Flight Line Service Manual For Rate Based Autopilots

Flight Line Service Manual
For Rate Based Autopilots
P/N 87102
MEGGITT AVIONICS/S-TEC FLIGHT LINE SERVICE MANUAL FOR RATE BASED AUTOPILOTS
List of Effective Pages * The asterisk indicates pages changed, added, or deleted by the current change.
*Section 5 deleted in its entirety.
RETAIN THIS RECORD IN THE FRONT OF THE MANUAL. ON

Record of Revisions RECEIPT OF REVISIONS, INSERT REVISED PAGES. THEN
ENTER DATE INSERTED AND INITIAL.
REV REVISION INSERTION SB NUMBER REV REVISION INSERTION SB NUMBER
NO. DATE DATE/BY INCLUDED NO. DATE DATE/BY INCLUDED
1st Ed 11 May 2001 None
1st Rev. 15 May 2003
i
PAGE INTENTIONALLY BLANK
ii
SECTION 1
OVERVIEW
1st Ed. May 11, 2001 1-1

1-2 1st Ed. May 11, 2001

1.1 Service Manual Organization
Overview Section 1
Roll Centering Section 2
Functional Ground Tests Section 3
Simulator Operation Section 4
Pilot's Operating Handbooks Section 5
Heading Interconnect Drawings Section 6
System Interconnect Drawings Section 7
System Specifications Section 8
Glossary Section 9
1.2 Purpose
This manual provides flight line service information for the following S-TEC MEGGITT rate based autopilots:
System 20/30/30 ALT

System 40/50
System 55/55X/550
System 60-1/60-2
System 65
System 60 PSS
1.3 Required Test Equipment
Nomenclature P/N
Flight Line Autopilot Tester 95101
Breakout Box 9524
Adapter Cable 39198
Adapter Cable 39199
Extender Assembly 01264
1.4 Service Philosophy
The first objective is to determine if the installed autopilot system is functioning properly on the ground. This is
accomplished by performing the functional ground test for that particular system. No external test equipment is
required.
The second objective is to isolate a failure to a system component. The equipment listed in section 1.3 is designed
to aid in this effort. The Flight Line Autopilot Tester (P/N 95101) is used to simulate some of the major system
components. It is shown in Fig. 1-1 and contains the following, each removable from a suitcase for remote use about
the aircraft:
Nomenclature P/N
Tool, Roll Centering Adjustment 95101-1
Simulator, Heading System * 95101-2
Simulator, Servo, Roll/Pitch/Trim 95101-3
Simulator, Altitude Transducer 95101-4
Simulator, Turn Coordinator 95101-5
Cable Assembly, Extension for 95101-2 (6406/52D54) 39307
Cable Assembly, Extension for 95101-2 (6443) 39308
Cable Assembly, Extension for 95101-3 39309
Service Manual, Flight Line 87104
1st Ed. May 11, 2001 1-3

* Simulates only the following Heading Systems:
Manufacturer Type P/N

S-TEC DG 6406
S-TEC HSI 6443
EDO AIRE DG 52D54
The Breakout Box (P/N 9524), Adapter Cables (P/N 39198 & 39199), and Extender Assembly (P/N 01264) are
used to measure autopilot system power, signals, and continuity. They are connected as shown in Fig. 1-2.
The third objective is to determine if the system is functioning properly in flight. This is accomplished by performing
the flight procedures contained in the respective Pilot's Operating Handbook (POH). However, for return of aircraft to
service, refer to the Aircraft Flight Manual Supplement (AFMS).
1.5 Technical Support
PH 800-872-7832
FAX 940-325-8808
1-4 1st Ed. May 11, 2001

Fig. 1-1. Flight Line Autopilot Tester
1st Ed. May 11, 2001 1-5

5 0 P IN 5 0 P IN 5 0 P IN
M ALE FE M A LE M ALE
TO R O L L H A R N E S S 0101/0102,
9524 0109 R FGC 0103/0104,
N E VE R C O N N EC T
BR EA KO UT S IM U LTA N EO U S LY 0116/0117,
B OX 0110 P FG C 0141/0142,
TO PIT C H H A R N E S S PRO G/ANNUN
7 8 P IN 7 8 P IN 7 8 P IN
M ALE FE M A LE M ALE
SYS 60-1/60-2/65/PSS
5 0 P IN 5 0 P IN 5 0 P IN
M ALE FE M A LE M ALE 0129/0 130
9524 RO LL O N LY,
TO R O L L/P IT C H
HARN ESS
BR EA KO UT 0131/0 132
B OX RO LL & P ITCH ,
PRO G /C O MP
SYS 40/50
4 4 P IN 5 0 P IN 5 0 P IN 5 0 P IN 5 0 P IN 4 4 P IN 4 4 P IN
M ALE FE M A LE M ALE FE M A LE M ALE FE M A LE M ALE
9524 01260
TO R O L L/P IT C H T C /R O LL C O M P,
HARN ESS
BR EA KO UT 01261
3 91 99 B OX 3 91 98 PITC H C O M P
A D A P TE R A D A P TE R
C A B LE C A B LE
SYS 20/30/30 ALT
5 0 P IN 5 0 P IN 5 0 P IN 5 0 P IN 5 0 P IN
M ALE F E M A LE M ALE FE M A LE M ALE
TO H A R N E S S
01264 9524 01192
E XTEN DE R BR EA KO UT RO LL & P ITCH
AS S EM BLY B OX PR O G /C O M P
TO H A R N E S S
5 0 P IN 5 0 P IN 5 0 P IN
M ALE F E M A LE M ALE
SYS 55/55X/550
Fig. 1-2. Breakout Connections
1-6 1st Ed. May 11, 2001

SECTION 3
FUNCTIONAL GROUND TESTS
1st Ed. May 11, 2001 3-1

Table of Contents
3.1 Functional Ground Test for System 20 ............................................................................................................... 3-3
3.3 Functional Ground Test for System 30 ALT ...................................................................................................... 3-7
3.5 Functional Ground Test for System 50 ............................................................................................................. 3-10
3.7 Functional Ground Test for System 55X .......................................................................................................... 3-17
3.8 Functional Ground Test for System 550 ........................................................................................................... 3-21
3.9 Functional Ground Test for System 60-1 ............................................................................................................ 3-25
3.10 Functional Ground Test for System 60-2 ............................................................................................................ 3-27
3.12 Functional Ground Test for System 60 PSS ........................................................................................................ 3-35
3-2 1st Ed. May 11, 2001

