AUTOPILOT SERVO INSTALLATION MANUAL
Mooney M20B Mark 21 · Maintenance Manual
Overview
This manual provides detailed instructions for the installation of SkyView Autopilot servos and associated bracketry specifically for the Mooney M20J and M20K aircraft models. It is designed for FAA-certified Airframe and Powerplant Technicians, assuming they possess the necessary knowledge and training to perform the outlined procedures. The manual emphasizes the importance of following FAA guidelines and ensuring compliance with existing aircraft configurations. It includes installation steps, required tools, and safety precautions to ensure a successful and airworthy installation of the autopilot system.
- The manual is for Mooney M20J and M20K aircraft only.
- Installation requires FAA-certified technicians with relevant experience.
- Disconnect the aircraft battery before installation activities.
- Torque all fasteners according to AC 43.13-1B specifications.
- Calibrate autopilot servos after installation using the SkyView System.
Document
Source
Originally published by www.dynoncertified.com. Sprinkle hosts a reference copy with an added summary, specifications and searchable full text.
Document details
- Type
- Maintenance Manual
- Year
- 2024
- Pages
- 10
- File size
- 3.6 MB
- Publisher
- www.dynoncertified.com
Common. Rarer than 3% of the aircraft models we track.
Most owners only have the POH. Here's the essential set for the Mooney M20B Mark 21.
- Pilot's Operating Handbook / AFM
- Checklist
- Maintenance Manual
- Parts Catalog (IPC)
- Systems & Wiring
- Service Bulletins
- Type Certificate (TCDS)
Free — save the M20 to your watchlist and track it in one place.
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In this document
Introduction
The manual outlines the installation procedures for SkyView Autopilot servos in Mooney M20J and M20K aircraft. It emphasizes the need for compliance with FAA regulations and provides references to additional documentation for wiring and calibration.
Installation Compliance
Technicians must ensure that any modifications to the aircraft do not hinder compliance with STC SA02594SE. A completed FAA Form 337 must be submitted before returning the aircraft to service.
Installation Steps
The manual details step-by-step instructions for installing pitch, yaw, and roll servos, including securing control surfaces, drilling pilot holes, and attaching brackets. Specific torque values and safety wiring procedures are provided.
Safety Precautions
Before starting installation, technicians should disconnect the aircraft battery, lubricate flight control bellcranks, and ensure that all components are compatible with the aircraft's existing systems.
Calibration and Testing
After installation, technicians must calibrate the servos within the SkyView System and verify that all controls operate smoothly without interference from the installed components.
Safety notes
- Ensure all flight control bellcranks are lubricated as per manufacturer instructions.
- Disconnect the aircraft battery before starting installation activities.
- Verify compatibility of rudder pushrods before installation.
Full document text
Introduction This manual provides instructions for installing SkyView Autopilot servos and bracketry in the following Mooney aircraft: M20J (S/N 24-0001 through 24-3431) • M20K (S/N 25-0001 through 25-2035) • Information about wiring autopilot servos to the SkyView Network is provided in the SkyView System Installation Manual; procedures to calibrate autopilot servos and Instructions for Continued Airworthiness (ICA) are provided in the SkyView General Maintenance Manual document at dynoncertified.com/docs. This document is released, archived, and controlled according to the Dynon’s document control process. To revise this document, a letter is submitted to the FAA with the revision. The FAA then accepts and approves any revision to the Airworthiness Limitations section. 