SkyView HDX Autopilot Servo Installation & Maintenance Manual

SkyView HDX Autopilot Servo Installation & Maintenance Manual Cessna Series 182 Models: 182E–182T, T182, R/TR182 Includes Instructions for Continued Airworthiness (ICA) STC SA02594SE 104142-000 Rev B 7/8/2022 Copyright © 2022 by Dynon Avionics, Inc. Dynon Avionics grants third parties' permission to print this document Contact Information Dynon Avionics, Inc. 19825 141st Place NE Woodinville, WA 98072 Technical Support Phone: +1 (425) 399-7742, 8:00 AM – 5:00 PM (Pacific Time) Monday – Friday Email: support@dynoncertified.com Sales Phone: +1 (425) 650-1269, 8:00 AM – 5:00 PM (Pacific Time) Monday – Friday Email: sales@dynoncertified.com Find Us on the Web dynoncertified.com – Dynon Certified homepage dynoncertified.com/docs – Product documentation dynoncertified.com/download – Software updates for products dynoncertified.com/support – Support resources dynoncertified.com/register – Register your Dynon Avionics product Stay in Touch dynoncertified.com/newsletter – Sign up to receive Dynon’s newsletter forum.flydynon.com – Dynon-hosted forum for customers and pilots preflight.dynon.com – Dynon’s blog facebook.com/dynonavionics instagram.com/dynonavionics twitter.com/dynon Videos and Training youtube.com/DynonAvionics – Training, events, and other videos on YouTube Copyright ©2022 Dynon Avionics, Inc. All rights reserved. No part of this manual may be reproduced, copied, transmitted, disseminated, or stored in any storage medium, for any purpose without the express written permission of Dynon Avionics. Dynon Avionics hereby grants permission to download a single copy of this manual and of any revision to this manual onto a hard drive or other electronic storage medium to be viewed for personal use, provided that such electronic 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. Information in this document is subject to change without notice. Dynon Avionics reserves the right to change or improve its products and to make changes in the content without obligation to notify any person or organization of such changes. Visit the Dynon Avionics website (dynon.com) for current updates and supplemental information concerning the use and operation of this and other Dynon Avionics products. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | iii Revision History REV DYNON SUBMITTAL DATE FAA ACCEPTANCE DATE DESCRIPTION OF CHANGES A 02/24/2022 ECO 373555 Accepted by Seattle ACO on 3/11/2022 Initial Submission B 7/8/2022 ECO 380329 Accepted by Anchorage ACO on 7/13/2022 Revised bridle cable tension value in Sections 7.2, 7.3, 11.8, and 11.9. Page | iv SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Table of Contents 1 Introduction ........................................................................................... 1-1 1.1 Document Control...................................................................................................... 1-1 1.2 Using this Manual ...................................................................................................... 1-1 1.3 Intended Audience..................................................................................................... 1-1 1.4 Manual Iconography .................................................................................................. 1-2 1.5 Reference Documents ............................................................................................... 1-2 1.6 Mechanical Drawings ................................................................................................ 1-2 1.7 Product Delivery and Warranty .................................................................................. 1-2 1.8 Product Registration .................................................................................................. 1-3 1.9 Installation Record ..................................................................................................... 1-3 2 Airworthiness Limitations .................................................................... 2-1 3 Basic Control and Operation ................................................................ 3-1 4 Installation Compliance ........................................................................ 4-1 4.1 Pre-installation Information ........................................................................................ 4-1 5 Control Cable Verification .................................................................... 5-1 6 Materials ................................................................................................ 6-1 6.1 Roll Servo Materials .................................................................................................. 6-1 6.2 Pitch Servo Materials................................................................................................. 6-3 7 Initial Servo and Bracketry Installation................................................ 7-1 7.1 Additional Tools ......................................................................................................... 7-1 7.2 Roll Servo Installation ................................................................................................ 7-1 7.3 Pitch Servo Installation .............................................................................................. 7-5 8 Servo Electrical Connection ................................................................. 8-1 8.1 Custom Wire Harness Preparation ............................................................................ 8-2 9 Electric Trim Control ............................................................................. 9-1 10 Servo Troubleshooting ....................................................................... 10-1 10.1 Servos Offline Messages ......................................................................................... 10-1 10.2 Servo Slip Messages ............................................................................................... 10-2 10.3 Abnormal Operation ................................................................................................ 10-2 11 Servo Maintenance.............................................................................. 11-1 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | v 11.1 Service .................................................................................................................... 11-1 11.2 Calibration Procedure .............................................................................................. 11-1 11.3 Test Procedure ........................................................................................................ 11-2 11.4 Servo Operation Check ........................................................................................... 11-2 11.5 Servo Capstan Removal and Attachment ................................................................ 11-4 11.6 Cable Guard Adjustment ......................................................................................... 11-5 11.7 Shear Screw Replacement ...................................................................................... 11-5 11.8 Roll Servo Removal and Replacement .................................................................... 11-6 11.9 Pitch Servo Removal and Installation ...................................................................... 11-9 12 Figures ................................................................................................. 12-1 12.1 Roll Servo Figures ................................................................................................... 12-1 12.2 Pitch Servo Figures ............................................................................................... 12-15 12.3 Servo Capstan Removal/Installation Figure .......................................................... 