3.1 Functional Ground Test for System 20
Power-Up Test
1. Set the Battery Master Switch to the ON position.
2. Set the Avionics Master Switch to the ON position.
3. Set the A/P Master Switch to the ON position.
4. Verify that RDY, ST, HD, LO TRK, and HI TRK all annunciate on the A/P for 7 seconds, and then
extinguish.
5. Verify that within 3 minutes RDY alone becomes annunciated on the A/P.
6. Verify that the Low Voltage Flag on the A/P is out of view.
Stabilizer Channel Test
7. Center the A/P TURN CMD knob under its index.
8. Engage the A/P ST mode.
9. Turn the A/P TURN CMD knob to the left.
10. Verify that the A/C control wheel turns to the left.
12. Verify that the A/C control wheel stops.
13. Turn the A/P TURN CMD knob to the right.
14. Verify that the A/C control wheel turns to the right.
Note: If the A/P is not equipped with a Heading System, proceed to step 34.
Heading Channel Test
17. Center the HDG bug under the lubber line.
18. Engage the A/P HDG mode.
19. Turn the HDG bug to the left.
1st Ed. May 11, 2001 3-3

23. Turn the HDG bug to the right.
Navigation Channel Test with Heading System (DG or HSI) Installed
27. Tune the Navigation Receiver to the local VOR frequency.
28. Adjust the OBS (DG) or Course Pointer (HSI) for a 100% leftward deflection of the Left/Right needle from
center.
29. Engage the A/P LO TRK or HI TRK mode.
31. Adjust the OBS (DG) or Course Pointer (HSI) for a 100% rightward deflection of the Left/Right needle from
center.
33. Adjust the OBS (DG) or Course Pointer (HSI) for a centered Left/Right needle to stop the A/C control
wheel.
Note: Proceed to step 41.
Navigation Channel Test with No Heading System Installed
35. Adjust the OBS for a 100% leftward deflection of the Left/Right needle from center.
38. Adjust the OBS for a 100% rightward deflection of the Left/Right needle from center.
40. Adjust the OBS for a centered Left/Right needle to stop the A/C control wheel.
A/P Disconnect Test
41. Press and hold the A/P Push Mode Switch for 3 seconds, or press the optional Remote Disconnect Switch.
42. Verify that RDY flashes on the A/P and the audible alert sounds for 5 seconds, after which RDY alone
remains annunciated and the audible alert ceases.
END OF TEST
3-4 1st Ed. May 11, 2001

Power-Up Test
4. Verify that RDY, ALT, ST, HD, LO TRK, HI TRK, TRIM UP, and TRIM DN all annunciate on the A/P.
5. Verify that the TRIM UP annunciation extinguishes after 2 seconds.
6. Verify that RDY, ST, HD, LO TRK, HI TRK, and TRIM DN annunciations all extinguish after 7 seconds.
7. Verify that the ALT annunciation extinguishes after 10 seconds.
9. Verify that the Low Voltage Flag on the A/P is out of view.
11. Engage the A/P ST mode.
1st Ed. May 11, 2001 3-5

center.
center.
wheel.
Altitude Channel Test
44. Apply fore and aft pressure to the A/C control wheel to sense its freedom of movement.
45. Engage the A/P ALT mode.
3-6 1st Ed. May 11, 2001

46. Apply fore and aft pressure to the A/C control wheel to verify its reduced freedom of movement.
Trim Channel Test
47. Apply maximum aft pressure to the A/C control wheel.
48. Verify that:
a. After 3 seconds, TRIM DN becomes annunciated on the A/P and the audible alert sounds a steady tone.
b. After 7 seconds, TRIM DN flashes and the audible alert becomes periodic.
49. Apply maximum fore pressure to the A/C control wheel.
50. Verify that:
a. After 3 seconds, TRIM UP becomes annunciated on the A/P and the audible alert sounds a steady
tone.
b. After 7 seconds, TRIM UP flashes and the audible alert becomes periodic.
A/P Disconnect Test
51. Press and hold the A/P PUSH MODE Switch for 3 seconds, or press the optional Remote Disconnect
Switch.
52. Verify that RDY flashes on the A/P and the audible alert sounds for 5 seconds, after which RDY alone
END OF TEST
3.3 Functional Ground Test for System 30 ALT
Power-Up/Altitude Channel Tests
2. Push the ALT HOLD ON/OFF Switch to the ON state.
3. Verify that ON, ALT, TRIM UP, and TRIM DN all annunciate on the ALT HOLD ON/OFF Switch.
4. Verify that the TRIM UP annunciation extinguishes after 2 seconds.
5. Verify that the TRIM DN annunciation extinguishes after 7 seconds.
6. Verify that the ALT annunciation extinguishes after 10 seconds.
7. Apply fore and aft pressure to the A/C control wheel to sense its reduced freedom of movement.
Trim Channel Test
9. Verify that:
1st Ed. May 11, 2001 3-7

a. After 3 seconds, TRIM DN becomes annunciated on the ALT HOLD ON/OFF Switch and the audible
alert sounds a steady tone.
b. After 7 seconds, TRIM DN flashes and the audible alert becomes periodic.
11. Verify that:
a. After 3 seconds, TRIM UP becomes annunciated on the ALT HOLD ON/OFF Switch and the audible
alert sounds a steady tone.
b. After 7 seconds, TRIM UP flashes and the audible alert becomes periodic.
A/P Power-Down Test
12. Push the ALT HOLD ON/OFF Switch to the OFF state.
13. Verify that all annunciations on the ALT HOLD ON/OFF Switch are extinguished.
END OF TEST
Power-Up Test
3. Set the A/P Master Switch to the TEST position.
4. Verify that the following are all annunciated on the A/P:
STB HDG NAV
APR REV
5. Verify that the RDY lamp is illuminated on the A/P.
7. Verify that all of the annunciations and the RDY lamp are extinguished.
8. Verify that within 3 minutes the RDY lamp becomes illuminated on the A/P.
9. Verify that the Low Voltage Flag on the Turn Coordinator is out of view.
11. Engage the A/P STB mode.
3-8 1st Ed. May 11, 2001

center.
32. Engage the A/P NAV mode.
center.
36. Engage the A/P REV mode.
1st Ed. May 11, 2001 3-9

center.
wheel.
A/P Disconnect Test
52. Press the A/P ON/OFF Mode Switch, or the optional Remote Disconnect Switch.
53. Verify that:
a. All of the annunciations are extinguished.
b. The RDY lamp is illuminated.
END OF TEST
Power-Up Test
3-10 1st Ed. May 11, 2001