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. Dynon does not provide a printed version of this document. However, Dynon grants permission to third parties to print this document, as necessary. It is important to use the most recent version when installing SkyView autopilot components. The most recent PDF version is available for download at dynoncertified.com/docs. This manual 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. 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. PITCH AND YAW SERVOS LOCATED BETWEEN FS130.00 AND FS164.50 ROLL SERVO LOCATED BETWEEN WS147.75 AND WS163.00 B104368-000 Dynon Technical Support: 425-399-7742, 8-5 PT, M-F support@dynoncertified.com REV DATE: AUTOPILOT SERVO INSTALLATION MANUAL DOC. NO. ©2024 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. 11/21/2024 SHEET 1 OF 10 Mooney M20J and M20K 19825 141st PL NE Woodinville, WA 98072 425-402-0433 www.dynon.com Note Regarding Rudder Pushrod Ends Some M20Js have rudder pushrods with tapered ends. Dynon's pushrod clamps are only compatible with pushrods with flat ends; therefore, M20Js with tapered-ended rudder pushrods are ineligible for autopilot installation. It is important to visually inspect the rudder pushrods in M20Js to determine compatibility prior to purchase. Important Installation Information Always install avionics equipment in accordance with the instructions in this manual and the guidance and approved engineering methods outlined the following FAA documents: AC 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 instructions in this manual assume the aircraft areas affected by the autopilot servo installation are unmodified from the factory-delivered configuration. The technician 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. The technician performing the installation should record where the autpilot components are installed in the airplane. This information should then be entered into airplane’s permanent record. Dynon provides a document template to record this information. Download the SkyView Equipment Installation Record document at dynoncertified.com/docs. Ensure the following before and during installation activities: Make sure all flight control bellcranks are lubricated in accordance with • manufacturer’s instructions. Remove any previously installed autopilot equipment, including rivets • and other hardware, that may interfere with the new servo installation. Remove any non-essential insulation or interior materials that may • interfere with the servo installation. 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. The following non-typical tools are needed to complete the installation: Drill fixture for MS21047L08 nutplates, • Calibrated tensiometer. • Document Revision History Airworthiness Limitations For any Airworthiness Limitations associated with installing SkyView autopilot servos, see the SkyView General Maintenance Manual document at dynoncertified.com/docs. It is the principal ICA document for the SkyView system. Basic Control and Operation Operating instructions and control descriptions are found in the SkyView Airplane Flight Manual Supplement document at dynoncertified.com/docs. Operating limitations for the SkyView Autopilot are also found in the SkyView Airplane Flight Manual Supplement document. Product Delivery and Registration Upon delivery, visually inspect all SkyView Autopilot components, brackets, fasteners, cable harnesses, and accessories for damage and loss that may have occurred during shipping (see Materials on Sheet