12-32 Page | vi SkyView HDX Autopilot Servo Installation & Maintenance Manual - 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SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 1-1 1 Introduction This document provides installation and configuration information for SkyView autopilot servos and bracketry in Cessna 182 series of airplanes. It also provides Instructions for Continued Airworthiness (ICA) for use by authorized personnel to service and maintain the servos according to Federal Aviation Regulation (FAR) 14 CFR § 23.1529 and 14 CFR 23 Appendix G. This document does not provide ICA for the SkyView HDX system. That information is provided in the SkyView HDX General Maintenance Manual document at dynoncertified.com/docs. 1.1 Document Control This document is released, archived, and controlled according to the Dynon’s document control system. To revise this document, a letter is submitted to the FAA with the revision. The FAA then accepts and approves any revision to Section 2: Airworthiness Limitations. After FAA acceptance/approval, Dynon posts the revised document for customer use at dynoncertified.com/docs, and STC owners and installers are notified of the new revision via an official Dynon Marketing email release. 1.2 Using this Manual To save paper, Dynon does not provide a printed version of this manual. However, Dynon grants permission to third parties to print this manual, as necessary. The most recent PDF version is available for download at dynoncertified.com/docs. This manual is updated periodically. It is important to use the most recent version when servicing SkyView components. Dynon suggests keeping a PDF version of the manual on a smartphone, tablet, or laptop computer while servicing SkyView components. Using the manual electronically allows quick navigation of the document, figures to be viewed in color, and keyword searches. 1.3 Intended Audience This document is intended for FAA-certified Airframe and Powerplant Technicians. It assumes technicians have the typical aircraft knowledge and training required to perform the procedures in this manual. Page | 1-2 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B 1.4 Manual Iconography This manual uses the following iconography: Alerts reader to critical guidance that if not followed could result in an unsafe condition. Alerts reader to FAA regulatory information. Alerts reader to important installation and/or maintenance information. Alerts reader to helpful tips or suggestions. 1.5 Reference Documents The following documents are referenced in or supplement this manual: • 103261-000 - SkyView HDX System Installation Manual, current revision • 103221-000 - SkyView HDX General Maintenance Manual, current revision • 103488-000 - SkyView HDX Wiring Diagram - Single Engine, current revision • 103272-000 - SkyView HDX Airplane Flight Manual Supplement, current revision • 103777-000 - SkyView HDX System Equipment Installation Record, current revision • 103000-000 - Dynon Servo Shear Screw Replacement Kit Instructions, current revision • FAR 23.1311-1C - Installation of Electronic Display in Part 23 Airplanes • AC 43.13-1B - Acceptable Methods, Techniques, and Practices - Aircraft Inspection • AC 43.13-2B - Acceptable Methods, Techniques, and Practices - Aircraft Alterations 1.6 Mechanical Drawings All mechanical drawings included in this manual are for reference purposes only. They should not be scaled or copied and used as templates or patterns. 1.7 Product Delivery and Warranty Upon delivery, visually inspect all components, brackets, fasteners, cable harnesses, and accessories for damage that may have occurred during shipping. If damage has occurred, contact Dynon Technical Support. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 1-3 1.8 Product Registration Register SkyView components at dynoncertified.com/register. Product registration verifies ownership, expedites warranty claims, and allows Dynon to send notification when product Service Bulletins and Technical Advisories are published. This site also allows owners and installers to register to receive news and product announcements from Dynon. Dynon will not share contact information with third-parties or send announcements without explicit consent. 1.9 Installation Record The mechanic or facility performing the installation should record where each component has been installed in the airplane. This documentation should be entered into airplane’s permanent record. Dynon provides a document template to record this information. Download the SkyView HDX Equipment Installation Record document at dynoncertified.com/docs. Page | 1-4 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B This page intentionally left blank. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 2-1 2 Airworthiness Limitations For any Airworthiness Limitations associated with the installation of SkyView autopilot servos, see the SkyView HDX General Maintenance Manual document at dynoncertified.com/docs. It is the principal ICA document for the SkyView HDX system. Page | 2-2 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B This page intentionally left blank. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 3-1 3 Basic Control and Operation Pilots interact with all autopilot functions through a SkyView HDX display unit. No special operating procedures are required for using the SkyView Autopilot. Control descriptions and detailed operating procedures are found in the SkyView HDX Airplane Flight Manual Supplement document at dynoncertified.com/docs. Operating limitations for the SkyView Autopilot are listed in the SkyView HDX Airplane Flight Manual Supplement document at dynoncertified.com/docs. Page | 3-2 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B This page intentionally left blank. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 4-1 4 Installation Compliance If the airplane receiving the installation has been modified, it may be difficult to use the information in this manual to completely substantiate the installation in compliance with STC SA02594SE. Therefore, it is the installer's responsibility to make the final determination of applicability for each individual airplane. Prior to completing the installation, and before returning the airplane to service, the installer must complete and submit a completed Form FAA 337 - Major Repair & Alteration (Airframe, Powerplant, Propeller, or Appliance) to the appropriate FAA Aircraft Registration Branch. The form must include the following: • Description of the autopilot servo installation. • Description of how the autopilot servos interface with existing equipment and systems. • Appropriately approved or acceptable data that demonstrates compliance. Refer to AC 43.9-1G - Instructions for Completion of FAA Form 337 for additional information. 4.1 Pre-installation Information Read and understand the following before proceeding with installation activities. Always install avionics equipment in accordance with the instructions in this manual and the guidance and approved engineering methods outlined the following FAA documents: • FAR 23.1311-1C - Installation of Electronic Display in Part 23 Airplanes • AC 43.13-1B - Acceptable Methods, Techniques, and Practices - Aircraft Inspection • AC 43.13-2B - Acceptable Methods, Techniques, and Practices - Aircraft Alterations The certified mechanic who will authorize the airplane's return to service should agree with the installation plan (i.e., methods, component locations, wiring harness routing, etc.) before installation activities begin. This will help avoid potential rework should any part of the installation be found non-compliant. Page | 4-2 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B This page intentionally left blank. