G450 Maintenance Training Manual

GULFSTREAM G450
MAINTENANCE TRAINING MANUAL

INTRODUCTION
SECOND EDITION
REVISION 0.0
FlightSafety International, Inc.
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www.FlightSafety.com
FOR TRAINING PURPOSES ONLY
NOTICE
The material contained in this training manual is based on information obtained from the aircraft manufacturer’s
Pilot Manuals and Maintenance Manuals. It is to be used for familiarization and training purposes only.
At the time of printing it contained then-current information. In the event of conflict between data provided
herein and that in publications issued by the manufacturer or the FAA, that of the manufacturer or the FAA shall
take precedence.
We at FlightSafety want you to have the best training possible. We welcome any suggestions you might have for
improving this manual or any other aspect of our training program.
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Copyright © 2013 by FlightSafety International, Inc.

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NOTE:
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GULFSTREAM G350/G450 MAINTENANCE TRAINING MANUAL
INTRODUCTION
CONTENTS
Page
INTRODUCTION........................................................................... 1-1
GENERAL....................................................................................... 1-2
AIRCRAFT GENERAL. ............................................................... 1-3
Systems. ................................................................................... 1-3
Revision 0.0 FOR TRAINING PURPOSES ONLY 1-i

NOTICE: These commodities, technology, or software were exported from the United States in accordance with the Export Administration Regulations. Diversion contrary to U.S. law is prohibited.
ILLUSTRATIONS
Figure Title Page
1-1 Interior Layouts............................................................... 1-4
1-2 Doors................................................................................ 1-6
1-3 Windows and Emergency Exits.................................... 1-8
1-4 Rolls Royce Tay 611-8C Engine............................... 1-10
1-5 Honeywell 36-150 APU. ............................................ 1-12
1-6 Hydraulics Synoptic.................................................... 1-14
1-7 Flight Control / Landing Gear / Brake Synoptic..... 1-16
1-8 Environmental Control Synoptic............................... 1-18
1-9 Fuel System Synoptic. ................................................ 1-20
1-10 Electric Power Synoptics............................................ 1-22
1-11 PlaneView™ Cockpit.................................................. 1-24
1-12 Right Electronic Equipment Racks. .......................... 1-26
Revision 0.0 FOR TRAINING PURPOSES ONLY 1-iii

INTRODUCTION
INTRODUCTION
This training manual provides a description of the major airframe and engine
systems installed in the Gulfstream G350 / G450. This information is intended
as an instructional aid only; it does not supersede, nor is it meant to substitute
for, any of the manufacturer’s maintenance or operating manuals. This mate-
rial has been prepared from the basic design data, and all subsequent changes
in airplane appearance or system operation will be covered during academic
training and by subsequent revisions to this manual.
Revision 0.0 FOR TRAINING PURPOSES ONLY 1-1

GENERAL Given the Gulfstream G350 / G450 Aircraft Maintenance Manual

(AMM), class notes, and this training manual (as specified by the
In addition to the basic Maintenance Training Manual, FlightSafety FlightSafety instructor), the client will be able to pass a written exami-
provides a supplemental Maintenance Schematic Manual (MSM) to be nation upon completion of this course to the grading level prescribed by
used concurrently. The MSM, commonly called the “flat manual,” is the FlightSafety Director of Maintenance Training. The maintenance
printed in an 11 x 17-inch format and contains schematics to be used technician will be able to:
only as a tool in understanding a system. They are not kept current. • Outline the ATA 100 system of maintenance documentation,
The corresponding schematic(s) in the manufacturer’s Maintenance including the major chapter headings and symbology.
Manual must be used when performing maintenance.
• Describe the meaning and application of each piece of manufac-
The second chapter of this manual, “ATA 100 / Publications,” is an turer’s maintenance documentation and use the documentation
introduction to the Air Transport Association format for aircraft main- in practical applications.
tenance manuals. It is intended to describe simply the basic format for • Perform routine servicing.
all ATA 100 maintenance manual chapters and also to explain where
variations may exist from one manufacturer to another. In addition, it • Outline the recommended maintenance schedule applicable
includes information on various Gulfstream Aerospace publications options and locate routine procedures in the manufacturer’s
useful to the maintenance technician. Maintenance Manual.
• Locate major components without reference to documentation
Following “ATA 100 / Publications,” each chapter of this book and other components with the aid of documentation.
has listed on the divider tab the ATA chapter included, such as “24
Electrical Power.” In some cases it was appropriate, for training • Describe the operation of all major systems in the normal and
purposes, to include more than one ATA chapter in one chapter of this various abnormal operating modes.
book, such as Chapter 51–57, “Structures,” which includes informa- • Perform selected normal and emergency cockpit procedures
tion from ATA Chapters 51 through 57. as required for engine start / run-up, APU start, battery check,
airplane taxiing, etc. (requires use of a simulator).
The goal of this course is to provide the very best training possible
for the clients in our maintenance initial program. So that there is no The FlightSafety instructor will modify the stated overall objective
uncertainty about what is expected of the client, the following basic conditions and criteria to satisfy selected performance requirements,
objectives are presented for this course. when appropriate. The performance levels specified will not vary from
those directed by the FlightSafety Director of Maintenance Training.