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10). If loss or damage has occurred, contact Dynon Technical Support. Register SkyView Autopilot 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. 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. REV DATE CHANGE DESCRIPTION A 04/04/2024 Initial Release B 11/21/2024 Revised information about autopilot installation eligibility on Sheet 2. B104368-000 DOC. NO. 19825 141st PL NE Woodinville, WA 98072 425-402-0433 www.dynon.com REV DATE: AUTOPILOT SERVO INSTALLATION MANUAL 11/21/2024 Mooney M20J and M20K SHEET 2 OF 10 Dynon Technical Support: 425-399-7742, 8-5 PT, M-F support@dynoncertified.com WS163.00 WS147.75 Access area through inspection hole located just forward and outboard of aileron pushrod. 4 x1 3 x1 5 x1 9.56±.07" 3.25±.07" 1.63±.07" 1.50±.07" WS147.75 Stringer Rivets Mark and drill 3 #30 pilot holes. Leading Edge of Wing INBD 0.75" 15 11 Centerline Centerline 2 3 11 15 3.25±.07" 1.63±.07" 9.56±.07 1.50±.07 WS147.75 Leading Edge of Wing Mark and drill 3 #30 pilot holes. Stringer Rivets INBD NOTE: If holes from a previous autopilot installation are present, and they are in the correct location, it is acceptable to use them. 2 x1 FWD INBD Roll Servo Complete Installation Roll Servo Installation STEP 1: Secure ailerons in center of travel. STEP 2: Measure, mark, and drill pilot holes in upper and lower wing skins. Roll Servo Bracketry STEP 3: Prepare brackets for installation: Assemble brackets. Do not fully tighten hardware at this time. A. TIP: Place additional hardware through lower slots and holes to ensure holes do not get blocked by upper bracket during fitment of bracket assembly in wing. Mark a centerline on the top of upper roll bracket using pre-drilled B. pilot hole as reference. Mark a centerline on the bottom of lower roll bracket 0.75" from C. outside edge. Lower Wing Skin Upper Wing Skin NOTE: If holes from a previous autopilot installation are present, and they are in the correct location, it is acceptable to use them. ITEM # DESCRIPTION 2 ROLL SERVO UPPER BRACKET 3 ROLL SERVO LOWER BRACKET 4 ROLL SERVO BELLCRANK ARM 5 ROLL SERVO PUSHROD 11 FLAT WASHER #10 (AN960-10) 15 HEX BOLT #10-32 (AN3-4A) B104368-000 DOC. NO. 19825 141st PL NE Woodinville, WA 98072 425-402-0433 www.dynon.com REV DATE: AUTOPILOT SERVO INSTALLATION MANUAL 11/21/2024 Mooney M20J and M20K SHEET 3 OF 10 Dynon Technical Support: 425-399-7742, 8-5 PT, M-F support@dynoncertified.com 2 17 x6 16 x3 17 x6 3 10 x3 9 x3 8 Examples of Safety Wiring 14 11 7 6 5 7 6 8.25" 1.27" MAX Servo Arm Nylon Washer Wave Washer Castle Nut 1 Shear ScrewUse pilot holes in wing skins to match drill #30 holes in brackets, and then final drill all holes up to #19. 16 x3 11 x3 14 x3 1 2 3 STEP 5: Attach nutplates to upper and lower brackets: Remove bracket assembly from aircraft. A. Use a #8 nutplate drill fixture to attach nutplates to brackets. B. STEP 4: Position bracket assembly in wing: Insert bracket assembly in wing and slide upper bracket as A. needed so bracket assembly contacts upper and lower wing skins. Tighten upper bracket hardware, and then mark position of B. upper bracket on lower bracket. Temporarily fasten bracket using pre-drilled hole in upper C. bracket and align centerlines on brackets with pilot holes in wing skins. Clamp bottom bracket to wing skin. D. Use pilot holes in wing skins to match drill #30 holes in upper E. and lower brackets. Using temporary fasteners as needed, final drill all holes up to F. #19. STEP 5: Temporarily remove servo arm from roll servo. IMPORTANT: DO NOT remove shear screw from servo disc! STEP 6 : Assemble roll servo pushrod and set to length. STEP 7: Attach roll servo to bracket assembly. STEP 8: Complete servo/bracket assembly: Attach