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 5-1 5 Control Cable Verification The SkyView Autopilot for the Cessna 182 series of airplanes is designed to attach to the airplane's original control cables. It is important for installers to verify the condition and diameter of the control cables before starting installation activities. The diameter of control cables should be measured in the vicinities where the autopilot servos will be installed. Frayed or overly worn control cables can cause the bridle cable clamps to slip under load. To measure the aileron control cable, installers need to access the area in the left wing between WS100 and WS118 (see Figure 1 for exact location) in accordance with the manufacturer's service manual. To measure the elevator control cables, installers need to access the area in the fuselage between FS172 and FS185 (see Figure 17 for exact location) in accordance with the manufacturer's service manual. Control Cable Specification: Dynon's bridle cable clamps are designed to meet the requirements below for wire rope as specified by MIL-DTL-83420. CONTROL CABLE NOMINAL DIAMETER MINIMUM DIAMETER MAXIMUM DIAMETER Aileron, Elevator 1/8" 0.125" 0.139" If the airplane's original control cables are outside this specification, contact Dynon Technical Support for a resolution. Out-of-specification control cables can cause cable clamps to slip under load. Page | 5-2 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B This page intentionally left blank. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 6-1 6 Materials 6.1 Roll Servo Materials The materials identified in Table 1 are provided to install the roll servo. ITEM numbers are also used to call-out parts in the figures in Section 12.1. Table 1: Roll Servo Installation Materials ITEM DYNON P/N DESCRIPTION QTY 1 503933-000 SERVO ASSEMBLY: SV42C-SERVO, CAPSTAN 0.68" R 1 1-1 SV42C SERVO 1 1-2 CAPSTAN 0.68" R 1 1-3 AN310-5 CASTLE NUT 5/16" 1 1-4 WAVE WASHER 5/16" 1 1-5 NYLON WASHER 5/16" 1 1-6 PHILIPS PAN HEAD SCREW #6-32 X 1/4" L, NYLOK 4 1-7 MS35333-37 INTERNAL STAR WASHER #6 4 1-8 CABLE GUARD 1 2 503674-000 CAPSTAN ACCESSORY KIT, 1/8" CONTROL CABLE 1 2-1 AN3-6A HEX BOLT #10-32 6 2-2 AN960-10 FLAT WASHER #10 6 2-3 AN365-10 LOCK NUT #10-32 6 2-4 BRIDLE CABLE CLAMP 1/8" 4 2-5 BRIDLE CABLE 1 2-6 ST2-2 STOP SWAGE, 1/16" CABLE 2 3 503965-000 UPPER ROLL SERVO BRACKET 1 4 503966-000 LOWER ROLL SERVO BRACKET 1 5 504232-000 ROLL SERVO TEMPLATE 1 6 104168-000 ROLL SERVO HARDWARE KIT 1 Page | 6-2 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B ITEM DYNON P/N DESCRIPTION QTY 6-1 MS24665-210 COTTER PIN 1 6-2 AN3H-4A HEX BOLT #10-32, DRILLED HEAD 4 6-3 AN960-10 FLAT WASHER #10 4 6-4 MS35333-39 INTERNAL STAR WASHER #10 1 6-5 AN525-832R7 PHILLIPS WASHER HEAD SCREW #8-32, 7/16" L 6 6-6 MS21051-08 NUTPLATE 6 6-7 MS20426AD-3-3.5 FLUSH MOUNT RIVET 12 NOTE: An item without a Dynon part number is packaged in a kit. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 6-3 6.2 Pitch Servo Materials The materials identified in Table 2 are provided to install the pitch servo. ITEM numbers are also used to call-out parts in the figures in Section 12.2. Table 2: Pitch Servo Installation Materials ITEM DYNON P/N DESCRIPTION QTY 7 504160-000 SERVO ASSEMBLY: SV42C SERVO, CAPSTAN 0.80" R 1 7-1 SV42C SERVO 1 7-2 CAPSTAN 0.80" R 1 7-3 AN310-5 CASTLE NUT 5/16" 1 7-4 WAVE WASHER 5/16" 1 7-5 NYLON WASHER 5/16" 1 7-6 PHILLIPS PAN HEAD SCREW #6-32 X 1/4" L, NYLOK 4 7-7 MS35333-37 INTERNAL STAR WASHER #6 4 7-8 CABLE GUARD 1 8 503674-000 CAPSTAN ACCESSORY KIT, 1/8" CONTROL CABLE 2 8-1 AN3-6A HEX BOLT #10-32 6 8-2 AN960-10 FLAT WASHER #10 6 8-3 AN365-10 LOCK NUT #10-32 6 8-4 BRIDLE CABLE CLAMP 1/8" 4 8-5 BRIDLE CABLE 1 8-6 ST2-2 STOP SWAGE, 1/16" CABLE 2 9 503970-000 PITCH SERVO BASE BRACKET 1 10 503972-000 PITCH SERVO RISER BRACKET 1 11 503971-000 PITCH SERVO SHEAR CLIP 4 12 503986-000 PITCH SERVO PHENOLIC CABLE GUARD BRACKET 1 13 504212-000 PITCH SERVO PHENOLIC CABLE GUARD 1 14 104167-000 PITCH SERVO HARDWARE KIT 1 Page | 6-4 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B ITEM DYNON P/N DESCRIPTION QTY 14-1 MS24665-210 COTTER PIN 1 14-2 AN3H-4A HEX BOLT #10-32, DRILLED HEAD 4 14-3 AN3-4A HEX BOLT #10-32 6 14-4 AN960-10 FLAT WASHER #10 10 14-5 AN525-832R8 PHILLIPS WASHER HEAD SCREW #8-32, 1/2" L 12 14-6 AN525-832R7 PHILLIPS WASHER HEAD SCREW #8-32, 7/16” L 4 14-7 MS35206-246 PHILLIPS PAN HEAD SCREW #8-32, 5/8" L 2 14-8 AN960-8 FLAT WASHER #8 18 14-9 AN365-832A LOCK NUT #8-32 18 14-10 MS21047-03 NUTPLATE 6 14-11 MS20470AD-3-4 UNIVERSAL HEAD RIVET 8 14-12 MS20426AD-3-4 FLUSH MOUNT RIVET 12 NOTE: An item without a Dynon part number is packaged in a kit. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 7-1 7 Initial Servo and Bracketry Installation This section provides instructions for installing the roll and pitch servos and associated bracketry, attaching bridle cable assemblies to the aileron and elevator control cables, and the checking the physical installations. The instructions apply to the Cessna 182 series of airplanes listed on the cover of this document. These instructions assume that the areas affected by these installations are unmodified from the factory-delivered configuration. Printing the figures at the end of this document and keeping them on-hand during installation activities is recommended. 7.1 Additional Tools The following non-typical tools are needed to complete the installation: • Angle Drill, • #10 Nutplate Drill Jig, • Swage compression tool appropriate for ST2-2 stop swages, • Wire rope cutters. 7.2 Roll Servo Installation The roll servo and bracketry are installed in the left wing between WS100 and WS118 (see Figure 1 for exact location). To install the roll servo, installers need to access this area in accordance with the manufacturer's service manual. See Figure 16 for an example of a complete installation. Remove any previously installed autopilot equipment that may interfere with the new servo installation. Make sure all flight control cables are rigged and tensioned in accordance with manufacturer’s instructions. Failure to do so may result in poor autopilot system performance. Always disconnect aircraft battery before starting installation activities. Always deburr drilled holes. Unless otherwise specified, torque all fasteners per specifications in AC 43.13-1B, Table 7-1. Include specified friction drag value when torquing screws. Page | 7-2 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B To install the roll servo: 1. Remove capstan from roll servo (see Section 11.5 for instructions). DO NOT remove shear screw from servo disc! 2. Temporarily attach lower roll servo bracket to plate template (see Figure 3). 3. Insert and position lower bracket assembly into wing, as shown in Figure 4. 4. Insert upper roll servo bracket into wing and temporarily attach to lower bracket assembly, as shown in Figure 4. 5. Take note of bracket assembly position in relation to WS100.50. If bracket assembly does not fit in location shown in Figure 4 without contacting rivets on rear spar, contact Dynon Technical Support. When properly located, bracket assembly will almost contact the bend radius at the top of the rear spar. 6. Remove bracket assembly from wing. (Leave plate template attached to lower bracket.) 7. From outside aircraft, position upper bracket, as shown in Figure 5 and noted in Step 5. Make sure upper bracket is positioned between rivets with adequate edge margins for 0.17" diameter holes. 8. Use inboard pilot hole in upper bracket to mark a hole location (see Figure 5), drill (#40) hole through wing, and then temporarily fasten upper bracket to wing. 9. Use outboard pilot hole in upper bracket to drill (#40) hole through wing. 10. Remove upper bracket from wing. 11. Insert upper bracket into wing and temporarily fasten using holes made in Step 8 and Step 9. 12. Use pilot holes in upper bracket to match drill (#18) holes through bracket and wing. Temporarily fasten upper bracket to wing after each hole is drilled. 