4. Verify that the TRIM UP and TRIM DN lamps are illuminated on the A/P.
5. Verify that the TRIM UP lamp extinguishes after 2 seconds, and the re-appears after 4 seconds.
6. Verify that the TRIM DN lamp extinguishes after 7 seconds.
STB HDG NAV
APR ALT REV
8. Verify that the RDY lamp is illuminated on the A/P.
10. Verify that all of the annunciations and lamps are extinguished.
11. Verify that within 3 minutes the RDY lamp becomes illuminated on the A/P.
1st Ed. May 11, 2001 3-11

center.
center.
center.
43. Adjust the OBS (DG) or Course Pointer (HSI) for a centered Left/Right needle to stop the A/C control wheel.
3-12 1st Ed. May 11, 2001

55. Apply maximum fore and aft pressure to the A/C control wheel to sense its freedom of movement.
57. Apply for and aft pressure to the A/C control wheel to verify its reduced freedom of movement.
Trim Channel Test
59. Verify that:
a. After 3 seconds, the TRIM DN lamp becomes illuminated on the A/P.
b. After 7 seconds, the TRIM DN lamp flashes.
60. Apply fore pressure to the A/C control wheel.
61. Verify that:
a. After 3 seconds, the TRIM UP lamp becomes illuminated on the A/P.
b. After 7 seconds, the TRIM UP lamp flashes.
A/P Disconnect Test
62. Press the A/P ON/OFF Mode Switch, or the optional Remote Disconnect Switch.
63. Verify that:
a. All of the annunciations are extinguished.
b. The TRIM UP and TRIM DN lamps are extinguished.
c. The RDY lamp is illuminated.
END OF TEST
1st Ed. May 11, 2001 3-13

Power-Up Test
4. Verify that the following all annunciate on the A/P for 10 seconds, and then extinguish:
HDG RDY NAV CWS APR FAIL REV TRIM ALT GS VS +18
Navigation Channel Test
Note: If the heading system is an HSI, this test cannot be performed. In that case, proceed to step 33.
21. Engage the A/P HDG mode to stop the A/C control wheel.
3-14 1st Ed. May 11, 2001

32. Adjust the OBS for a centered Left/Right needle.
33. Move the A/C control wheel until the elevator is in the neutral position.
35. Command a pitch up using the A/P ALT/VS modifier knob.
36. Verify that the A/C control wheel moves in the aft direction.
37. Engage the A/P VS mode to stop the A/C control wheel.
39. Command a pitch down using the A/P ALT/VS modifier knob.
40. Verify that the A/C control wheel moves in the fore direction.
Vertical Speed Channel Test
44. Engage the A/P ALT mode to stop the A/C control wheel.
45. Engage the A/P VS mode.
1st Ed. May 11, 2001 3-15

Trim Channel Test
Note: If the A/P is equipped with autotrim, proceed to step 53.
50. Verify that:
a. After 3 seconds, TRIM becomes annunciated on the A/P and the audible alert sounds.
b. After 7 seconds, TRIM flashes and the audible alert ceases.
52. Verify that:
53. Set the A/P Trim Master Switch to the ON position.
55. Verify that:
a. After 3 seconds, the A/C trim wheel begins to run nose down with increasing speed, and TRIM
becomes annunciated on the A/P.
b. After 7 seconds, TRIM flashes.
57. Verify that:
a. After 3 seconds, the A/C trim wheel begins to run nose up with increasing speed, and TRIM becomes
annunciated on the A/P.
58. Apply aft pressure to the A/C control wheel until the A/C trim wheel stops.
59. Press either fore or aft on both segments of the A/P Manual Electric Trim Switch, and then release.
60. Verify that the A/P disconnects as follows:
RDY flashes on the A/P and the audible alert sounds for 5 seconds, after which RDY alone remains
annunciated.
3-16 1st Ed. May 11, 2001
61. Press aft and maintain pressure on both segments of the A/P Manual Electric Trim Switch.
62. Verify that the A/C trim wheel runs nose up at full speed and TRIM flashes.
63. Press and hold the A/P Disconnect/Trim Interrupt Switch.
64. Verify that the A/C trim wheel stops.
65. Release the A/P Disconnect/Trim Interrupt Switch.
66. Verify that the A/C trim wheel resumes running nose up at full speed.
67. Release the A/P Manual Electric Trim Switch.
68. Verify that the A/C trim wheel stops and the TRIM annunciation is extinguished.
69. Press fore and maintain pressure on both segments of the A/P Manual Electric Trim Switch.
70. Verify that the A/C trim wheel runs nose down at full speed and TRIM flashes.
74. Verify that the A/C trim wheel resumes running nose down at full speed.
END OF TEST
A/P Disconnect Test
77. Press the A/P Disconnect/Trim Interrupt Switch.
78. Verify that RDY flashes on the A/P and an audible alert sounds for 5 seconds, after which RDY alone
END OF TEST
3.7 Functional Ground Test for System 55X
Power-Up Test
1st Ed. May 11, 2001 3-17

HDG RDY NAV CWS APR FAIL GPSS REV TRIM ALT GS VS +16
3-18 1st Ed. May 11, 2001

Trim Channel Test
1st Ed. May 11, 2001 3-19

50. Verify that:
52. Verify that:
55. Verify that:
57. Verify that:
annunciated.

3-20 1st Ed. May 11, 2001
END OF TEST
A/P Disconnect Test
END OF TEST
Power-Up Test
HDG RDY NAV CWS APR FAIL GPSS REV TRIM ALT GS VS +30
1st Ed. May 11, 2001 3-21

