2000 SERIES SPEEDBRAKE INSTALLATION MANUAL MOONEY M20 SERIES & M22 STC NO. SA4342NM NOTE: READ THESE DIRECTIONS BEFORE STARTING!

Transcription

1 INSTALLATION REPORT NO Serial Number PRECISE FLIGHT, INC SERIES SPEEDBRAKE INSTALLATION MANUAL MOONEY M20 SERIES & M22 NOTE: READ THESE DIRECTIONS BEFORE STARTING! THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION ON THE PRECISE FLIGHT, INC. COMPANY AND ITS RECEIPT OR POSSESSION DOES NOT CONVEY ANY RIGHTS TO REPRODUCE, DISCLOSE ITS CONTENTS, OR TO MANUFACTURE, USE, OR SELL ANYTHING IT MAY DESCRIBE. REPRODUCTION, DISCLOSURE, OR USE WITHOUT SPECIFIC WRITTEN AUTHORIZATION OF THE PRECISE FLIGHT, INC. COMPANY IS STRICTLY FORBIDDEN. N O T I C E THESE DOCUMENTS MUST BE KEPT WITH AIRCRAFT RECORDS" REVISION B 03/19/2001 PAGE 1

2 T A B L E O F C O N T E N T S T A B L E O F C O N T E N T S...2 R E V I S I O N S...3 INSTALLATION INSTRUCTIONS...4 A. INSTALLATION OVERVIEW...4 B. LIST OF...5 C. LOCATING WING CUTOUTS...6 C.1. FIGURE - WING TEMPLATE...6 D. RIVET REMOVAL...7 E. DOUBLER PLACEMENT...8 F. WING CUTOUTS...9 F.1. FIGURE - WING CUTOUT...9 G. DOUBLER INSTALLATION (PRELIMINARY)...10 H. UPPER DOUBLER INSTALLATION...11 I. SPEEDBRAKE CARTRIDGE INSTALLATION (TEMPORARY)...12 J. EXTERIOR PANEL AND INTERIOR REMOVAL...14 K. INSTALLATION OF THE ASSYMETRIC LOGIC CONTROL...15 L. WIRING THE SPEEDBRAKE CARTRIDGES TO THE ALC...16 M. WIRING THE ASSYMETRIC LOGIC CONTROL...17 N. CIRCUIT BREAKER AND SWITCH...18 O. SPEEDBRAKE CARTRIDGE INSTALLATION (PERMANENT)...19 P. PLACARDS...20 Q. DOCUMENTATION...21 TROUBLE SHOOTING GUIDE CARTRIDGE FAILS TO OPERATE DO NOT OPERATE THE SPEEDBRAKES BY HAND DO NOT USE SPRAY LUBRICANTS ON SPEEDBRAKES FOR ADDITIONAL TECHNICAL ASSISTANCE...22 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS...23 APPENDIX A...24 PARTS LIST...24 ELECTRICAL LOAD ANALYSIS FORMS...24 INSTALLATION INSTRUCTION DRAWINGS S S S S S S S S0015 REVISION B 03/19/2001 PAGE 2

3 R E V I S I O N S REV NO. PAGE DESCRIPTION DATE NAME - All Initial release 10/20/99 STP A 10 Sect. G, Step 4, Incl. Statement to clarify 04/05/00 STP Doubler placement A 11 Sect. H, Step 5, Add instructions to 04/05/00 STP correct for possible existence of interference from wing skin B 15 Sect. K, Table & Step 1, Change PN s of old ALC s to new ALC PN 03/19/01 MAO REVISION B 03/19/2001 PAGE 3