13. Insert and temporarily fasten lower bracket assembly to upper bracket, as shown in Figure 6. Make sure lower bracket is positioned between rivets with adequate edge margins for 0.17" diameter holes. 14. Use inboard pilot hole in lower bracket to drill (#40) hole through wing, and then temporarily fasten lower bracket to wing. 15. Use outboard pilot hole in lower bracket to drill (#40) hole through wing. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 7-3 16. Use pilot holes in lower bracket to match drill (#18) holes through bracket and wing. Temporarily fasten lower bracket to wing after each hole is drilled 17. Remove bracket assembly from wing and disassemble. 18. Countersink rivet holes in upper and lower brackets, and then attach nutplates to brackets (see Figure 7). 19. Permanently fasten upper bracket to wing (see Figure 8). 20. Permanently fasten lower bracket to roll servo (see Figure 9). 21. Safety wire roll servo bolts (see Figure 14 for example). 22. Slide a swage stop onto one end of bridle cable, and then position it per specifications in Figure 10. 23. Crimp swage stop to bridle cable, and then trim bridle cable end flush with outside edge of swage stop. 24. Repeat Steps 22 and 23 on the other end of bridle cable. 25. Insert bridle cable's engagement swage into capstan's engagement hole. 26. Start from swage engagement hole and wrap bridle cable one complete revolution in each direction around capstan. Securing bridle cable to capstan grooves with tape prevents cable from unraveling when handling. 27. Attach capstan to roll servo, as shown in Figure 11. Position servo capstan so orientation mark on capstan faces away from servo, capstan is in 12 'o' clock position, and servo is fully seated on servo disc. The capstan has a hole that fits over shear screw head. 28. Insert roll servo assembly into wing, as shown in Figure 12. 29. Permanently fasten roll servo assembly to upper bracket and wing (see Figure 13). 30. Safety wire upper roll servo bolt (see Figure 14 for example). To attach the roll servo to the aileron cable: 1. Secure ailerons and/or yoke in center of travel. 2. Make sure aileron control cable in area where bridle cable clamps will attach is clean and free of dirt and grease. 3. Use bridle cable clamps to loosely connect inboard and outboard bridle cable ends to aileron control cable, as shown in Figure 15. Make sure clamps contact swage stops at each end of bridle cable. 4. Position bridle cable clamps so that: • Swage engagement hole is in the 12 'o' clock position. Page | 7-4 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B • Clamps are located as shown in Figure 15. • Clamps are positioned to avoid contacting any structure. 5. Make sure bridle cable does not contact cable guard. The bridle cable will prematurely wear if bridle cable and cable guard make contact when control is in a neutral position. 6. If cable guard interferes with bridle cable, adjust cable guard position (see Section 11.6 for instructions)., and then repeat Step 5. 7. Tension and temporarily secure bridle cable to 15-20 lbs. Make sure swage engagement hole is located upward and on same side as cables exit. The tension on bridle cable should never exceed manufacturer's specified tension for control cable. 8. When satisfied with tension and capstan position, tighten all bridle cable clamp nuts to 35-40 in-lb. 9. Use a feeler gauge to measure gaps between bridle cable clamp halves (top and bottom). Make sure gaps meet the following criteria: • Gap measurements on both sides of clamp are not less than 0.003" and not more than 0.050". If clamp gap measurements do not meet criteria above, measure diameter of control cable, and then contact Dynon Technical Support for a resolution. Out-of-specification cable clamps can slip under load. 10. Permanently attach capstan to roll servo (see Section 11.5 for instructions). To check the roll servo installation: 1. Release ailerons and/or yoke. 2. Move aileron control through full range of motion per manufacturer's maintenance instructions, and verify the following: • Control is smooth throughout (i.e., no grinding, rubbing, or roughness). • Bridle cable clamps do not contact any structures during entire travel. • Capstan never rotates more than 150 degrees in either direction from neutral. 3. Cycle the control surface several times, return it to neutral, and verify the following: • Swage engagement hole is in the 12 'o' clock position. • Position of bridle cable clamps closely matches Figure 15. • Bridle cable tension has not changed. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 7-5 7.3 Pitch Servo Installation The pitch servo and bracketry are installed in the fuselage between FS172 and FS185 (see Figure 17 for exact location). To install the pitch servo, installers need to access this area in accordance with the manufacturer's service manual. See Figure 33 for an example of a complete installation. Remove any previously installed autopilot equipment that may interfere with the new servo installation. Make sure all flight control cables are rigged and tensioned in accordance with manufacturer’s instructions. Failure to do so may result in poor Autopilot system performance. Always disconnect aircraft battery before starting installation activities. Always deburr drilled holes. Unless otherwise specified, torque all fasteners per specifications in AC 43.13-1B, Table 7-1. Include specified friction drag value when torquing screws. To install the pitch servo: 1. If required for access, remove aircraft battery in accordance with manufacturer's service instructions. 2. Remove capstan and cable guard from pitch servo (see Section 11.5 for instructions). DO NOT remove shear screw from servo disc! 3. Temporarily attach pitch servo to pitch servo riser bracket (see Figure 19). 4. Position pitch servo base bracket, as shown in Figure 20. 5. Place riser bracket assembly on base bracket, and then adjust both brackets as needed to position servo capstan as shown in Figure 21. Aligning pitch servo capstan with elevator control cable, as shown in Figure 21, is critical for an airworthy installation. 6. Use holes in brackets and bracket edges to mark locations for positioning base bracket on fuselage skin and riser bracket on base bracket. 7. Remove riser bracket assembly from airplane. Leave base bracket in position. 8. Use pilot holes in base bracket to match drill (#18) holes through base bracket and fuselage skin (see Figure 22). Page | 7-6 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B 9. Position shear clips, as shown in Figure 23. 10. Use pilot holes in shear clips to match drill (#40) holes through base bracket (see Figure 23). 11. Use pilot holes in shear clips to match drill (#18) holes through shear clips and FS172 and FS185 frames (see Figure 23). 12. Remove base bracket and shear clips from airplane. 13. On a workbench, use pilot holes in riser brackets to match drill (#10) holes through riser bracket and base bracket (see Figure 24). 14. Use nutplate drill jig to drill (#40) rivet holes through base bracket. 15. Countersink rivet holes in riser bracket, and then attach nutplates to bracket (see Figure 25). 16. Rivet shear clips to base bracket (see Figure 26). 17. Attach pitch servo to riser bracket (see Figure 27). Position servo capstan so orientation mark on capstan faces away from servo, capstan is in 6 'o' clock position, and servo is fully seated on servo disc. The capstan has a hole that fits over shear screw head. 18. Attach cable guard bracket to riser bracket (Figure 28). 19. Position phenolic cable guard so elevator control cable is centered in upper (larger) hole in cable guard, and then clamp cable guard to cable guard bracket. 20. Use pilot holes in cable guard bracket to match drill (#18) holes through cable guard bracket and phenolic cable guard (see Figure 28). 21. Safety wire pitch servo bolts (see Figure 29 for example). 22. Permanently fasten base bracket to fuselage skin (see Figure 30). 