3-22 1st Ed. May 11, 2001

Trim Channel Test
50. Verify that:
1st Ed. May 11, 2001 3-23

52. Verify that:
55. Verify that:
57. Verify that:
annunciated.
3-24 1st Ed. May 11, 2001

69. Press fore and maintain pressure on both segments on the A/P Manual Electric Trim Switch.
END OF TEST
A/P Disconnect Test
END OF TEST
3.9 Functional Ground Test for System 60-1
Power-Up Test
RDY REV
HDG NAV APR
CAP
FAIL SOFT
6. Verify that all of the annunciations are extinguished.
1st Ed. May 11, 2001 3-25

3-26 1st Ed. May 11, 2001

A/P Disconnect Test
35. Press the A/P Disconnect Switch.
RDY flashes on the A/P for 5 seconds, and then it alone remains annunciated.
3.10 Functional Ground Test for System 60-2
Manual Excessive G-Force Test
RDY FD REV
HDG NAV APR
VS ALT GS
SEL CAP DSABL
FAIL SOFT TRIM
5. Verify that the UP and DN Switches on the A/P are both illuminated.
11. Press and hold the A/P UP Switch while maintaining a grasp on the A/C control wheel.
12. Verify that the pitch servo disengages after 1/2 second, by sensing the increased freedom of A/C control
wheel movement in the fore and aft directions.
13. Release the A/P UP Switch.
14. Verify that the pitch servo immediately re-engages, by sensing the reduced freedom of A/C control wheel
movement in the fore and aft directions.
15. Press and hold the A/P DN Switch while maintaining a grasp on the A/C control wheel.
1st Ed. May 11, 2001 3-27

17. Release the A/P DN Switch.
Power-Up Test
20. Verify that all of the annunciations and illuminations are extinguished.
3-28 1st Ed. May 11, 2001

50. Press and hold the A/P UP Switch.
53. Press and hold the A/P DN Switch.
Note: There will be a slight delay in this movement as the A/C control wheel decelerates aft to the null.
1st Ed. May 11, 2001 3-29

Trim Channel Test
65. Verify that:
a. After 3 seconds the A/P DN Switch illuminates, TRIM annunciates, and the audible alert sounds a
steady tone.
b. After 7 seconds the A/P DN Switch flashes, TRIM flashes, and the audible alert becomes periodic.
67. Verify that:
a. After 3 seconds the A/P UP Switch illuminates, TRIM annunciates, and the audible alert sounds a
steady tone.
b. After 7 seconds the A/P UP Switch flashes, TRIM flashes, and the audible alert becomes periodic.
Note: Proceed to Step 92.
70. Verify that after 3 seconds the A/C trim wheel begins to run nose down with increasing speed.
72. Verify that after 3 seconds the A/C trim wheel begins to run nose up with increasing speed.
3-30 1st Ed. May 11, 2001

END OF TEST
A/P Disconnect Test
END OF TEST
4. Press and hold the A/P UP Switch while maintaining a grasp on A/C control wheel.
5. Verify that the pitch servo engages by sensing the reduced freedom of A/C control wheel movement in the
fore and aft directions.
7. Verify that the pitch servo disengages by sensing the increased freedom of A/C control wheel movement in
the fore and aft directions.
8. Press and hold the A/P DN Switch while maintaining a grasp on A/C control wheel.
9. Verify that the pitch servo engages by sensing the reduced freedom of A/C control wheel movement in the
fore and aft directions.
1st Ed. May 11, 2001 3-31

11. Verify that the pitch servo disengages by sensing the increased freedom of A/C control wheel movement in
the fore and aft directions.
Power-Up Test
12. Verify that within 3 minutes RDY becomes annunciated on the A/P Remote Annunciator.
14. Press the FD/AP Switch on the A/P Control Head to turn ON the A/P.
3-32 1st Ed. May 11, 2001

1st Ed. May 11, 2001 3-33

Trim Channel Test
58. Verify that:
a. After 3 seconds both TRIM and DN annunciate on the A/P Control Head, and the audible alert sounds
a steady tone.
b. After 7 seconds both TRIM and DN flash, and the audible alert becomes periodic.
60. Verify that:
a. After 3 seconds both TRIM and UP annunciate on the A/P Control Head, and the audible alert sounds
a steady tone.
b. After 7 seconds both TRIM and UP flash, and the audible alert becomes periodic.
a. RDY flashes on the A/P Remote Annunciator for 5 seconds, and then it alone remains annunciated.
b. ON alone remains annunciated on the A/P Control Head.
70. Verify that the A/C trim wheel runs nose up at full speed and TRIM flashes on the A/P Control Head.
3-34 1st Ed. May 11, 2001

78. Verify that the A/C trim wheel runs nose down at full speed and TRIM flashes on the A/P Control Head.
END OF TEST
A/P Disconnect Test
a. RDY flashes on the A/P Remote Annunciator for 5 seconds, and then it alone remains annunciated.
b. ON alone remains annunciated on the A/P Control Head.
END OF TEST
3.12 Functional Ground Test for System 60 PSS
VS ALT GS TRIM
5. Verify that the UP and DN Switches on the A/P are both illuminated.
1st Ed. May 11, 2001 3-35

9. Press and hold the A/P UP Switch while maintaining a grasp on the A/C control wheel.
13. Press and hold the A/P DN Switch while maintaining a grasp on the A/C control wheel.
Power-Up Test
18. Verify that all of the annunciations and illuminations are extinguished.
3-36 1st Ed. May 11, 2001

Trim Channel Test
36. Verify that:
a. After 3 seconds the A/P DN Switch illuminates, TRIM annunciates, and the audible alert sounds a
steady tone.
b. After 7 seconds the A/P DN Switch flashes, TRIM flashes, and the audible alert becomes periodic.
38. Verify that:
a. After 3 seconds the A/P UP Switch illuminates, TRIM annunciates, and the audible alert sounds a
steady tone.
b. After 7 seconds the A/P UP Switch flashes, TRIM flashes, and the audible alert becomes periodic.
Note: Proceed to Step 63.
All annunciations are extinguished.
48. Verify that the A/C trim wheel runs nose up at full speed.
1st Ed. May 11, 2001 3-37

SECTION 4
SIMULATOR OPERATION
1st Ed. May 11, 2001 4-1

Table of Contents
4.1 Operating Procedure for Heading System Simulator (P/N 95101-2) ................................................................ 4-3
4.2 Operating Procedure for Servo Simulator (P/N 95101-3) .................................................................................. 4-4
4.2.1 Roll Servo ............................................................................................................................................. 4-4
4.2.1.1 Heading System Installed ...................................................................................................... 4-4