AIRCRAFT GENERAL The basic operating weight of the Gulfstream G350 / G450 is 43,000
lbs and includes the manufacturer’s bare empty weight, engine oil,
and the typical operating items listed below:
Systems • Flight crew, three at 170 lbs each: 510 lbs
Design Characteristics • Flight attendant, one at 170 lbs: 170 lbs
The mission for which the Gulfstream G350 / G450 aircrafts are • Crew baggage, four at 30 lbs: 120 lbs
designed is to provide executive travelers with the longest-range non-
• Unusable / Un-drainable fuel: 105 lbs
stop capability available.
• Supplies: 406 lbs
Aircraft Weights Maximum payload for the Gulfstream G350 / G450 with maximum
The G350 / G450 aircraft weights are: fuel on board is 2,500 lbs, including passengers (8) and baggage.
The maximum useable fuel weight for the Gulfstream G350 / G450
• Maximum ramp: 74,300 lbs (74,300 AC 4001 – 4239 w/o ASC is 29,500 lbs.
016 )
• Allows 400 lbs of fuel for engine run-up and taxi Aircraft Performance
• Maximum takeoff: 73,900 lbs (73,900 AC 4001 – 4239 w/o The Gulfstream G350 / G450 has been designed to a range specifica-
ASC 016 ) tion of 4,350 nm. This criterion dictated fuselage size, wing, engines,
• Maximum landing: 66,000 lbs fuel capacity, and weight. The normal cruising speed of the Gulfstream
G350 / G450 is 459 Knots True Airspeed (KTAS) / 0.80 Mach, which
• Maximum zero fuel: 49,000 lbs is also the long-range cruise airspeed. High speed cruise is 488 KTAS
Aircraft 4240 and sub and aircraft having ASC 016 installed have a / 0.85 Mach (maximum operating Mach 0.885). Maximum cruising
max ramp weight and a MTOW increase of 700 lbs. altitude is 45,000 feet. With the aircraft at 45,000 feet, the cabin alti-
tude would be equivalent to 6,000 feet (1,829 meters).

AFT GALLEY GULFSTREAM 450-SP
• 12 WINDOWS IN LIVING AREA 3 LIVING AREAS

• LENGTH OF LIVING AREA = 29’ 10”
• CABIN VOLUME = 1,525 CU FT
FWD GALLEY GULFSTREAM 450-SP
• 12 WINDOWS IN LIVING AREA 3 LIVING AREAS

• LENGTH OF LIVING AREA = 31’ 10”
• CABIN VOLUME= 1,525 CU FT
Figure 1-1. Interior Layouts

Cabin Standards Interior Dimensions

The interior dimensions are:
Seats
All passenger compartment seats must meet regulatory requirements. • Cabin length: 40 ft 4 in. (12.3 m)
The maximum number of passengers the Gulfstream G350 / G450 can • Cabin height: 6 ft 2 in. (1.9 m)
carry is 19 (13 is typical). All seats are secured to the aircraft struc-
ture, have three point restraints, and may be configured as follows • Cabin width: 7 ft 4 in. (2.2 m)
(Figure 1‑1): • Cabin volume: 1,525 cu ft (43.13 cu m)
• Single forward facing seats are designed to meet a 16-g • Baggage compartment length: 4 ft 7 in. (1.9 m)
requirement.
• Baggage compartment volume: 169 cu ft (4.8 cu m)
• Seats have various levels of foam options (soft to firm) and
various seat coverings from which to choose. • Baggage compartment capacity: 65 lbs/sq ft
• Side facing seats must also meet a 16-g requirement.
• Seat belts are lever or push-button release type. notes
• Double seats are available with the same standards as the single
seats.
• Triple (divan) style seats 37 to 39 inches wide are available and
include stowage underneath.