23. Permanently fasten riser bracket assembly to base bracket (see Figure 31). To attach the pitch servo to the elevator up cable: 1. Secure elevator and/or yoke in center of travel. 2. Insert bridle cable's engagement swage into capstan's engagement hole. 3. Start from swage engagement hole and wrap bridle cable one complete revolution in each direction around capstan. Securing bridle cable to capstan groove with tape prevents cable from unraveling when handling. 4. Make sure elevator control cable in area where bridle cable clamps will attach is clean and free of dirt and grease. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 7-7 5. Use bridle cable clamps to loosely connect forward and aft bridle cable ends to elevator control cable, as shown in Figure 32. 6. Position bridle cable clamps so that: • Swage engagement hole is in the 6 'o' clock position. • Clamps are located as shown in Figure 32. • Clamps are positioned to avoid contacting any structures. 7. Mark locations for swage stops on bridle cable at outside edges of bridle cable clamps. 8. Slide a swage stop onto one end of bridle cable, and then position it per specifications in Figure 32. 9. Crimp swage stop to bridle cable, and then trim bridle cable end flush with outside edge of swage stop. 10. Repeat Steps 8 and 9 on the other end of bridle cable. 11. Make sure bridle cable does not contact cable guard. The bridle cable will prematurely wear if bridle cable and cable guard make contact when control is in a neutral position. 12. If cable guard interferes with bridle cable, adjust cable guard position (see Section 11.6 for instructions), and then repeat Step 11. 13. Tension and temporarily secure bridle cable to 15-20 lbs. Make sure swage engagement hole is on opposite side of capstan from elevator up cable. The tension on bridle cable should never exceed manufacturer's specified tension for control cable. 14. When satisfied with tension and capstan position, tighten all bridle cable clamp nuts to 35-40 in-lb. 15. Use a feeler gauge to measure gaps between bridle cable clamp halves (top and bottom). Make sure gaps meet the following criteria: • Gap measurements on both sides of clamp are not less than 0.003" and not more than 0.050". If clamp gap measurements do not meet criteria above, measure diameter of control cable, and then contact Dynon Technical Support for a resolution. Out-of-specification cable clamps can slip under load. 16. Permanently attach capstan and cable guard to pitch servo (see Section 11.5 for instructions). Page | 7-8 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B To check the pitch servo installation: 1. Release elevator and/or yoke. 2. Move elevator control through full range of motion per manufacturer's maintenance instructions, and verify the following: • Control is smooth throughout (i.e., no grinding, rubbing, or roughness). • Bridle cable clamps do not contact any structures during entire travel. • Capstan never rotates more than 150 degrees in either direction from neutral. 3. Cycle the control surface several times, return it to neutral, and verify the following: • Swage engagement hole is in the 6 'o' clock position. • Position of bridle cable clamps closely matches Figure 32. • Bridle cable tension has not changed. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 8-1 8 Servo Electrical Connection Refer to the following documents at dynoncertified.com/docs for complete electrical connection guidance: • SkyView HDX Wiring Diagram - Single Engine • SkyView HDX System Installation Manual Dynon provides the SV-NET-SERVO Network Autopilot Servo Cable Kit to aid in wiring the servos. Contact Dynon Sales for more information. Servo electrical harnesses must be routed through the airframe structure as outlined in AC 43.13-1B, Chapter 11, Section 3. Power for all servos must be controlled by a switch labeled AP Power that is installed prominently on the instrument panel. This provides the pilot the ability to quickly turn off power to the servos should it be needed. See the SkyView HDX System Installation Manual for more information. An Autopilot Disconnect (AP DISC) button must be installed prominently on the instrument panel or yoke/wheel. This provides the pilot the ability to quickly disengage the pitch and roll servos. See the SkyView HDX System Installation Manual for more information. Servo power and Autopilot Disconnect circuits are required to be separate from the signal and power circuits provided over the SkyView Network. The servos should receive power from a common power source with circuit protection sized for the loads associated with all servos. Terminate servo electrical harnesses with a D9 connector with female pins; terminate pigtails on servo electrical harnesses with mating D9 connector with male pins. Servo electrical harnesses must not chafe against airframe structure. after all electrical connection activities are complete, visually inspect all harness routing. Servo electrical harnesses cannot interfere with the airplane's flight controls. After all electrical connection activities are complete, confirm this by moving all controls through full range of motion per manufacturer's maintenance instructions. After electrically connecting the autopilot servos, perform the Servo Calibration Procedure (see Section 11.2 for instructions). Page | 8-2 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B 8.1 Custom Wire Harness Preparation If your SkyView Autopilot installation requires customized wire harnesses, refer to Table 3 for wire/pin connection guidance and the SkyView HDX Wiring Diagram - Single Engine and SkyView HDX System Installation Manual documents at dynoncertified.com/docs for additional electrical installation information. Each harness requires one D9M and one D9F connector. Table 3: Autopilot Servo Harness, Pin/Wire Connections D9 Harness Pin # D9 Harness Wire Function D9 Harness Wire Color Connection / Notes 1 SkyView Network Data 1A Green SkyView Network D9 Connector, Pin 1 2 Ground Black Common Airframe Ground 3 Autopilot Disconnect Yellow A/P DISC Button 4 SkyView Network Data 2B White w/ Blue SkyView Network D9 Connector, Pin 4 5 None No Wire No Connection 6 SkyView Network Data 1B Blue SkyView Network D9 Connector, Pin 6 7 Power Red Electrical Bus Use 10A Circuit Breaker / Fuse 8 SkyView Network Data 2A White w/ Green SkyView Network D9 Connector, Pin 8 9 None No Wire No Connection SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 9-1 9 Electric Trim Control Existing pitch trim motors certified for the airplane can be controlled through the SkyView Autopilot. Such trim motors must operate on 10–30 Volts with a maximum current draw of 5 Amps. This includes trim motors with or without a clutch. Instructions for connecting to a trim motor, configuring SkyView HDX for trim control, and functionally testing the feature are found in the SkyView HDX System Installation Manual document at dynoncertified.com/docs. Page | 9-2 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B This page intentionally left blank. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 10-1 10 Servo Troubleshooting This section provides troubleshooting information for the autopilot servos. See the SkyView HDX General Maintenance Manual document at dynoncertified.com/docs for information about troubleshooting the SkyView Autopilot interface. 10.1 Servos Offline Messages Condition: One or more of the following messages appear on SkyView HDX display unit: • PITCH SERVO OFFLINE • ROLL SERVO OFFLINE If all three messages annunciate: 1. Verify Master Power is ON. 2. Verify Autopilot circuit breaker and switch are ON. 3. Verify all harness connectors for all servos are properly mated. 4. Verify electrical power to all servos. 5. Verify adequate ground quality for all servos. If condition persists, or if only one message annunciates: 1. Enter SETUP menu (simultaneously hold Buttons #7 and #8). 