4.2.1.2 No Heading System Installed and A/P with STB Mode ....................................................... 4-5
4.2.2 Pitch Servo ............................................................................................................................................ 4-6
4.2.2.1 Heading System Installed ...................................................................................................... 4-6

4.2.2.2 No Heading System Installed and A/P with STB Mode ....................................................... 4-7
4.2.2.3 Pitch Only A/P ....................................................................................................................... 4-8
4.2.3 Trim Servo .......................................................................................................................................... 4-10
4.3 Operating Procedure for Altitude Transducer Simulator (P/N 95101-4) ........................................................ 4-10
4.3.1 Heading System Installed ................................................................................................................... 4-10
4.3.2 No Heading System Installed and A/P with STB Mode .................................................................... 4-11
4.3.3 Pitch Only A/P .................................................................................................................................... 4-12
4.4 Operating Procedure for Turn Coordinator Simulator (P/N 95101-5) ............................................................ 4-13
4.4.1 Heading System Installed ................................................................................................................... 4-13
4.4.2 No Heading System Installed and A/P with STB Mode .................................................................... 4-15
4-2 1st Ed. May 11, 2001

4.1 Operating Procedure for Heading System Simulator (P/N 95101-2)
This procedure applies to the following Heading Systems:
MFG TYPE P/N

S-TEC DG 6406
S-TEC HSI 6443
EDO AIRE DG 52D54
1. Set the A/P Master Switch to the OFF position.
2. Set the Avionics Master Switch to the OFF position.
3. Set the Battery Master Switch to the OFF position.
4. Disconnect the A/P cable harness from the Heading System.
Note: For the 6443 HSI, only the topmost DB-25 connector needs to be disconnected.
5. Identify which one of the following Extender Cables is to be used:
P/N 39307 (for use with 6406/52D54)

P/N 39308 (for use with 6443)
6. Plug the proper end of the Extender Cable into the A/P cable harness, in place of the actual Heading
System.
7. Plug the other end of the Extender Cable into the proper Heading System Simulator connector (6406,
6443, or 52D54).
8. Connect the black lead Pin Plug from the Heading System Simulator to Airframe Ground.
Note: This Pin Plug may be inserted into an Airframe Ground Pin Jack on S-TEC Breakout Box
P/N 9524, if used. Otherwise, rely on the Pin Jack Alligator Clip supplied.
9. Set the Heading Error Selector Switch on the Heading System Simulator to 0°.
10. Turn the A/C control wheel until the ailerons are in the neutral position.
15. Wait until RDY alone becomes annunciated on the A/P display, upon completion of the power-up self-test.
17. Adjust the A/P roll centering as required to null any lateral A/C control wheel movement.
19. Set the Heading Error Selector Switch on the Heading System Simulator to the 10° RT TO HDG position.
1st Ed. May 11, 2001 4-3

21. Set the Heading Error Selector Switch on the Heading System Simulator back to the 0° position.
23. Set the Heading Error Selector Switch on the Heading System Simulator to the 10° LT TO HDG position.
25. Set the Heading Error Selector Switch on the Heading System Simulator back to the 0° position.
Note: 45° may be selected instead of 10° in steps 19 and 23.
4.2 Operating Procedure for Servo Simulator (P/N 95101-3)
4.2.1 Roll Servo
4.2.1.1 Heading System Installed
4. Disconnect the A/P cable harness from the Roll Servo.
5. Plug the proper end of Extender Cable P/N 39309 into the A/P cable harness, in place of the actual Roll
Servo.
6. Plug the other end of the Extender Cable into the Servo Simulator connector.
13. Verify that the voltage at the Servo Simulator SOL jack relative to the SOL GND jack is approximately:
12 VDC (A+ = 14VDC)

24 VDC (A+ = 28 VDC)
14. Verify that the voltage at the Servo Simulator MOTOR 1 jack relative to the MOTOR 2 jack is approx-
imately 0 VDC.
4-4 1st Ed. May 11, 2001

16. Verify that the voltage at the Servo Simulator MOTOR 1 jack relative to the MOTOR 2 jack is positive.
19. Verify that the voltage at the Servo Simulator MOTOR 1 jack relative to the MOTOR 2 jack is negative.
4.2.1.2 No Heading System Installed and A/P with STB Mode
4. Disconnect the A/P cable harness from the Roll Servo.
5. Plug the proper end of Extender Cable P/N 39309 into the A/P cable harness, in place of the actual Roll
Servo.
12 VDC (A+ = 14VDC)

24 VDC (A+ = 28 VDC)
14. Verify that the voltage at the Servo Simulator MOTOR 1 jack relative to the MOTOR 2 jack is approxi-
mately 0 VDC.
1st Ed. May 11, 2001 4-5

4.2.2 Pitch Servo
4.2.2.1 Heading System Installed
4. Disconnect the A/P cable harness from the Altitude Transducer.
5. Plug the proper end of Extender Cable P/N 39310 into the A/P cable harness, in place of the actual
Altitude Transducer.
6. Plug the other end of the Extender Cable into the Altitude Transducer Simulator connector.
7. Set the Pitch Command Selector Switch on the Altitude Transducer Simulator to the ENG A/P ALT
MODE position.
8. Disconnect the A/P cable harness from the Pitch Servo.
9. Plug the proper end of Extender Cable P/N 39309 into the A/P cable harness, in place of the actual Pitch
Servo.
11. Set the Trim Command Selector Switch on the Servo Simulator to the NEUTRAL position.
17. Center the HDG bug under the lubber line to null lateral movement of the A/C control wheel.
12 VDC (A+ = 14VDC)

24 VDC (A+ = 28 VDC)
mately 0 VDC.
21. Set the Pitch Command Selector Switch on the Altitude Transducer Simulator to the PITCH UP position.
23. Set the Pitch Command Selector Switch on the Altitude Transducer Simulator to the PITCH DN position.
4-6 1st Ed. May 11, 2001