4 INSTALLATION INSTRUCTIONS A. INSTALLATION OVERVIEW The installation of Precise Flight, Inc. SpeedBrakes consists of the following: 1. Cutting rectangular openings in the top of each wing skin, using locating templates. 2. Installing doublers to reinforce the cutout areas, requiring removing and replacing existing rivets. 3. Wiring the SpeedBrakes will require removing the front seats, pilot side panel, and aft belly pan. Wires will then be run through the wing and fuselage to a centrally located control unit, installing a circuit breaker to protect the system, and a switch to actuate the system. 4. Functionally check SpeedBrakes. 5. Filling out necessary FAA paperwork to return the aircraft to service. Each section will include a list of tools and parts required. REVISION B 03/19/2001 PAGE 4

5 B. LIST OF Automatic center punch Bucking Bars Chip chaser Clecos: 3/32, 1/8, and side grip clamps Cleco pliers Copy of AC B Die grinder with abrasive cutter wheel Drills: #40, #30, #12, and 5/8 capacity Unibit Drill motor Primer (per Mil-P-23377D) Felt marker: Ultra fine point Files: 1/4 inch round and 6 inch flat Inspection mirror Masking tape: 3/4 inch Micro adjust countersink: 100 degree #40 pilot Needle nose pliers Nutplate Jig 8-32 Pencil Rivet gun: Cherry-Max Rivet gun: with flush set, 1/8 inch set /8, 3/32 Ruler: 12 inch (minimum) Screw driver: Phillips #1 and #2 tip Snips: Prosnip offset snips 20SR, 20SL or equivalent Soldering iron Solder: rosin core Tape measure: 12 feet minimum Volt-Ohm meter Wire crimper, cutter, and stripper 3M adhesive or equivalent REVISION B 03/19/2001 PAGE 5

6 C. LOCATING WING CUTOUTS Automatic center punch Masking tape Tape Measure 541S Template 541S0006 (Right Wing) 541S Template 541S0007 (Left Wing) 1. Using template 541S0006, place the template on the right aircraft wing between Wing Stations and and align template with trailing edge. Adjust template so that the row of rivets marked CRITICAL RIVET LINE maintain 2D edge clearance on doubler joggle and doubler edge as shown on template. Once aligned, secure the template to the wing skin using masking tape. 2. Identify and mark the 25, #4 existing rivets to be removed. 3. Locate the two points labeled corner rivet location and center punch transfer these two locations. 4. Locate the 4 new rivet locations along Wing Station 88.75, center punch transfer these locations. 5. Remove the template and set aside. 6. Repeat steps 1 thru 5 on the left wing using Template 541S0007. C.1. FIGURE WING TEMPLATE REVISION B 03/19/2001 PAGE 6

7 D. RIVET REMOVAL Drills: #40, #30 Drill motor 1. On the right wing upper skin, with the rivets established in Step C-2, identify all rivet types and their sizes. 2. Drill out all rivets marked using the proper size drill. A rivet centering drill tool may be helpful in drilling out the rivets. 3. Drill the 2, #30 corner rivet location holes. 4. Repeat steps 1 thru 3 on the left wing. REVISION B 03/19/2001 PAGE 7

8 E. DOUBLER PLACEMENT Clecos: 1/ Upper doubler right Cleco pliers Upper doubler left Drills: #30 541S Right template Drill motor 541S Left template Felt marker: Ultra fine line WING SKIN 1. On the upper right wing, cleco the upper doubler (P/N 04668) onto the wing skin using the 2 corner rivet location holes and 2, 1/8 clecos. See Template 541S Using a #30 drill, drill through the remaining new rivet holes on the doubler into the wing. Use Clecos to secure the doubler as you go. 3. With an ultra fine felt marker trace the wing cutout onto the wing skin. This line will be used in making the cutout in the wing skin. 4. Remove the doubler and identify it as the right wing then set aside. 5. Repeat steps 1 thru 4 on the left wing using upper doubler P/N See Template 541S0007. REVISION B 03/19/2001 PAGE 8