2. Go to SYSTEM SETUP -> SKYVIEW NETWORK SETUP-> NETWORK STATUS 3. Locate SV32/SV42 servos in list of network devices. If necessary, use knobs to scroll through entire list. If a servo entry is not listed under network devices, press BACK, and perform a SkyView Network configuration (refer to the SkyView HDX System Installation Manual document). 4. If any servos are highlighted in RED: a) Verify Autopilot system circuit breaker and switch are ON. b) Inspect and fix wiring to affected servo, or common wiring if multiple servos are offline. 5. If any servos are highlighted in YELLOW, a software upgrade did not complete properly (refer to the SkyView HDX System Installation Manual document at dynoncertified.com/docs). 6. If all above fails, contact Dynon Technical Support. Page | 10-2 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B 10.2 Servo Slip Messages Condition: One or more of the following messages appear and persist on SkyView HDX display unit: 1. PITCH SERVO SLIP 2. ROLL SERVO SLIP The momentary appearance of SERVO SLIP messages is expected due to certain weather conditions during autopilot operation. If a SERVO SLIP message persists, contact Dynon Technical Support for assistance. 10.3 Abnormal Operation Condition: One or more autopilot axes fail to move as expected or operate in an unexpected manner. To test for bridle cable clamp slippage: 1. On ground, engage the autopilot into Level Mode. 2. Have an assistant observe the bridle cable clamps during Step #2. 3. From exterior of the airplane, grasp, and gently attempt to move the affected control surface (i.e., elevator, aileron). 4. If cable clamp slips, remove and install the clamp per guidance in Section 11.8 or 11.9. To test for broken shear screw: 1. On ground, engage the autopilot into Level Mode. 2. From exterior of the airplane, grasp, and gently attempt to move the affected control surface (i.e., elevator, aileron). 3. If autopilot does not resist attempt to move control surface, contact Dynon Technical Support to request a Shear Screw Replacement Kit (P/N 102991-000). SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 11-1 11 Servo Maintenance This section provides maintenance information for the autopilot servos. See the SkyView HDX General Maintenance Manual document at dynoncertified.com/docs for information about troubleshooting the autopilot’s system interface. No special tools or facility are required to service autopilot servos. 11.1 Service Every 12 months (1 calendar year), the autopilot servo components and wiring harnesses should be inspected to ensure continued integrity of the installation (see below). • Inspect for security of servo attachment, which includes visual inspection of brackets and other supporting structures that attach to the airplane. • Inspect for signs of corrosion. • Inspect condition of wiring, shield terminations, routing, and attachment/clamping, along with any airplane penetration points. In the event of system failures, contact Dynon Technical Support. Always have a properly rated mechanic or qualified facility remove a failed component. 11.2 Calibration Procedure The SkyView Autopilot servo settings are available for download as a configuration file that is loaded into the SkyView HDX display unit. This file configures the autopilot servo performance settings to meet the applicable certification regulations. Servo calibration cannot be performed without the following: • An ADAHRS module (SV-ADAHRS-200) installed and configured in the SkyView Network. • All servos installed and configured in the SkyView Network. • V-speeds correctly entered in the SkyView HDX. (See the SkyView HDX System Installation Manual document at dynoncertified.com/docs for instructions.) To make a new servo appear on SkyView HDX, configure the SkyView Network (SYSTEM SETUP > NETWORK SETUP > CONFIGURE). (See the SkyView HDX System Installation Manual document at dynoncertified.com/docs for instructions.) To calibrate the servos, enter the Servo Calibration Wizard (SETUP MENU > HARDWARE CALIBRATION > AP SERVO CALIBRATION > CALIBRATION) and follow the onscreen instructions to calibrate the servo(s). SkyView HDX checks the status of the AP Disengage Button. If SkyView HDX detects that the button is pressed (the input is grounded) upon entering AP SERVO CALIBRATION, the AP Page | 11-2 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Disengage Button is assumed to be stuck (or incorrectly installed), resulting in the following message being displayed, and the Autopilot servo calibration is aborted: "The servo disconnect switch appears to be pressed and may be installed incorrectly. The servo disconnect switch should be a type Momentary, Push Button Normal Open (PBNO). Press cancel below to return to the servo calibration menu." If the servo calibration procedure is not successful, inspect the button and servo wiring. (See the SkyView HDX System Installation Manual document at dynoncertified.com/docs for instructions.) If button type and wiring is correct, call Dynon Technical Support. If the servo calibration procedure is successful, SkyView HDX will automatically instruct you to run the servo test procedure. (See Section 11.3 for instructions.) 11.3 Test Procedure The servo test procedure requires a successful servo calibration. The servo test procedure verifies that each servo is configured properly by moving the control surfaces while the installer verifies the correct movement. You may run this procedure on its own at any time after a successful servo calibration. SkyView HDX will not display AP status on the Top Bar until after this test procedure is successfully completed. To run this procedure on its own (after a successful servo calibration procedure), enter the Servo Test Wizard (SETUP MENU > HARDWARE CALIBRATION > AP SERVO CALIBRATION > TEST) and follow the onscreen instructions to test the servo(s). 11.4 Servo Operation Check Complete the following procedures to confirm the autopilot servos are operating correctly. To check the pitch and roll axes: 1. Make sure master power and autopilot servo power are ON. 2. Center, and lightly hold in place, flight control yoke. 3. Align HDG/TRK bug with current heading. 4. Select ALT and HDG. 5. Engage autopilot. 6. Set vertical speed to +1000. 7. Set altitude to 1000 feet above current. Yoke should move in Nose Up direction. 8. Press and hold ALT button to return altitude bug to current. Yoke should move back to neutral position. 9. Change HDG/TRK bug to right of current heading. Yoke should move in direction of a right roll. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 11-3 10. Change HDG/TRK bug to left of current heading. Yoke should move in direction of a left roll. To check Autopilot Disconnect: 1. Make sure master power and autopilot servo power are ON. 2. Engage autopilot. 3. Complete the following: • Press AP button in Autopilot Control menu, and make sure autopilot disconnects. "AUTOPILOT DISCONECT" aural indication should be heard. • Turn AP Servo Power switch OFF, and make sure autopilot disconnects. "AUTOPILOT DISCONECT" aural indication should be heard. • If installed, press AP button on Autopilot Control Panel, and make sure autopilot disconnects. "AUTOPILOT DISCONECT" aural indication should be heard. • If installed, press panel-mounted Autopilot Disconnect button, and make sure autopilot disconnects. "AUTOPILOT DISCONECT" aural indication should be heard. • If installed, press yoke-mounted Autopilot Disconnect button, and make sure autopilot disconnects. "AUTOPILOT DISCONECT" aural indication should be heard. Page | 11-4 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B 11.5 Servo Capstan Removal and Attachment Dynon's autopilot servos are shipped with capstans installed. Servo installation procedures often require the temporary removal and re-attachment of capstans. Unless otherwise specified, torque all fasteners per specifications in AC 43.13-1B, Table 7-1. Include specified friction drag value when torquing screws. Reference Figure 34 when performing the following procedure. To remove and re-attach the capstan: 1. Remove cotter pin that secures castle nut to servo shaft. 