MODE position.
26. Set the Trim Command Selector Switch on the Servo Simulator to the TRIM UP position.
27. Verify that after a 3 second delay, the A/P annunciates TRIM UP.
29. Verify that the TRIM UP annunciation is extinguished.
30. Set the Trim Command Selector Switch on the Servo Simulator to the TRIM DN position.
31. Verify that after a 3 second delay, the A/P annunciates TRIM DN.
33. Verify that the TRIM DN annunciation is extinguished.
4.2.2.2 No Heading System Installed and A/P with STB Mode
MODE position.
Servo.
1st Ed. May 11, 2001 4-7

17. Center the A/P TURN CMD knob under its index to null lateral movement of the A/C control wheel.
12 VDC (A+ = 14VDC)

24 VDC (A+ = 28 VDC)
mately 0 VDC.
MODE position.
4.2.2.3 Pitch Only A/P
4-8 1st Ed. May 11, 2001

MODE position.
Servo.
15. Wait until the A/P has completed its power-up self-test.
12 VDC (A+ = 14VDC)

24 VDC (A+ = 28 VDC)
mately 0 VDC.
MODE position.
1st Ed. May 11, 2001 4-9

4.2.3 Trim Servo
4. Disconnect the A/P cable harness from the Trim Servo.
5. Plug the proper end of Extender Cable P/N 39309 into the A/P cable harness, in place of the actual Trim
Servo.
imately 0 VDC.
12. Press AFT and hold the Manual Electric Trim Switch to command TRIM UP.
12 VDC (A+ = 14VDC)

24 VDC (A+ = 28 VDC)
imately:
12 VDC (A+ = 14VDC)

24 VDC (A+ = 28 VDC)
15. Release the Manual Electric Trim Switch.
16. Press FORE and hold the Manual Electric Trim Switch to command TRIM DN.
imately:
-12 VDC (A+ = 14VDC)

-24 VDC (A+ = 28 VDC)
4.3 Operating Procedure for Altitude Transducer Simulator (P/N 95101-4)
4.3.1 Heading System Installed
4-10 1st Ed. May 11, 2001

MODE position.
13. Center the HDG bug under the lubber line to null lateral movement of the A/C control wheel.
17. Verify that the A/C control wheel moves in the FORE direction.
18. Set the Pitch Command Selector Switch on the Altitude Transducer back to the ENG A/P ALT MODE
position.
21. Verify that the A/C control wheel moves in the AFT direction.
MODE position.
4.3.2 No Heading System Installed and A/P with STB Mode
1st Ed. May 11, 2001 4-11

MODE position.
13. Center the A/P TURN CMD knob under its index to null lateral movement of the A/C control wheel.
18. Set the Pitch Command Selector Switch on the Altitude Transducer to the ENG A/P ALT MODE
position.
MODE position.
4.3.3 Pitch Only A/P
4-12 1st Ed. May 11, 2001

MODE position.
11. Wait until the A/P has completed its power-up self-test.
16. Set the Pitch Command Selector Switch on the Altitude Transducer to the ENG A/P ALT MODE
position.
MODE position.
4.4 Operating Procedure for Turn Coordinator Simulator (P/N 95101-5)
4.4.1 Heading System Installed
4. Disconnect the A/P cable harness from the Turn Coordinator.
5. Connect the proper end of Extender Cable P/N 39311 into the A/P cable harness, in place of the actual
Turn Coordinator.
6. Connect the other end of the Extender Cable into the Turn Coordinator Simulator connector.
7. Set the Gyro Tach Selector Switch on the Turn Coordinator Simulator to the NOT RDY position.
8. Set the % Std Rate Turn Selector Switch on the Turn Coordinator Simulator to the 0% position.
1st Ed. May 11, 2001 4-13

14. Wait 30 seconds for the A/P to complete its power-up self-test.
15. Set the Gyro Tach Selector Switch on the Turn Coordinator Simulator to the RDY position.
16. Verify that RDY becomes annunciated on the A/P display.
18. Verify that RDY becomes extinguished on the A/P display.
21. Adjust the HDG bug slightly as required to null any A/C control wheel creep.
23. Set the % Std Rate Turn Selector Switch on the Turn Coordinator Simulator to the 50% RT position.
27. Set the % Std Rate Turn Selector Switch on the Turn Coordinator Simulator to the 50% LT position.
29. Set the % Std Rate Turn Selector Switch on the Turn Coordinator Simulator to the 0° position.
Notes:
1. 75% or 90% may be selected instead of 50% in steps 23 and 27.
2. Turning the HDG bug sufficiently to the right will cause the A/C control wheel to stop in step 24.
3. Turning the HDG bug sufficiently to the left will cause the A/C control wheel to stop in step 28.
4. Setting the % Std Rate Turn Selector Switch to the VARY position enables custom turn rate selection
using the Vary Adjust Pot. The scale is ± 1 VDC for a std rate turn (3°/sec), as measured at the TURN
RATE jack relative to the TURN RATE REF jack. The voltage polarity is negative for a right turn, and
positive for a left turn.
4-14 1st Ed. May 11, 2001

4.4.2 No Heading System Installed and A/P with STB Mode
4. Disconnect the A/P cable harness from the Turn Coordinator.
5. Connect the proper end of Extender Cable P/N 39311 into the A/P cable harness, in place of the actual Turn
Coordinator.
6. Connect the other end of the Extender Cable into the Turn Coordinator Simulator connector.
14. Wait 30 seconds for the A/P to complete its power-up self-test.
16. Verify that RDY becomes annunciated on the A/P display.
18. Verify that RDY becomes extinguished on the A/P display.
21. Adjust the A/P TURN CMD knob slightly as required to null any A/C control wheel creep.
23. Set the % Std Rate Turn Selector Switch on the Turn Coordinator Simulator to the 50% RT position.
1st Ed. May 11, 2001 4-15

27. Set the % Std Rate Turn Selector Switch on the Turn Coordinator Simulator to the 50% LT position.
29. Set the % Std Rate Turn Selector Switch on the Turn Coordinator Simulator to the 0° position.
Notes:
1. 75% or 90% may be selected instead of 50% in steps 23 and 27.
2. Turning the HDG bug sufficiently to the right will cause the A/C control wheel to stop in step 24.
3. Turning the HDG bug sufficiently to the left will cause the A/C control wheel to stop in step 28.
4. Setting the % Std Rate Turn Selector Switch to the VARY position enables custom turn rate
selection using the Vary Adjust Pot. The scale is ± 1 VDC for a std rate turn (3°/sec), as measured
at the TURN RATE jack relative to the TURN RATE REF jack. The voltage Polarity is negative
for a right turn, and positive for a left turn.
4-16 1st Ed. May 11, 2001