MAIN ENTRANCE DOOR BAGGAGE COMPARTMENT DOOR

36 X 60 INCHES 40 X 36 INCHES
Figure 1-2. Doors

Doors NOTES
The main entrance door is a 36 x 60 inch passenger entrance door.
The baggage compartment door is a 40 x 36 inch plug-type door on

the left side of the airplane (Figure 1‑2).
An unpressurized tail compartment houses the Auxiliary Power Unit

(APU), the air-conditioning units, and other equipment. The entrance
to this compartment is from the ground, through an access (ventral)
door with a self-contained folding ladder.
There are also several service doors located all over the aircraft; these
are discussed in Chapter 51-57, “Structures.”
notes

Figure 1-3. Windows and Emergency Exits

Windows NOTES
There are twelve windows in the passenger cabin (six per side). They
are located 49 inches apart on center and are elliptical in shape (19 x
26 inches), water tight, and electrically heated (Figure 1‑3).
Emergency Exits
Of the twelve windows in the passenger compartment, four are remov-
able; two on the left and two on the right side located over the wing.
The removable windows are capable of being opened from either inside
or outside for emergency egress. The main entrance door is certified
as an emergency exit, and the baggage compartment door may also
be used as an auxiliary emergency exit (Figure 1‑3).
notes

Figure 1-4. Rolls Royce Tay 611-8C Engine

Aircraft Systems NOTES

Engines
The Gulfstream G350 / G450 has two aft fuselage-mounted Rolls-
Royce Tay 611-8C engines with a static thrust of 13,850 pounds each at
ISA +15°C (86°F) (Figure 1‑4). Each engine is a high bypass turbofan
with a bypass ratio of 3.0:1 and is controlled by a Full Authority Digital
Engine Control (FADEC).
Control of the Tay engine is electronic, via dual-channel Engine

Electronic Controllers (EECs). Nothing mechanical connects the
pilot’s power levers and the engines. The power levers send electronic
signals to the EEC’s microprocessors, which command engine power.
This system protects against engine overspeed and overtemperature.
notes

272 100
APU DOOR
24 25
APU SYNOPTIC
Figure 1-5. Honeywell 36-150 APU

Auxiliary Power Unit NOTES

The Auxiliary Power Unit (APU) is the 36-150, developed by
Honeywell (Figure 1‑5). The APU is a gas turbine engine that starts
with aircraft or ground DC power and then operates on aircraft-
supplied fuel. The APU is to provide an alternate source of pneumatic
power for the main engine start system and the environmental control
system, and provide shaft power to drive the auxiliary AC generator.
Engine operation is controlled by four systems: fuel, lubrication,
electrical and pneumatic. The control system consists of an Electronic
Control Unit (ECU) and sensors that measure APU operating param-
eters, which the ECU uses to control the engine. The ECU ensures
the APU and all of its subsystems operate correctly in response to all
environmental and load conditions.
The APU provides pneumatic power in the form of compressed air for
operation of aircraft main engine starters and environmental control.
The engine has five basic operating modes: ready to load (full rpm
with no shaft or bleed load), main engine starting (bleed load), envi-
ronmental control (bleed load), electrical power generation (shaft load)
and combination operation (simultaneous shaft and bleed loads). The
APU can be started and provide 40 KVA of electrical power up to its
maximum operating altitude of 37,000 feet.. APU operations can be
monitored from the APU control panel located on the cockpit overhead
panel or using the 1/6 synoptic page APU BLEED.

Left Right
HYDRAULICS
30 °C 30 °C
- Full Full -
Low -
- Low
1.6 g
4.8 g
Aux Left Right

0 psi 3000 psi 3000 psi
L T/R R T/R
Aileron
Elev
Flt Spl
Gnd Spl
Stl Bar
YD1 Rudder YD2
NWS PTU
Main Door 0 psi
Flaps
Gnd Spl Ctrl
HMG
Brakes
ACCUM
Ldg Gear
3000 psi BOTTLE 3100 psi
Figure 1-6. Hydraulics Synoptic

Hydraulics NOTES
There are two main hydraulic systems, each of which is powered
by an engine-driven hydraulic pump. A Power Transfer Unit (PTU)
provides another source of power to drive the left hydraulic system. An
electrically powered auxiliary system pump is provided for emergency
use. The HYDRAULICS synoptic page depicts system operation and
indicates abnormal conditions in the system (Figure 1‑6).
NOTES

Pitch Trim Stabilizer 3000

P
22° Up -3.6 ° r 2000
e 1000
10.0 Leading Edge s
0° Down s 500
8° Dn B
r Left psi Right
a
k Accum 3000
e
T 6
e 5
m 4
20 ° 20 ° p 3
2
WOW: G G G 15 15 1 15 15
Left °Cx100 Right
Combined WOW: G
Peak Temp R.O. 270 °C at 2006 UTC
FLIGHT CONTROL / LANDING GEAR SYNOPTICS BRAKES SYNOPTIC
Figure 1-7. Flight Control / Landing Gear / Brake Synoptic

