approximately three seconds in duration through the cockpit speaker s and headphones and a continuous tone from the sonalert for approximately three seconds if installed 2 An abnormal disconnect will be accompanied by an abnormal disconnect aural alert continuous high low tones through the cockpit speaker s and headphones and a continuous tone from the sonalert if installed The ab...

Page 35: ...ght controls to the right 10 Firmly grasp the control wheel and press the AP DISC TRIM INT switch on the pilot s flight controls 11 Verify that the autopilot disconnects and the roll control moves freely 9 3 1 2 Pitch Servo Functional Check 1 Verify that the steps in Section 9 3 1 have been completed 2 Center the elevator controls approximately mid travel 3 Engage the autopilot by pressing the AP ...

Page 36: ...op 9 Verify that the elapsed time for full travel of the pitch trim is within the range specified in the appropriate model specific installation manual addendum 190 02291 XX If the elapsed time is not within the specified range refer to Section 5 2 in this manual 10 While monitoring elapsed time actuate the TRIM Switch on the pilot s flight controls in the NOSE DN direction until the trim runs aga...

Page 37: ...ress the AP button on the GMC 507 14 Verify that the autopilot disengages 15 Press the AP DISC TRIM INT switch on the pilot s flight controls 16 Press the GO AROUND switch 17 Verify the following a TO is annunciated for both lateral and vertical modes on the G5 b The flight director command bars are displayed and indicate wings level and pitch up to the angle as shown on the appropriate Install Ma...

Page 38: ... switch on the pilot s flight controls until the trim runs against the other mechanical stop while monitoring the run time 3 Verify that the elapsed time for full travel of the pitch trim is within the range specified on the appropriate model specific installation manual addendum 190 02291 XX If the elapsed time is not within the specified range refer to Section 5 2 in this manual 4 Repeat the tes...

Page 39: ...eft turn and that the flight controls move toward the left 9 Adjust the heading bug to the right of the aircraft heading 10 Verify that the flight director command bars indicate a right turn and that the flight controls move toward the right 11 Center the heading bug at the aircraft heading 12 Click the UP DN thumbwheel on the GMC 507 UP four times 13 Verify that the command bars indicate a fly up...

Page 40: ...e degrees of the aircraft heading verify that that VOR displays green on the G5 and that ROL is not displayed on the G5 10 Center course pointer on the aircraft heading 11 Adjust the simulated course and the aircraft course pointer 20 degrees to the left of current aircraft heading 12 Verify that the flight director command bars indicate a left turn and that the flight controls move toward a left ...

Page 41: ... the flight director command bars indicate a right turn and that the flight controls drive to the right 14 Press the AP DISC TRIM INT switch to disengage the autopilot 15 Press the FD button to remove the flight director bars from the G5 9 3 2 6 ILS APR Checks 1 Simulate an ILS Localizer and Glideslope using a ramp tester 2 Tune the NAV radio to the Localizer frequency 3 Set the G5 to display the ...

Page 42: ... section 2 Set the air data test set to 3000 ft altitude and 120 kts airspeed 3 Engage the autopilot by pressing the AP button on the GMC 507 4 Verify ROL and PIT are displayed on the GMC 507 5 Press the IAS button on the GMC 507 6 Verify that IAS is displayed in green and PIT extinguishes on the G5 7 Verify that 120 KT 2 KT is displayed to the right of IAS on the G5 8 Rotate the UP DN thumbwheel ...

Page 43: ... the GMC 507 UP until 1000 FPM is displayed on the G5 8 Verify that the flight director command bars indicate pitch up and the flight controls respond in the direction of the command bars 9 Rotate the UP DN thumbwheel on the GMC 507 DN until 1000 FPM is displayed on the G5 10 Verify that the flight director command bars indicate pitch down and the flight controls respond in the direction of the co...

Page 44: ... respond in the direction of the command bars 11 Return the air data test set to 3000 ft altitude and 120 kts airspeed 12 Press the ALT button on the GMC 507 to deselect ALT mode 13 Verify that PIT illuminates in green on the G5 14 Press the AP DISC TRIM INT switch to disengage the autopilot 15 Press the FD button to remove the flight director bars from the G5 9 3 2 10 ALTS Mode Check NOTE Disable...

Page 45: ... of ALT on the G5 with ALTS in white to the right of PIT on the G5 17 Press the AP DISC TRIM INT switch to disengage the autopilot 18 Press the FD button to remove the flight director bars from the G5 19 Return the air data test set to field elevation and 0 kts airspeed 9 3 2 11 LVL Mode Check 1 Set the heading bug to the aircraft heading 2 Press the FD button on the GMC 507 to engage the flight d...

Page 46: ... this appendix must be used to record information for a specific installation of the GFC 500 Autopilot system The completed copy must be kept with the aircraft permanent records This appendix includes the following information General installation information Interfaced equipment GFC 500 Autopilot configuration log GFC 500 Autopilot wiring diagrams ...

Page 47: ...________________________________________ GSA 28 Pitch Servo Part Number_______________________________________________________________ Serial Number______________________________________________________________ Mod Level_________________________________________________________________ GSA 28 Roll Servo Part Number_______________________________________________________________ Serial Number________...

Page 48: ... Disabled Autopilot Roll Maximum Torque Servo Gain Servo Direction Normal Reverse Clutch Monitor Enabled Disabled AP Disc Input Open A Expert Configuration G Fine Adjust Amount Fine Adjust Time Sec Autopilot Pitch Maximum Torque Servo Gain Servo Direction Normal Reverse Clutch Monitor Enabled Disabled AP Disc Input Open A Minimum Airspeed Limit Kt Maximum Airspeed Limit Kt Vertical Speed Gain Vert...

Page 49: ...tering Gain Yaw Rate Filter Constant Yaw Acceleration Filter Constant Roll Trim Trim Control Disabled Pitch Trim Trim Control Garmin Servo Maximum Torque Clutch Monitor Enabled Disabled Servo Direction Normal Reverse Trim Direction Normal Reverse Auto Trim Enabled Disabled Low Airspeed Threshold Kt High Airspeed Threshold Kt Fastest Movement Speed Slowest Movement Speed Maximum Run Time Sec AP Dis...

Page 50: ...ltitude Alert Enabled Disabled Lighting Bus Voltage V Calibrate Pitch Roll E Calibrate Yaw Offset F Electronic Stability Protection Roll Atttitude Protection Enabled Disabled Roll Limit Pitch Attitude Protection Enabled Disabled Pitch Up Limit Pitch Down Limit Airspeed Protection Enabled Disabled Minimum Airspeed Limit Kt Maximum Airspeed Limit Kt Default ESP Powerup State Enabled Auto Engage LVL ...

Page 51: ...ut Pushing and holding the knob while this row is highlighted will cause all of the mode annunciators white arrows above each mode button on the GMC 507 to illuminate and the sonalert output to be driven low causing a tone in the sonalert if installed for approximately one second E This row is utilized when installing a new GMC 507 or if the G5 has been recalibrated in Pitch and Roll Refer to Sect...

Page 52: ...quipment Locations and Wiring For the locations of installed equipment refer to the appropriate Install Manual Addendum 190 02291 XX 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 ...

Page 53: ...GFC 500 Autopilot with ESP Part 23 AML STC Maintenance Manual Page A 8 190 02291 01 Revision 1 Figure A 2 Equipment Location and Wire Routing Twin Engine Airplane ...

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