SECTION 6
HEADING INTERCONNECT DRAWINGS
1st Ed. May 11, 2001 6-1

Table of Contents
System 20/30 ....................................................................................................................................................... 6-3
System 40/50 ....................................................................................................................................................... 6-5
System 55/55X ................................................................................................................................................... 6-9
System 60-1/60-2/65 ......................................................................................................................................... 6-11
6-2 1st Ed. May 11, 2001

1st Ed. May 11, 2001 6-3

6-4 1st Ed. May 11, 2001

1st Ed. May 11, 2001 6-5

6-6 1st Ed. May 11, 2001

1st Ed. May 11, 2001 6-7

6-8 1st Ed. May 11, 2001

1st Ed. May 11, 2001 6-9

6-10 1st Ed. May 11, 2001

1st Ed. May 11, 2001 6-11

6-12 1st Ed. May 11, 2001

1st Ed. May 11, 2001 6-13

6-14 1st Ed. May 11, 2001

SECTION 7
SYSTEM INTERCONNECT DRAWINGS
1st Ed. May 11, 2001 7-1

Table of Contents
System 20/30 ....................................................................................................................................................... 7-3
System 30 ALT.................................................................................................................................................... 7-5
System 40/50 ....................................................................................................................................................... 7-7
System 55 ............................................................................................................................................................ 7-9
System 55/55X 7-11
System 60-1 ....................................................................................................................................................... 7-13
System 60-2 ....................................................................................................................................................... 7-15
System 65 .......................................................................................................................................................... 7-17
PSS .................................................................................................................................................................... 7-19
7-2 1st Ed. May 11, 2001

1st Ed. May 11, 2001 7-3

7-4 1st Ed. May 11, 2001

1st Ed. May 11, 2001 7-5

7-6 1st Ed. May 11, 2001

1st Ed. May 11, 2001 7-7

7-8 1st Ed. May 11, 2001

1st Ed. May 11, 2001 7-9

7-10 1st Ed. May 11, 2001

1st Ed. May 11, 2001 7-11

7-12 1st Ed. May 11, 2001

1st Ed. May 11, 2001 7-13

7-14 1st Ed. May 11, 2001

1st Ed. May 11, 2001 7-15

7-16 1st Ed. May 11, 2001

1st Ed. May 11, 2001 7-17

7-18 1st Ed. May 11, 2001

1st Ed. May 11, 2001 7-19

7-20 1st Ed. May 11, 2001

SECTION 8
SYSTEM SPECIFICATIONS
1st Ed. May 11, 2001 8-1

8-2 1st Ed. May 11, 2001

Programmer/Computer, System 20/30

Power Required: 14/28 VDC
Weight: 2.2 lb.
Dimensions: 3.250 x 3.250 x 7.100 in.
TSO: C9c, C3d
Programmer/Computer, System 40
Weight: 2.1 lb.
Dimensions: 3.340 x 3.340 x 8.200 in.
TSO: C9c
Weight: 2.8 lb.
Dimensions: 3.340 x 3.340 x 8.200 in.
TSO: C9c
Weight: 2.7 lb.
Dimensions: 6.350 x 1.500 x 9.460 in.
TSO: C9c, C52a
Programmer/Computer, System 55X

Weight: 2.7 lb.
Dimensions: 6.350 x 1.500 x 9.460 in.
TSO: C9c, C52a

Power Required: 28 VDC
Weight: 2.7 lb.
Dimensions: 6.350 x 1.500 x 9.460 in.
TSO: C9c, C52a
Programmer, System 60-1

Weight: 1.8 lb.
Dimensions: 3.343 x 3.343 x 5.200 in.
TSO: C9c, C52a
Programmer, System 60-2

Weight: 1.8 lb.
Dimensions: 3.343 x 3.343 x 5.200 in.
TSO: C9c, C52a
Programmer, System 65
Weight: 0.60 lb.
Dimensions: 2.00 x 2.00 x 5.124 in.
TSO: C9c, C52a
Programmer, PSS
Weight: 1.1 lb.
Dimensions: 4.500 x 1.312 x 6.000 in.
TSO: C9c, C52a
1st Ed. May 11, 2001 8-3
Roll Computer, System 60-1/60-2/65

Weight: 2.3 lb.
Dimensions: 5.250 x 2.100 x 13.33 in.
TSO: C9c, C52a
Pitch Computer, System 30/30 ALT

Weight: 1.1 lb.
Dimensions: 3.250 x 1.812 x 5.800 in.
TSO: C9c
Pitch Computer, System 60-2/65/PSS

Weight: 3.0 lb.
Dimensions: 5.250 x 2.100 x 13.33 in.
TSO: C9c, C52a
RemoteAnnunciator, System 65
Weight: 0.90 lb.
Dimensions: 3.420 x 1.600 x 6.500 in.
TSO: C9c, C52a
Turn Coordinator
Flag Voltage Detector Operating Limits: 9 VDC
Flag RPM Detector Operating Limits: Nominal RPM less 20%
Weight: 1.8 lbs.
Dimensions: 3.250 x 3.250 x 6.550 in.
TSO: C3b
Absolute Pressure Transducer

Power Required: 10 VDC, Supplied by Programmer/Computer
Pressure Range: 0-15 PSI Absolute
Overpressure: 150% of Operating Maximum
Weight: 0.20 lbs.
Dimensions: 3.000 x 2.430 x 1.880 in.
Roll/Trim Servo
Weight: 2.9 lbs.
Dimensions: 3.880 x 3.750 x 7.250 in.
TSO: C9c
Pitch Servo
Weight: 2.9 lbs.
Dimensions: 3.880 x 3.750 x 7.250 in.
TSO: C9c
Current Requirements, System 20 @14 VDC @ 28 VDC

Average Operating Current: 1.0 Amp 0.5 Amp
Maximum Current: 3.0 Amp 2.0 Amp

8-4 1st Ed. May 11, 2001

Current Requirements, System 30 ALT @14 VDC @ 28 VDC




Current Requirements, System 55X @14 VDC @ 28 VDC


Average Operating Current: N/A 0.5 Amp
Maximum Current: N/A 3.0 Amp
Current Requirements, System 60-1 @14 VDC @ 28 VDC