Flight Controls Main Landing Gear Brakes

Gulfstream G350 / G450 flight controls feature conventional The pilot or the copilot can apply brakes on either main landing gear
mechanical linkages with dual servo hydraulic boost for all axes. Roll by pressing the applicable brake pedal. Pressing a left pedal applies
authority is augmented by combined aileron and spoiler action. Electric both brakes on the left main landing gear; pressing a right brake pedal
and manual pitch trim is available. Roll and yaw trim are manually applies both brakes on the right main landing gear.
operated, and dual-channel yaw dampers are provided. The FLIGHT
CONTROL synoptic page depicts system operation and indicates The brake system applies up to 3000 psi hydraulic pressure from the
abnormal conditions in the system (Figure 1‑7). left hydraulic system to the main landing gear brakes in response to
cockpit brake pedal commands. The pilot and copilot brake pedals
Landing Gear are mechanically linked to the left and right brake metering valves in
the nose wheel well. The metering valve opens in response to brake
The Gulfstream G350 / G450 landing gear is fully retractable, tricycle pedal deflection, porting increased pressure with greater brake pedal
type with standard dual wheels. Oil-pneumatic shock struts provide application. The left and right brake metering valves are supplied by
support of the aircraft during landing and while on the ground. The gear both the left and auxiliary hydraulic systems. Immediately downstream
is electrically controlled and hydraulically actuated and is normally of the metering valves in the nose wheel well are two shuttle valves.
pressurized from the left hydraulic system. The landing gear incorpo- The shuttle valves select the higher of either left or auxiliary system
rates an electronically controlled antiskid braking system and a nose pressure.
wheel steering system. The FLIGHT CONTROL synoptic page depicts
landing gear position and combined weight on wheels information.

Figure 1-8. Environmental Control Synoptic

Environmental Control System NOTES

The Environmental Control System (ECS) can sustain a maximum
pressure differential of 9.64 psid. This allows a 6,000 foot cabin
altitude at FL450. The ECS consists of dual air cycle machines, a
three-zone temperature control, water separators and ozone filters.
Dual digital controls that are tied into the flight management system
normally govern cabin pressurization. The ECS / PRESS synoptic page
depicts operation of the pneumatic system and indicates any abnormal
conditions within the system (Figure 1‑8).
NOTES

Figure 1-9. Fuel System Synoptic

Fuel System NOTES

The fuel system consists of two integral wing tanks with a total usable
capacity 29,500 pounds. Cross-flow capability by way of a cross-feed
valve allows fuel from either tank manifold to feed the opposite tank
manifold. Fuel transfer between tanks is provided through the intertank
valve. This provides for fuel balancing.
Refueling is accomplished by gravity or pressure fueling. Automatic

or manual refueling capability is available in the pressure fueling
mode. The FUEL synoptic page depicts operation of the fuel system
and indicates any abnormal conditions within the system (Figure 1‑9).
notes

AC POWER
AC Power DC POWER
L Gen APU Ext R Gen Left Main AC Bus Right Main AC Bus
115 V 115 V --- V 115 V
400 Hz 400 Hz --- Hz 400 Hz
24 % 0 % --- % 24 %
LGen APU HMG Ext RGen
V 115 115 --- --- 115
Left Left Right Right
Ess TRU Main TRU Main TRU Ess TRU
L Main AC Bus Ess AC Bus R Main AC Bus Hz 400 400 --- --- 400 28.2 V 28.4 V
Aux
28.4 V 28.4 V
23 % 19 % TRU 19 % 18 %
E-Inv % 24 0 --- --- 24 31.0 V

0 %
L Ess DC Bus R Ess DC Bus DC Power L Main DC Bus R Main DC Bus

Aux TRU LEss LMain Aux RMain REss
---- V
--- %
V 28.2 28.4 31.0 28.4 28.4 Ext
---- V GND SVC Bus
--- A
L Stby AC Bus R Stby AC Bus % 23 19 0 19 18
L Ess DC Bus R Ess DC Bus
HMG LBatt Ext RBatt
--- V Left Right
--- Hz
V 28.7 ---- 28.7 Batt Batt
28.7 V 28.7 V
--- % 0 A 0 A
A 0 --- 0
AC SYNOPTIC AC / DC SYNOPTIC DC SYNOPTIC