servo arm limiter to roll servo. A. Install fourth servo bolt. B. Use 0.032" wire to safety wire servo bolts. C. ITEM # DESCRIPTION 1 ROLL SERVO 2 ROLL SERVO UPPER BRACKET 3 ROLL SERVO LOWER BRACKET 5 ROLL SERVO PUSHROD 6 JAM NUT #10-32 7 BEARING ROD END #10-32, RH, MALE 8 SERVO ARM LIMITER 9 PHIL PAN HEAD SCREW #6-32, 1/4"L, NYLOCK 10 INT STAR LOCK WASHER #06 (MS535333-37P) 11 FLAT WASHER #10 (AN960-10) 14 HEX BOLT #10-32, 17/32"L, 1/8"G, DRILL HEAD (AN3H-4A) 16 NUTPLATE #8-32 (MS21047L08) 17 RIVET 3/16"L, 3/32"D (MS20426AD3-3) B104368-000 DOC. NO. 19825 141st PL NE Woodinville, WA 98072 425-402-0433 www.dynon.com REV DATE: AUTOPILOT SERVO INSTALLATION MANUAL 11/21/2024 Mooney M20J and M20K SHEET 4 OF 10 Dynon Technical Support: 425-399-7742, 8-5 PT, M-F support@dynoncertified.com 21 x2 11 x2 20 x2 4 22 23 12 19 x6 18 24 Castle Nut Wave Washer Nylon Washer 13 11 Servo Arm 23 22 Pushrod Assembly 12 STEP 11: Attach roll servo bellcrank arm to aircraft bellcrank. STEP 9: Attach roll servo pushrod assembly to servo arm. IMPORTANT: It is critical to an airworthy installation to insert the hex bolt through innermost hole in the servo arm and in the direction shown. STEP 10: Attach servo arm, with servo pushrod assembly, to roll servo. IMPORTANT: Position servo arm so it is fully seated on servo disc. The servo arm has a hole that fits over the shear screw head. IMPORTANT: Tighten servo castle nut to 1-4 in-lbs. DO NOT over tighten! Over tightening may prevent capstan from rotating freely in event of shear screw failure. Check Roll Servo Installation Release ailerons. 1. Move aileron control through full range of motion per 2. manufacturer's maintenance instructions, and verify the following: Aileron control is smooth throughout (i.e., no grinding, • rubbing, or roughness). Roll servo pushrod and bellcrank do not contact any other • controls, structures, wiring, insulation, or interior materials during entire travel. At extents of travel in both directions, servo arm never rotates • more than 60 degrees in either direction from neutral. Aileron control travel is limited by manufacturer's control stop • not the servo arm limiter. Cycle the control several times, return it to neutral, and verify 3. the servo arm points downward in roughly the 6 o'clock position. STEP 12: Attach pushrod assembly to bellcrank arm and secure entire roll servo assembly to wing skins. INBD ITEM # DESCRIPTION 4 ROLL SERVO BELLCRANK ARM 11 FLAT WASHER #10 (AN960-10) 12 FLAT WASHER 3/16", LARGE AREA (AN970-3) 13 HEX BOLT #10-32, 29/32"L, 1/2"G, DRILL SHANK (AN3-7) 18 HEX BOLT #10-32, 1-9/32"L, 7/8"G, DRILL SHANK (AN3-11) 19 PHIL WASH HEAD SCREW #8-32, 7/16"L (AN525-832R7) 20 HEX BOLT #10-32, 1-1/32"L, 5/8"G (AN3-10A) 21 LOCK NUT #10-32 (AN365-1032A) 22 CASTLE NUT #10-32 (AN310-3) 23 COTTER PIN 1/16" X 1/2" (MS24665-151) 24 COTTER PIN 5/64" X 3/4" (MS24665-210) B104368-000 DOC. NO. 19825 141st PL NE Woodinville, WA 98072 425-402-0433 www.dynon.com REV DATE: AUTOPILOT SERVO INSTALLATION MANUAL 11/21/2024 Mooney M20J and M20K SHEET 5 OF 10 Dynon Technical Support: 425-399-7742, 8-5 PT, M-F support@dynoncertified.com 2 x1 3 x1 4 x1 7 x1 6 x4 10 x1 8 x2 9 x1 2 3 4 11.00±.25" FS164.50 FS130.00 Measure 11" from FS130.00 to edge of tab. Pitch and Yaw Servo Complete Installation FS130.00 FS164.50 5 x1 Pitch and Yaw Servo Installation Pitch and Yaw Servo Bracketry FWD STEP 2: Temporarily fasten left and right longeron brackets to pitch/yaw servo tray. STEP 3: Position pitch/yaw servo tray assembly as shown below. IMPORTANT: When positioning pitch/yaw servo tray assembly, ensure pilot holes in longeron bracket tabs are centered on longeron webs and tabs do not contact bend radii of longerons. STEP 1: Secure elevator and rudder in center