2. Mark position of castle nut in relation to servo shaft, and then remove castle nut from servo shaft. 3. Remove wave washer from servo shaft. 4. Removed nylon washer from servo shaft. 5. Remove capstan from servo shaft. The shear screw does not need to be removed from the servo disc. The capstan has a hole that fits over the shear screw head. If the shear screw is loosened, it must be completely removed and replaced (see Section 11.7 for instructions). 6. Place capstan onto output shaft, aligning hole in capstan with shear screw head located in servo disc. 7. Replace nylon washer on servo shaft. 8. Replace wave washer on servo shaft. 9. Finger-tighten castle nut onto servo shaft, and then use a wrench to tighten until slot in castle nut lines up with hole for cotter pin in servo shaft. DO NOT overtighten the castle nut! Tightening the castle nut beyond 4 in-lbs may prevent the capstan from rotating freely in the event of shear screw failure. 10. Install new cotter pin to secure castle nut to servo shaft. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 11-5 11.6 Cable Guard Adjustment Dynon's Autopilot servos are shipped with cable guards installed. The cable guard may need to be repositioned to avoid interference with the flight control cables or the bridle cables during servo installation procedures. The following procedure details the task of adjusting a cable guard. Unless otherwise specified, torque all fasteners per specifications in AC 43.13-1B, Table 7-1. Include specified friction drag value when torquing screws. Reference Figure 34 when performing the following procedure. To adjust the cable guard: 1. Remove capstan from servo shaft (see Section 11.5 for instructions). 2. Remove screws and star washers that secure capstan guard to servo. 3. Rotate capstan guard to correct position. 4. Secure capstan guard to servo with screws and star washers. 5. Re-attach capstan to servo shaft (see Section 11.5 for instructions). 11.7 Shear Screw Replacement Dynon servos come equipped with a capstan. The capstan connects to the servo via a frangible shear screw. The shear screw can be broken by the pilot to restore system movement should a servo become jammed. It is possible for turbulence loads acting on the airplane to cause a shear screw to fail, even though the servo never jammed. In the event of a shear screw failure, contact Dynon Technical Support to request a Shear Screw Replacement Kit (P/N 102991-000). Shear screw replacement instructions are provided in the Dynon Servo Shear Screw Replacement Instructions document included in the Shear Screw Replacement Kit (P/N 102991-000). Page | 11-6 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B 11.8 Roll Servo Removal and Replacement This section provides instructions for removing and replacing a roll servo and connecting it back to the control system. The roll servo and bracketry are installed in the left wing between WS100 and WS118 (see Figure 1 for exact location). To service the roll servo, installers need to access this area in accordance with the manufacturer's service manual. See Figure 16 for an example of a complete installation. Make sure all flight control cables are rigged and tensioned in accordance with manufacturer’s instructions. Failure to do so may result in poor autopilot performance. Always disconnect aircraft battery before starting removal and installation activities. Unless otherwise specified, torque all fasteners per specifications in AC 43.13-1B, Table 7-1. Include specified friction drag value when torquing screws. To remove the roll servo: 1. Disconnect D9 cable harness connector from servo. 2. Mark locations of bridle cable clamps on aileron control cable. Securing bridle cable to capstan grooves with tape prevents cable from unraveling when handling. 3. Loosen bridle cable clamps. 4. Remove capstan (with bridle cable) from roll servo (see Section 11.5 for instructions). DO NOT remove shear screw from servo disc! 5. Remove safety wiring from roll servo bolts. 6. Remove bolts and washers that secure roll servo to upper and lower roll servo brackets (see Figure 13). Retain hardware for servo installation. 7. Remove roll servo and capstan (with bridle cable) from aircraft. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 11-7 To replace the roll servo: 1. Secure ailerons and/or yoke in neutral position. 2. Secure roll servo to upper and lower roll servo brackets (see Figure 13). 3. Safety wire roll servo bolts (see Figure 14 for example). 4. Attach capstan (with bridle cable) to roll servo, as shown in Figure 11. Position servo capstan so orientation mark on capstan faces away from servo, capstan is in 12 'o' clock position, and servo is fully seated on servo disc. The capstan has a hole that fits over shear screw head. 5. Make sure aileron control cable in area where bridle cable clamps will attach is clean and free of dirt and grease. 6. Use bridle cable clamps to loosely connect bridle cable ends to aileron control cable at marks made during removal process. Make sure clamps contact swage stops at each end of bridle cable, as shown in Figure 15. 7. Make sure bridle cable does not contact cable guard. The bridle cable will prematurely wear if bridle cable and cable guard make contact when control is in a neutral position. 8. If cable guard interferes with bridle cable, adjust cable guard position (see Section 11.6 for instructions), and then repeat Step 7. 9. Tension and temporarily secure bridle cable to 15-20 lbs. Make sure swage engagement hole is located upward and on same side as cables exit. The tension on bridle cable should never exceed manufacturer's specified tension for control cable. 10. When satisfied with tension and capstan position, tighten all bridle cable clamp nuts to 35-40 in-lb. 11. Use a feeler gauge to measure gaps between bridle cable clamp halves (top and bottom). Make sure gaps meet the following criteria: • Gap measurements on both sides of clamp are not less than 0.003" and not more than 0.050". If clamp gap measurements do not meet criteria above, measure diameter of control cable, and then contact Dynon Technical Support for a resolution. Out-of-specification cable clamps can slip under load. 12. Connect D9 cable harness connector to servo. Page | 11-8 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B To check the roll servo installation: 1. Release ailerons and/or yoke. 2. Move aileron control through full range of motion per manufacturer's maintenance instructions, and verify the following: • Control is smooth throughout (i.e., no grinding, rubbing, or roughness). • Bridle cable clamps do not contact any structures during entire travel. • Capstan never rotates more than 150 degrees in either direction from neutral. 3. Cycle the control surface several times, return it to neutral, and verify the following: • Swage engagement hole is in the 12 'o' clock position. • Bridle cable clamps are located as shown in Figure 15. • Bridle cable tension has not changed. After all Autopilot servos have been serviced, perform servo calibration procedure (see Section 11.2 for instructions). SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 11-9 11.9 Pitch Servo Removal and Installation This section provides instructions for removing and installing a pitch servo and connecting it back to the control system. The pitch servo and bracketry are installed in the fuselage between FS172 and FS185 (see Figure 17 for exact location). To service the pitch servo, installers need to access this area in accordance with the manufacturer's service manual. See Figure 33 for an example of a complete installation. Make sure all flight control cables are rigged and tensioned in accordance with manufacturer’s instructions. Failure to do so may result in poor autopilot performance. Always disconnect aircraft battery before starting removal and installation activities. Unless otherwise specified, torque all fasteners per specifications in AC 43.13-1B, Table 7-1. Include specified friction drag value when torquing screws. To remove the pitch servo: 1. Disconnect D9 cable harness connector from servo. 