9 F. WING CUTOUTS Die grinder w/abrasive cutter Cover Plate Drill: 1/4 inch Drill motor Files: 1/4 inch round & 6 inch flat Snips: 20SR, 20SL Various methods may be employed to make the cutouts in the wings. Use Extreme Care! It has been proven helpful to do the following: 1. Mask off the wing around the area to be cut. 2. Drill a 1/4 inch hole well inside all 4 radiused corners. 3. Using a 1/4 inch round file, file close to the traced lines. 4. Using a die grinder and abrasive cutter, or snips, cut lines between the holes, staying well within the traced lines. 5. File the openings up to the traced lines using a combination of the 1/4 inch round and 6-inch flat files. 6. Cleco the doubler on top of the wing skin and finish filing the opening to the doubler. 7. Use the Cover Plate P/N to check the size of the opening. The Cover Plate should fit snug in the opening. 8. Repeat steps 1 thru 7 on the Left wing. NOTE: The cutouts will be the finished product. Care must be taken when finishing these openings. F.1. FIGURE WING CUTOUT REVISION B 03/19/2001 PAGE 9

10 G. DOUBLER INSTALLATION (PRELIMINARY) PART NO. QUANTITY DESCRIPTION Bucking bars or 2 Upper doubler Chip chaser 541S Right Wing Template Clecos: 1/8 541S Left Wing Template Cleco pliers Countersink: 100 degree #30 pilot Drills: #30 Drill motor Primer (Mil -P-23377D) Rivet gun: 1/8 Inspection mirror Ruler: 12 inch (minimum) The upper doublers are positioned under the skin and on top of the rib flanges with the joggle below the stringer. RIGHT WING 1. Reference drawing template 541S Insert the Doubler (P/N 04668) into the wing through the cutout. 3. Position the Doubler between the skin and rib flanges, and below stringer. 4. Orient the holes in the doubler with the holes in the wing skin and cleco in place. Be sure that the Doubler is placed between the outboard and inboard wing skins on the outboard end. NOTE: The joggled edge on the doubler and outboard edge of the joggle may need to be trimmed to allow cutout hole alignment. Use inspection mirror to check this interference. Insure that 2D rivet spacing is maintained after trimming. 5. Using a felt tip marker, transfer the rivet location for the stringer and ribs onto the doubler 6. Remove clecos and doubler, confirm 2D edge distance on ribs, doubler flange, and joggle. 7. Position the Doubler again between the skin and rib flanges, and below stringer. 8. Using a #30 drill, drill through the skin into the doubler on all the previously removed rivets. 9. Remove the Doubler and deburr. Remove all bucked ends and any chips inside the wing. 10. Repeat steps 1 thru 9 on the left wing using P/N Reference drawing #541S0007. REVISION B 03/19/2001 PAGE 10

11 H. UPPER DOUBLER INSTALLATION Bucking bars or Upper Doubler Clecos: 1/ Support Flange Cleco pliers Rivets Rivet gun Rivets Cherry-Max Rivet Cherry-Max Rivet Rivets RIGHT WING Reference Drawings 541S0006 & 541S Insert the Upper Doubler (P/N 04668) through the opening in the wing skin. 2. Orient the upper doubler with the cutout in the top skin and the previously drilled holes. 3. Insert the Support Flange (P/N 04670) under the upper doubler. You may need to slide the support flange between the upper doubler and wing ribs to obtain the correct position. 4. Cleco the upper doubler and support flange in place. 5. Use inspection mirror to check that upper doubler support flange does not interfere with outboard overlapping wing skin. If interference exists, trim the outboard wing skin using a stainless steel backing plate to avoid cutting the inboard (exposed) wing skin; be sure to maintain edge distance on all rivets. Or, trim the upper doubler support flange being careful to maintain edge distance on all rivets. 6. Remove the support flange and rivet the upper doubler in place. Reference drawing # 541S0006 and 541S0007 for correct rivets. 7. Rivet the support flange to the upper doubler. Reference drawing # 541S0006 and 541S0007 for correct rivets. 8. Repeat steps 1 thru 7 on the left wing using P/N REVISION B 03/19/2001 PAGE 11