of travel. ITEM # DESCRIPTION 2 PITCH/YAW SERVO BRACKET TRAY 3 PITCH/YAW SERVO LONGERON BRACKET, RH 4 PITCH/YAW SERVO LONGERON BRACKET, LH 5 PITCH SERVO PUSHROD CLAMP, THIN 6 PITCH/YAW SERVO PUSHROD CLAMP 7 PITCH/YAW SERVO PUSHROD CLAMP, TAB 8 PITCH/YAW SERVO BRIDLE CABLE EXTENDER 9 YAW SERVO CLEARANCE BRACKET 10 YAW SERVO BELLCRANK SPACER B104368-000 DOC. NO. 19825 141st PL NE Woodinville, WA 98072 425-402-0433 www.dynon.com REV DATE: AUTOPILOT SERVO INSTALLATION MANUAL 11/21/2024 Mooney M20J and M20K SHEET 6 OF 10 Dynon Technical Support: 425-399-7742, 8-5 PT, M-F support@dynoncertified.com 1 30 2 18 x4 19 x4 18 x4 19 x4 Safety Wires FS164.50 FS130.00 Use pilot holes in longeron bracket tabs to match drill #30 holes through longeron, and then final drill all holes up to #12. 2 PLACES 26 16 18 26 16 18 Swage Hole Swage Orientation Mark 11 Pitch Servo Capstan Wrap pitch servo bridle cable 1/2-time around capstan in each direction. Long End Short End Swage Hole 31 Swage Orientation Mark Yaw Servo Capstan Wrap yaw servo bridle cable 1-time around capstan in each direction. Short End Long End Pan Head Screw x4 Cable Guard Int Tooth Lock Washer x4 Nylon Washer Wave Washer Castle Nut Capstan Pitch Servo Shown Shear Screw STEP 4: Attach left and right longeron brackets to longerons. On both sides of fuselage, clamp pitch/yaw servo tray A. assembly to longerons at marks made in Step 3. IMPORTANT: When positioning pitch/yaw servo tray assembly, ensure pilot holes in longeron bracket tabs are centered on longeron webs and tabs do not contact bend radii of longerons. Use pilot holes in longeron bracket tabs to match drill #30 B. holes through longerons. Final drill all holes up to #12. C. Secure longeron brackets to longerons. D. STEP 7: Re-attach cable guards to pitch and yaw servos. NOTE: Cable guard and attachment hardware are included in servo sales assemblies. FWD STEP 8: Use 0.032" wire to safety wire pitch and yaw servo bolts. STEP 9: Wrap bridle cables around pitch and yaw servo capstans. IMPORTANT: Ensure ends of bridle cables exit capstans as detailed below. . NOTE: Securing (e.g., taping) bridle cables to capstan grooves prevents them from unraveling when handling.. STEP 5: Temporarily remove capstans and cable guards from pitch and yaw servos. Keep hardware for re-installation. IMPORTANT: DO NOT remove shear screws from servo discs! STEP 6: Attach pitch and yaw servos to pitch/yaw servo tray bracket. ITEM # DESCRIPTION 1 PITCH SERVO 2 PITCH/YAW SERVO BRACKET TRAY 11 BRIDLE CABLE 16 LOCK NUT #10-32 (AN365-1032A) 18 FLAT WASHER #10 (AN960-10) 19 HEX BOLT #10-32, 17/32", 1/8"G, DRILL HEAD (AN3H-4A) 26 HEX BOLT #10-32, 21/32"L, 1/4"G (AN3-5A) 30 YAW SERVO 31 BRIDLE CABLE B104368-000 DOC. NO. 19825 141st PL NE Woodinville, WA 98072 425-402-0433 www.dynon.com REV DATE: AUTOPILOT SERVO INSTALLATION MANUAL 11/21/2024 Mooney M20J and M20K SHEET 7 OF 10 Dynon Technical Support: 425-399-7742, 8-5 PT, M-F support@dynoncertified.com 18 x3 11 25 FS130.00 FS164.50 31 18 x3 25 1528 6 x2 21 18 6 x2 21 18 15 28 Elevator Pushrod Rudder Pushrod 28 x2 15 18 x2 27 10 17 23 24 20 15 x2 18 Elevator Pushrod Rudder Pushrod 28 9 5 7 1 31 Nylon Washer Wave Washer Castle Nut Yaw Servo Capstan 30 Pitch Servo Capstan 11 29 29 Castle Nut Wave Washer Nylon Washer Swage faces away from elevator pushrod. Swage faces toward rudder pushrod. STEP 10: Re-attach pitch and yaw servo capstans with bridle cables. IMPORTANT: Position servo capstans so orientation marks face away from servo and are fully seated on servo discs. The capstans have holes that fit over the shear screw heads. IMPORTANT: Position pitch servo capstan so swage hole will face away from elevator pushrod; position yaw servo capstan so swage hole will face toward