Current Requirements, System 60-2 @14 VDC @ 28 VDC


Current Requirements, PSS @14 VDC @ 28 VDC

1st Ed. May 11, 2001 8-5

8-6 1st Ed. May 11, 2001

SECTION 9
GLOSSARY
1st Ed. May 11, 2001 9-1

9-2 1st Ed. May 11, 2001

GLOSSARY
Term Meaning
A/C (AC) Aircraft

A/P Autopilot
A+ Aircraft Power (14 VDC or 28 VDC)
AC Alternating Current
ACCEL Acceleration
AFM Airplane Flight Manual
AFMS Airplane Flight Manual Supplement
ALR Alert
ALT Altitude
APR Approach
ARINC Aeronautical Radio, Incorporated
ATC Air Traffic Control
C (CAP) Capture Gain Condition, Course Captured
CB Circuit Breaker
CCW Counterclockwise
CDI Course Deviation Indicator
CMD Command
CON'T Continued
CRS Course
CS Capture Soft Gain Condition, Tracking Course or Localizer
CTRK DEV Cross Track Deviation
CW Clockwise
CWS Control Wheel Steering
DC Direct Current
DG Directional Gyro
DISC Disconnect
DN Down
DSBL Disable
DTA Data
DVM Digital Volt Meter
ED Edition
ENG Engage
EXC Excitation
FAA Federal Aviation Administration
FAF Final Approach Fix
FD Flight Director
FPM Feet Per Minute
GND Ground
GPS Global Positioning System
GPSS Global Positioning System Steering
GS Glideslope
HDG (HD) Heading
Hg Mercury
HI-TRK High Gain Tracking
HSI Horizontal Situation Indicator
IFR Instrument Flight Rules
ILS Instrument Landing System
IMC Instrument Meteorological Conditions
IN. Inches
JPR Jumper
L/R Left/Right
LBS Pounds
LOC Localizer
LORAN Long Range Navigation
LO-TRK Low Gain Tracking
LT Left
MAN Manual
MOD Modify
MOT Motor
1st Ed. May 11, 2001 9-3

GLOSSARY (CON'T)
Term Meaning
N/A Not Applicable

N/C No Connection
NAV Navigation
NDU Navigational Display Unit
OBS Omnibearing Selector
P/N Part Number
POH Pilot's Operating Handbook
POHS (POH/S) Pilot's Operating Handbook Supplement
POT Potentiometer
PSI Pounds Per Square Inch
PSS Pitch Stabilization System
RDY Ready
REF Reference
REV Reverse
RPM Revolutions Per Minute
RT Right
S Soft Gain Condition, Tracking Course
S/A Selector Alerter
SB Service Bulletins
SFM Supplemental Flight Manual
SOL Solenoid
ST (STB) Stabilizer
TACH Tachometer
T/C (TC) Turn Coordinator
TSO Technical Standard Order
UUT Unit Under Test
VAC Volts Alternating Current
VDC Volts Direct Current
VFR Visual Flight Rules
VHF Very High Frequency
VMC Visual Meteorological Conditions
VOR Very High Frequency Omnidirectional Radio Range
Vpp Volts Peak-to-Peak
VS Vertical Speed
XDCR Transducer
YD Yaw Damper
9-4 1st Ed. May 11, 2001

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Flight Line Service Manual

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*Section 5 deleted in its entirety.

RETAIN THIS RECORD IN THE FRONT OF THE MANUAL. ON

1st Ed 11 May 2001 None

1st Rev. 15 May 2003

PAGE INTENTIONALLY BLANK

1st Ed. May 11, 2001 1-1

PAGE INTENTIONALLY BLANK

1-2 1st Ed. May 11, 2001

1.1 Service Manual Organization

System 20/30/30 ALT

1.3 Required Test Equipment

1.4 Service Philosophy

1st Ed. May 11, 2001 1-3

* Simulates only the following Heading Systems:

Manufacturer Type P/N

1.5 Technical Support

1-4 1st Ed. May 11, 2001

Fig. 1-1. Flight Line Autopilot Tester

1st Ed. May 11, 2001 1-5

SYS 20/30/30 ALT

Fig. 1-2. Breakout Connections

1-6 1st Ed. May 11, 2001

1st Ed. May 11, 2001 3-1

3.1 Functional Ground Test for System 20 ............................................................................................................... 3-3

3.2 Functional Ground Test for System 30 ............................................................................................................... 3-5

3.3 Functional Ground Test for System 30 ALT ...................................................................................................... 3-7

3.4 Functional Ground Test for System 40 ............................................................................................................... 3-8

3.5 Functional Ground Test for System 50 ............................................................................................................. 3-10

3.6 Functional Ground Test for System 55 ............................................................................................................... 3-14

3.7 Functional Ground Test for System 55X .......................................................................................................... 3-17

3.8 Functional Ground Test for System 550 ........................................................................................................... 3-21

3.9 Functional Ground Test for System 60-1 ............................................................................................................ 3-25

3.10 Functional Ground Test for System 60-2 ............................................................................................................ 3-27

3.11 Functional Ground Test for System 65 ............................................................................................................... 3-31

3.12 Functional Ground Test for System 60 PSS ........................................................................................................ 3-35

3-2 1st Ed. May 11, 2001

3.1 Functional Ground Test for System 20

1. Set the Battery Master Switch to the ON position.

2. Set the Avionics Master Switch to the ON position.

3. Set the A/P Master Switch to the ON position.

Stabilizer Channel Test

7. Center the A/P TURN CMD knob under its index.

8. Engage the A/P ST mode.

9. Turn the A/P TURN CMD knob to the left.

12. Verify that the A/C control wheel stops.

13. Turn the A/P TURN CMD knob to the right.

16. Verify that the A/C control wheel stops.

Heading Channel Test

17. Center the HDG bug under the lubber line.

18. Engage the A/P HDG mode.

19. Turn the HDG bug to the left.

21. Center the HDG bug under the lubber line.

22. Verify that the A/C control wheel stops.

1st Ed. May 11, 2001 3-3

23. Turn the HDG bug to the right.

25. Center the HDG bug under the lubber line.