2. Mark locations of cable clamps on elevator control cable. Securing bridle cable to capstan grooves with tape prevents cable from unraveling when handling. 3. Loosen bridle cable clamps. 4. Remove capstan (with bridle cable) from pitch servo (see Section 11.5 for instructions). DO NOT remove shear screw from servo disc! 5. Remove safety wiring from pitch servo bolts. 6. Remove bolts and washers that secure pitch servo to riser bracket (see Figure 19). Retain hardware for servo installation. 7. Remove pitch servo and capstan (with bridle cable) from aircraft. Page | 11-10 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B To replace the roll servo: 1. Secure elevator and/or yoke in neutral position. 2. Secure pitch servo to riser bracket (see Figure 27). 3. Safety wire pitch servo bolts (see Figure 29 for example). 4. Attach capstan (with bridle cable) to pitch servo (see Figure 27). Position servo capstan so orientation mark on capstan faces away from servo, capstan is in 12 'o' clock position, and servo is fully seated on servo disc. The capstan has a hole that fits over shear screw head. 5. Make sure elevator control cable in the area where bridle cable clamps will attach is clean and free of dirt and grease. 6. Use bridle cable clamps to loosely connect bridle cable ends to elevator control cable at marks made during removal process. Make sure clamps contact swage stops at each end of bridle cable, as shown in Figure 15. 7. Make sure bridle cable does not contact cable guard. The bridle cable will prematurely wear if bridle cable and cable guard make contact when control is in a neutral position. 8. If cable guard interferes with bridle cable, adjust cable guard position (see Section 11.6 for instructions), and then repeat Step 7. 9. Tension and temporarily secure bridle cable to 15-20 lbs. Make sure swage engagement hole is located upward and on same side as cables exit. The tension on bridle cable should never exceed manufacturer's specified tension for control cable. 10. When satisfied with tension and capstan position, tighten all bridle cable clamp nuts to 35-40 in-lb. 11. Use a feeler gauge to measure gaps between bridle cable clamp halves (top and bottom). Make sure gaps meet the following criteria: • Gap measurements on both sides of clamp are not less than 0.003" and not more than 0.050". If clamp gap measurements do not meet criteria above, measure diameter of control cable, and then contact Dynon Technical Support for a resolution. Out-of-specification cable clamps can slip under load. 12. Connect D9 cable harness connector to servo. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 11-11 To check the roll servo installation: 1. Release elevator and/or yoke. 2. Move elevator control through full range of motion, and verify the following: • Control is smooth throughout (i.e., no grinding, rubbing, or roughness). • Bridle cable clamps do not contact any structures during entire travel. • Capstan never rotates more than 150 degrees in either direction from neutral. 3. Cycle the control several times, return it to neutral, and verify the following: • Swage engagement hole is in the 6 'o' clock position. • Bridle cable clamps are located as shown in Figure 25. • Bridle cable tension has not changed. After all Autopilot servos have been serviced, perform servo calibration procedure (see Section 11.2 for instructions). Page | 11-12 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B This page intentionally left blank. SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 12-1 12 Figures 12.1 Roll Servo Figures Figure 1: Roll Servo Location Page | 12-2 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Figure 2: Roll Servo Bracketry SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 12-3 Figure 3: Attaching Lower Roll Servo Bracket to Servo Template Page | 12-4 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Figure 4: Positioning Roll Servo Bracketry SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 12-5 Figure 5: Positioning Upper Roll Servo Bracket and Marking Hole Page | 12-6 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Figure 6: Positioning Upper and Lower Roll Servo Brackets and Drilling Holes SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 12-7 Figure 7: Attaching Nutplates to Upper and Lower Roll Servo Brackets Page | 12-8 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Figure 8: Permanently Fastening Upper Roll Servo Bracket Figure 9: Attaching Lower Roll Servo Bracket to Roll Servo SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 12-9 Figure 10: Roll Servo Bridle Cable Length Figure 11: Attaching Roll Servo Capstan Page | 12-10 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Figure 12: Inserting Roll Servo / Lower Bracket Assembly SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 12-11 Figure 13: Attaching Roll Servo Assembly Page | 12-12 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Figure 14: Example of Safety Wiring Roll Servo Bolts SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 12-13 Figure 15: Attaching Bridle Cable to Aileron Control Cable Page | 12-14 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Figure 16: Roll Servo – Complete Installation SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 12-15 12.2 Pitch Servo Figures Figure 17: Pitch Servo Location Page | 12-16 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Figure 18: Pitch Servo Bracketry SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 12-17 Figure 19: Temporarily Attaching Pitch Servo to Riser Bracket Page | 12-18 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Figure 20: Positioning Pitch Servo Base Bracket SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 12-19 Figure 21: Positioning Pitch Servo Riser Bracket Assembly Page | 12-20 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Figure 22: Drilling Holes for Pitch Servo Base Bracket SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 12-21 Figure 23: Drilling Holes for Pitch Servo Shear Clips Page | 12-22 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Figure 24: Drilling Holes for Pitch Servo Riser Bracket SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 12-23 Figure 25: Attaching Nutplates to Pitch Servo Base Bracket Page | 12-24 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Figure 26: Riveting Pitch Servo Shear Clips to Base Bracket SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 12-25 Figure 27: Attaching Pitch Servo to Riser Bracket Page | 12-26 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Figure 28: Attaching Pitch Servo Cable Guide and Bracket to Riser Bracket SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 12-27 Figure 29: Example of Safety Wiring Pitch Servo Bolts Page | 12-28 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Figure 30: Attaching Pitch Servo Base Bracket to Fuselage SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 12-29 Figure 31: Attaching Pitch Servo Riser Bracket Assembly to Base Bracket Page | 12-30 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Figure 32: Attaching Bridle Cable to Elevator Control Cable SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B Page | 12-31 Figure 33: Pitch Servo – Complete Installation Page | 12-32 SkyView HDX Autopilot Servo Installation & Maintenance Manual - Cessna Series 182, Rev B 12.3 Servo Capstan Removal/Installation Figure Figure 34: Exploded View of a Typical Servo Capstan Assembly