12 I. SPEEDBRAKE CARTRIDGE INSTALLATION (TEMPORARY) Clecos: 1/8 Cleco pliers Screw Screw Drill bits: #27,.310 Drill motor 05097L &05097R 05115L & 05114R 2 OR 2 Cartridge Assy s. 12V Cartridge Assy s. 24V Double back tape Lower support Nutplate Jig Nutplates Rivets Cover Plate RIGHT WING 1. The SpeedBrake Cartridges are biased forward - less space forward than aft. Orient the Drain tube to the inboard side. The SpeedBrake cartridges are marked left and right - confirm you have the correct cartridge for the right wing installation. 2. Attach the Cover Plate (P/N 04663) to the SpeedBrake cartridge with the supplied 4-40 screws (P/N 07025). IMPORTANT NOTE: The supplied screws are the proper length - Use of alternate screws to attach the cover plate will interfere with proper SpeedBrake operation and will compromise the component warranty. 3. Place the SpeedBrake Cartridge in the wing and note the location on the lower wing skin where the drain tube would pass through. A small amount of grease on the end of the drain tube helps mark the position in lower wing. Insure that this point is 1" away from the edge of any stringer or rib. Drill 0.31" Dia. Hole and install snap bushing (P/N 06062) on bottom side of wing. 4. Attach Double Back tape to bottom flanges of the support bracket P/N Center the bracket on the bottom of the SpeedBrake Cartridge and place a spacer between the bracket and the cartridge to insure a spacing. The support bracket may have to bend slightly to remain on the cartridge. 5. Carefully install cartridge in the wing. Press down to insure that the cartridge is seated squarely in the opening and that the bracket adheres to the lower wing surface. The cover plate should fit flush in the opening when the cartridge is positioned correctly. 6. Match drill 2 holes in bottom wing skin with forward section of bracket. 7. Cleco in place and drill 2 holes in bracket through wing in the aft section of bracket. 8. Remove Bracket and deburr holes. REVISION B 03/19/2001 PAGE 12

13 9. Drill remaining holes in bracket using an 8-32 Nutplate Jig, countersink rivet holes, and install Nutplates P/N using the supplied Rivets P/N Attach bracket to the bottom wing skin using 4, 8-32 Screws (P/N 01431). 11. Repeat Steps 1 thru 10 for the left wing. REVISION B 03/19/2001 PAGE 13

14 J. EXTERIOR PANEL AND INTERIOR REMOVAL Screw drivers: Phillips #2, #1 1. Remove the front seats. 2. Remove pilot s side panel molding. 3. Remove the aft belly panel. REVISION B 03/19/2001 PAGE 14

15 K. INSTALLATION OF THE ASSYMETRIC LOGIC CONTROL (ALC) Copy of AC B Chp S Drawing Drills: #12 541S Drawing Drill motor 541S Drawing Screw driver: #2 Phillips 541S Drawing 3M Adhesive or Equivalent TY-RAP Washer # Nut Screw ALC-12V/24v Assy CABIN UNDER AFT SEATS AND FLOORBOARD 1 1 Grommet Clip 1. Reference drawing 541S0014. Place the ALC (P/N 05191) in place. Mark holes with felt marker and dimple with automatic center punch. 2. Drill 4 holes using a #12 drill, and deburr. 3. Install the ALC as shown using the four 8-32 screws, #8 washers, 8-32 nuts, and one Adel clamp. (P/N s 01431, 00452, 00485, 07014) 4. Be sure to route all three cable assemblies through the Adel clamp. 5. Install the grommet P/N 06064with 3M adhesive to avoid chaffing of the cable assemblies. 6. Install the clip with the self adhesive backing to the aluminum panel as shown. TY-RAP the 3 cable assemblies to the clip. (P/N s 06066, 00427) 7. Check to ensure that ALC unit and cable assembly installation does not interfere with any other aircraft system. REVISION B 03/19/2001 PAGE 15