rudder pushrod. IMPORTANT: Tighten servo castle nuts to 1-4 in-lbs. DO NOT over tighten! Over tightening may prevent capstan from rotating freely in event of shear screw failure. NOTE: Servo attachment hardware is included in servo sales assemblies. STEP 11: Attach forward pushrod clamps to elevator and rudder pushrods. IMPORTANT: Ensure pushrods are inserted into clamps as far as possible. STEP 12: Attach aft pushrod clamps to elevator pushrod; attach yaw clearance bracket to rudder bellcrank. IMPORTANT: Ensure pushrod is inserted into clamps as far as possible. IMPORTANT: For M20Ks, attach elevator down spring to elevator pushrod clamp's tab. STEP 13: Attach pitch/yaw servo tray, with servos and bridle cables, to left and right longeron brackets. ITEM # DESCRIPTION 1 PITCH SERVO 5 PITCH SERVO PUSHROD CLAMP, THIN 6 PITCH/YAW SERVO PUSHROD CLAMP 7 PITCH/YAW SERVO PUSHROD CLAMP, TAB 9 YAW SERVO CLEARANCE BRACKET 10 YAW SERVO BELLCRANK SPACER 11 BRIDLE CABLE 15 CASTLE NUT #10-32 (AN310-3) 17 FLAT WASHER 3/16", LARGE AREA (AN970-3) 18 FLAT WASHER #10 (AN960-10) 20 HEX BOLT #10-32, 21/32"L, 1/4"G, DRILL SHANK (AN3-5) 21 HEX BOLT #10-32, 1-1/32"L, 5/8"G, DRILL SHANK (AN3-10) 23 HEX BOLT #10-32, 1-17/32"L, 1-1/8"G, DRILL SHANK (AN3-14) 24 HEX BOLT #10-32, 1-25/32"L, 1-3/8"G, DRILL SHANK (AN3-16) 25 HEX BOLT #10-32, 17/32"L, 1/8"G (AN3-4A) 27 COPPER BUSHING 3/16"ID 28 COTTER PIN 1/16" X 1/2" (MS24665-151) 29 COTTER PIN 5/65" X 3/4" (MS24665-210) 30 YAW SERVO 31 BRIDLE CABLE B104368-000 DOC. NO. 19825 141st PL NE Woodinville, WA 98072 425-402-0433 www.dynon.com REV DATE: AUTOPILOT SERVO INSTALLATION MANUAL 11/21/2024 Mooney M20J and M20K SHEET 8 OF 10 Dynon Technical Support: 425-399-7742, 8-5 PT, M-F support@dynoncertified.com 0.15" Existing #10 Hole 8 Drilled #10 Hole CL Trim to length and drill hole on centerline. Round bracket edges, leaving adequate edge margin. 18 x2 15 x2 28 28 31 32 18 15 33 18 20 IMPORTANT: Tighten castle nuts that connect bridle cable assembly so 2 threads of bolts are exposed, and then insert cotter pins. Ensure there is no slack in hardware stacks and assembly has free rotational movement. Rudder Pushrod Rudder Pushrod 22 20 18 x2 13 12 11 29 x2 15 x2 18 x2 18 x2 22 18 15 28 18 22 20 Elevator Pushrod Elevator Pushrod 0.15" Existing #10 Hole 8 Drilled #10 Hole CL Trim to length and drill hole on centerline. Round bracket edges, leaving adequate edge margin. Check Pitch/Yaw Servo Installation Release elevator and rudder and/or yoke and pedals. 1. Move elevator and rudder controls through full range of motion per 2. manufacturer's maintenance instructions, and verify the following: Elevator and rudder controls are smooth throughout (i.e., no • grinding, rubbing, or roughness). Pitch and yaw servo bridle cables and connecting ends do not • contact any other controls, structures, wiring, insulation, or interior materials during entire travel. At extents of travel in both directions, there's a minimum of 30 • degrees of bridle cable engagement with capstan from swage engagement hole to where bridle cable departs from capstan. Elevator and rudder control travel is limited by manufacturer's • control stops. Cycle elevator and rudder controls several times, return them to 3. neutral, and verify the following: Pitch servo swage engagement hole faces away from elevator • pushrod. Yaw servo swage engagement hole faces toward rudder • pushrod. Pitch and yaw servo bridle cable tensions have not changed. • STEP 14: Connect pitch servo bridle cable assembly to elevator pushrod: Assemble bridle cable, turnbuckle, and turnbuckle pin eye. A. At aft end of pushrod, attach bridle cable assembly to B. pushrod clamp. At forward end of pushrod, attach extender bracket to C. pushrod clamp. While