Figure 1-10. Electric Power Synoptics

Electrical Power NOTES

The Electrical Power System (EPS) provides AC and DC power
and a means of control, protection and distribution of electrical
power required for ground and inflight operations of the aircraft
(Figure 1‑10). Primary electrical power is provided by the AC power
system, comprised of two engine-driven Integrated Drive Generators
(IDGs) and an APU driven generator. DC power is provided by
five Transformer Rectifier Units (TRUs) and supplemented by two,
24VDC, 45 amp / hour, lead acid batteries. A DC power Ground
Service Bus (GSB) is provided to allow routine aircraft servicing
without powering unnecessary aircraft systems.
The aircraft is equipped with a standby electrical power system that is

powered by a Hydraulic Motor Generator (HMG). The HMG provides
AC power if the APU generator and both main AC generators are
not available. If all the previously mentioned power sources fail,
emergency power battery packs provide power to support equipment
essential for safety of flight. There is also a 60 Hz converter to provide
power to outfitter installed equipment.

Figure 1-11. PlaneView™ Cockpit

PlaneView™ Avionics notes

The PlaneView™ system provides pilots with real-time information
about airports, weather, air traffic and terrain, all displayed on four
large landscape, flat-screen monitors (Figure 1‑11). These advance-
ments greatly improve situational awareness for pilots and provide
instant access to information necessary to make safe flying decisions
in adverse or low visibility conditions. The most significant advantage
is improved safety.
NOTES

MRC 2
MAU 2
Figure 1-12. Right Electronic Equipment Racks

PlaneView™ Avionics (Cont) NOTES

The Planeview™ system is based on the Honeywell EPIC architecture
and consists of three 16 user slot dual channel Modular Avionic Units
(MAUs), four large format flat panel displays, dual EGPWS, dual EPIC
radios, TCAS, three AV-900 Audio Control Panels (ACPs), various
controllers, sensors, and servos (Figure 1‑12).
The Epic system takes advantage of advancements in flat panel

display technology and cursor control devices and couples the stand-
alone functions into the avionics suite. Many control functions that
were previously individual Line Replaceable Units (LRUs) in older
systems are functionally integrated into the MAU and the Modular
Radio Cabinets (MRC) of the Epic system.
notes


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GULFSTREAM G450

MAINTENANCE TRAINING MANUAL

FOR TRAINING PURPOSES ONLY

Savannah Learning Center

Copyright © 2013 by FlightSafety International, Inc.

LIST OF EFFECTIVE PAGES

Dates of issue for original and changed pages are:

THIS PUBLICATION CONSISTS OF THE FOLLOWING:

*Zero in this column indicates an original page.

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-i

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-iii

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-1

GENERAL Given the Gulfstream G350 / G450 Aircraft Maintenance Manual

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-2

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-3

AFT GALLEY GULFSTREAM 450-SP

• 12 WINDOWS IN LIVING AREA 3 LIVING AREAS

FWD GALLEY GULFSTREAM 450-SP

• 12 WINDOWS IN LIVING AREA 3 LIVING AREAS

Figure 1-1. Interior Layouts

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-4

Cabin Standards Interior Dimensions

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-5

MAIN ENTRANCE DOOR BAGGAGE COMPARTMENT DOOR

Figure 1-2. Doors

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-6

The baggage compartment door is a 40 x 36 inch plug-type door on

An unpressurized tail compartment houses the Auxiliary Power Unit

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-7

Figure 1-3. Windows and Emergency Exits

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-8

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-9

Figure 1-4. Rolls Royce Tay 611-8C Engine

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-10

Aircraft Systems NOTES

Control of the Tay engine is electronic, via dual-channel Engine

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-11

Figure 1-5. Honeywell 36-150 APU

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-12

Auxiliary Power Unit NOTES

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-13

Aux Left Right

3000 psi BOTTLE 3100 psi

Figure 1-6. Hydraulics Synoptic

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-14

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-15

Pitch Trim Stabilizer 3000

FLIGHT CONTROL / LANDING GEAR SYNOPTICS BRAKES SYNOPTIC

Figure 1-7. Flight Control / Landing Gear / Brake Synoptic

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-16

Flight Controls Main Landing Gear Brakes

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-17

Figure 1-8. Environmental Control Synoptic

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-18

Environmental Control System NOTES

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-19

Figure 1-9. Fuel System Synoptic

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-20

Fuel System NOTES

Refueling is accomplished by gravity or pressure fueling. Automatic

Revision 0.0 FOR TRAINING PURPOSES ONLY 1-21

E-Inv % 24 0 --- --- 24 31.0 V

L Ess DC Bus R Ess DC Bus DC Power L Main DC Bus R Main DC Bus

AC SYNOPTIC AC / DC SYNOPTIC DC SYNOPTIC