pulling bridle cable taught, mark hole location on D. extender bracket. Drill #10 hole through extender bracket, and then trim E. bracket as needed. Attach bridle cable assembly to extender bracket. F. Make sure bridle cable does not contact cable guard. G. IMPORTANT: The bridle cable will prematurely wear if it contacts the cable guard throughout its travel. If cable guard interferes with bridle cable, adjust cable guard H. position as needed. NOTE: See the SkyView General Maintenance Manual document for cable guard adjustment instructions. Use turnbuckle to tension bridle cable to 15-20 lbs. While I. tensioning, make sure capstan's swage engagement hole continues to face away from elevator pushrod. IMPORTANT: Ensure no more than 3 threads on bridle cable end and pin eye end extend from turnbuckle. Safety wire turnbuckle with provided clips. J. STEP 15: Connect yaw servo bridle cable assembly to rudder pushrod: Assemble bridle cable, turnbuckle, and turnbuckle fork end. A. At aft end of pushrod, attach bridle cable assembly to B. clearance bracket. At forward end of pushrod, attach extender bracket to C. pushrod clamp. While pulling bridle cable taught, mark hole location on D. extender bracket. Drill #10 hole through extender bracket, and then trim E. bracket as needed. Attach bridle cable assembly to extender bracket. F. Make sure bridle cable does not contact cable guard. G. IMPORTANT: The bridle cable will prematurely wear if it contacts the cable guard throughout its travel. If cable guard interferes with bridle cable, adjust cable H. guard position as needed. NOTE: See the SkyView General Maintenance Manual document for cable guard adjustment instructions. Use turnbuckle to tension bridle cable to 15-20 lbs. While I. tensioning, make sure capstan's swage engagement hole continues to face toward rudder pushrod. IMPORTANT: Ensure no more than 3 threads on bridle cable end and fork end extend from turnbuckle. Safety wire turnbuckle with provided clips. J. IMPORTANT: Tighten castle nuts that connect bridle cable assembly so 2 threads of bolts are exposed, and then insert cotter pins. Ensure there is no slack in hardware stacks and assembly has free rotational movement. ITEM # DESCRIPTION 8 PITCH/YAW SERVO BRIDLE CABLE EXTENDER 11 BRIDLE CABLE 12 TURNBUCKLE BARREL #6-40 13 TURNBUCKLE PIN EYE #6-40, RH 15 CASTLE NUT #10-32 (AN310-3) 18 FLAT WASHER #10 (AN960-10) 20 HEX BOLT #10-32, 21/32"L, 1/4"G, DRILL SHANK (AN3-5) 21 HEX BOLT #10-32, 1-1/32"L, 5/8"G, DRILL SHANK (AN3-10) 22 HEX BOLT #10-32, 1-5/32"L, 3/4"G, DRILL SHANK (AN3-11) 28 COTTER PIN 1/16" X 1/2" (MS24665-151) 31 BRIDLE CABLE 32 TURNBUCKLE BARREL #6-40 33 TURNBUCKLE FORK END ##6-40, RH B104368-000 DOC. NO. 19825 141st PL NE Woodinville, WA 98072 425-402-0433 www.dynon.com REV DATE: AUTOPILOT SERVO INSTALLATION MANUAL 11/21/2024 Mooney M20J and M20K SHEET 9 OF 10 Dynon Technical Support: 425-399-7742, 8-5 PT, M-F support@dynoncertified.com Materials Electrical Connection After physically installing all autopilot servos, connect them to the SkyView Network. See the Autopilot Servos section of the SkyView System Installation Manual document at dynoncertified.com/docs. Servo Calibration After physically installing and electrically connecting all autopilot servos, calibrated them in the SkyView System. See the Autopilot Servo Calibration section of the SkyView General Maintenance Manual document at dynoncertified.com/docs. Electric Trim Control Existing pitch trim motors certified for the airplane can be controlled through the SkyView Autopilot system. 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 for trim control, and testing the feature are found in the SkyView System Installation Manual document at dynoncertified.com/docs. Servo Troubleshooting, Service, and Maintenance Instructions for Continued Airworthiness (ICA) for autopilot servos, including troubleshooting, service, and maintenance procedures, are provided in the SkyView General Maintenance Manual document at dynoncertified.com/docs. ITEM # DYNON PART # DESCRIPTION QTY PITCH SERVO KIT (Includes the Following) 1 1 503406-000 SV42C PITCH SERVO ASSY: MOONEY M20 1 504437-000 PITCH/YAW SERVO BRACKET KIT 1 2 504309-002 PITCH/YAW SERVO BRACKET TRAY 1 3 504307-002 PITCH/YAW SERVO LONGERON BRACKET, RH 1 4 504307-003 PITCH/YAW SERVO LONGERON BRACKET, LH 1 5 104844-003 PITCH SERVO PUSHROD CLAMP, THIN 1 6 104844-000 PITCH/YAW SERVO PUSHROD CLAMP 4 7 104844-001 PITCH SERVO PUSHROD CLAMP, TAB 1 8 504552-000 PITCH/YAW SERVO BRIDLE CABLE EXTENDER 2 9 504553-000 YAW SERVO CLEARANCE BRACKET 1 10 504499-000 YAW SERVO BELLCRANK SPACER 1 504573-000 BRIDLE CABLE KIT 1 11 504508-000 BRIDLE CABLE 1 12 104563-000 TURNBUCKLE BARREL #6-40 1 13 104564-000 TURNBUCKLE PIN EYE #6-40, RH 1 104656-000 TURNBUCKLE FORK END #6-40, RH (NOT USED) 1 14 104556-000 TURNBUCKLE SAFETY CLIP 2 104776-000 PITCH/YAW SERVO HARDWARE KIT 1 15 100899-001 CASTLE NUT #10-32 11 16 100976-011 LOCK NUT #10-32 4 17 100977-000 FLAT WASHER 3/16", LARGE 1 18 100978-003 FLAT WASHER #10 35 19 100981-001 HEX BOLT #10-32, 17/32"L, 1/8"G, DRILL HEAD 8 20 101844-002 HEX BOLT #10-32, 21/32"L, 1/4"G, DRILL SHANK 4 21 101844-005 HEX BOLT #10-32, 1-1/32"L, 5/8"G, DRILL SHANK 2 22 101844-006 HEX BOLT #10-32, 1-5/32"L, 3/4"G, DRILL SHANK 3 23 101844-009 HEX BOLT #10-32, 1-17/32"L, 1-1/8"G, DRILL SHANK 1 24 101844-011 HEX BOLT #10-32, 1-25/32"L, 1-3/8"G, DRILL SHANK 1 25 103666-001 HEX BOLT #10-32, 17/32"L, 1/8"G 6 26 103666-002 HEX BOLT #10-32, 21/32"L, 1/4"G 4 27 104747-000 COPPER BUSHING 3/16"ID 1 28 100904-002 COTTER PIN 1/16" X 1/2" 11 29 100904-001 COTTER PIN 5/64" X 3/4" 2 504573-000 YAW SERVO KIT (Includes the Following) 1 30 503933-000 SV42C YAW SERVO ASSY: MOONEY M20 1 504573-000 BRIDLE CABLE KIT 1 31 504508-000 BRIDLE CABLE 1 32 104563-000 TURNBUCKLE BARREL #6-40 1 104564-000 TURNBUCKLE PIN EYE #6-40, RH (NOT USED) 1 33 104565-000 TURNBUCKLE FORK END #6-40, RH 1 34 104556-000 TURNBUCKLE SAFETY CLIP 2 ITEM # DYNON PART # DESCRIPTION QTY ROLL SERVO KIT (Includes the Following) 1 1 504897-000 SV42 ROLL SERVO ASSY: MOONEY M20 1 504438-000 ROLL SERVO BRACKET KIT 1 2 504311-001 ROLL SERVO UPPER BRACKET 1 3 504310-001 ROLL SERVO LOWER BRACKET 1 4 104325-000 ROLL SERVO BELLCRANK ARM 1 104904-000 ROLL SERVO PUSHROD KIT 1 5 104317-000 ROLL SERVO PUSHROD, 0.5" OD 1 6 100975-000 JAM NUT #10-32 2 7 104568-000 BEARING ROD END #10-32RH, MALE 2 504903-000 ROLL SERVO LIMITING BRACKET KIT 1 8 104875-000 SERVO ARM LIMITING BRACKET 1 9 100494-000 PHIL PAN HEAD SCREW #6-32, 1/4"L, NYLOCK 3 10 100979-000 INT STAR LOCK WASHER #06 3 104777-000 ROLL SERVO HARDWARE KIT 1 11 100978-003 FLAT WASHER #10 9 12 100977-000 FLAT WASHER 3/16", LARGE 2 13 101844-004 HEX BOLT #10-32, 29/32"L, 1/2"G, DRILL SHANK 1 14 100981-001 HEX BOLT #10-32, 17/32"L, 1/8"G, DRILL HEAD 4 15 103666-001 HEX BOLT #10-32, 17/32"L, 1/8G 2 16 103990-008 NUTPLATE #8-32, SELF-LOCK, LOW-PRO 6 17 103665-001 RIVET, MS20426AD3-3.5 12 18 101844-007 HEX BOLT #10-32, 1-9/32"L, 7/8"G, DRILL SHANK 1 19 101880-004 PHIL WASH HEAD #8-32", 7/16"L 6 20 103666-005 HEX BOLT #10-32, 1-1/32"L, 5/8"G 2 21 100976-001 LOCK NUT #10 2 22 100899-001 CASTLE NUT #10-32 2 23 100904-002 COTTER PIN 1/16" X 1/2" 2 24 100904-001 COTTER PIN 5/64" X 3/4" 1 B104368-000 DOC. NO. 19825 141st PL NE Woodinville, WA 98072 425-402-0433 www.dynon.com REV DATE: AUTOPILOT SERVO INSTALLATION MANUAL 11/21/2024 Mooney M20J and M20K SHEET 10 OF 10 Dynon Technical Support: 425-399-7742, 8-5 PT, M-F support@dynoncertified.com