16 L. WIRING THE SPEEDBRAKE CARTRIDGES TO THE ALC Copy of AC B Chp S Drawing Ruler: 12 inch Plug Screw driver: #2 Phillips Wire holder Soldering iron Pin extractor Solder: rosin core inches Wire harness Volt-Ohm meter Sockets Wire crimper, cutter, & stripper Needle nose pliers Pins Plugs RIGHT WING LOWER 1. Remove inspection panels underneath the wing, from the SpeedBrake cutout to the wing root. 2. Carefully measure the distance from the right SpeedBrake cutout in the wing to the ALC mount in the cabin. Allow for routing through the wing with sufficient slack at both ends, then cut the Wiring Harness (P/N 02029). Save the scrap. 3. On the ALC end of the Wiring Harness strip the jacket back exposing 5/8 inch of conductors. 4. Remove 1/4 inch of insulation from all conductors. 5. Solder the end of each wire to the short end of a Pin (P/N 01725). 6. Insert the ends through the Wire Holder (P/N 01727). 7. Referring to Drawing #541S0015 for color to pin code, insert the sockets into their respective holes in the Plug (P/N 01729). 8. Attach the Wire Holder (P/N 01727) to the Plug (P/N 01729). Tighten the strain relief to the jacket. Check for pin continuity with a Volt-Ohm meter. 9. Connect the ALC Plug and Wire Harness plug together. Fish the cable through the wing using the J stiffener holes in the ribs where possible. Secure the wire according to AC B, Chapter On the SpeedBrake end of the Wiring Harness, strip the jacket back exposing 5/8 inch of conductors. 11. Repeat Steps 4 to 8 on the SpeedBrake end of the Wiring Harness using (P/N 01728, 01726, 01727). 12. For the Left SpeedBrake Cartridge, repeat Steps 1 to 11. REVISION B 03/19/2001 PAGE 16

17 M. WIRING THE ASSYMETRIC LOGIC CONTROL (ALC) Copy of AC B Chp S Drawing Needle nose pliers Plug Wire crimper, cutter, & stripper Wire Holder Soldering iron Solder: rosin core Wire Harness Socket 1. Route the remaining Wire Harness Cable (P/N 02029) from the ALC mount in the cabin, through the floorboards, pilot s side panel, and instrument panel, leaving sufficient slack at both ends. Secure the wire according to AC B, Chapter 11. Cut the Wiring Harness and save the scrap. 2. On the ALC end of the Wiring Harness strip the jacket back exposing 5/8 inch of conductors. 3. Remove 1/4 inch of insulation from all conductors. 4. Solder the end of each wire to the short end of a Socket (P/N 01728). 5. Insert the ends through the Wire Holder (P/N 01727). 6. Referring to Drawing #541S0015 for color to pin code, insert the sockets into their respective holes in the Plug (P/N 01726). 7. Attach the Wire Holder (P/N 01727) to the Plug (P/N 01726). Tighten the strain relief to the jacket. Check for pin continuity with a Volt-Ohm meter. REVISION B 03/19/2001 PAGE 17

18 N. CIRCUIT BREAKER AND SWITCH Copy of AC A Chp S Drawing Drills: 7/16, 5/8 capacity Unibit 541S Drawing Drill motor Circuit breaker Soldering iron Opt. Annunciator Solder: rosin core Option I Switch Kit Needle nose pliers OR Wire crimper, cutter, & stripper Option II Switch Kit Reference Drawing # 541S0002 & 541S At the instrument panel, install and wire the Circuit Breaker (P/N 01270). Reference Drawing # 541S0015 for proper wiring. 2. Insert the proper light bulbs into the switch or annunciator, depending on option ordered. (P/N s depend on kit option ordered. See Packing List for part numbers.) 3. Install the switch within full view and easy access of the pilot. Use Drawing # 541S0002, 541S0015, and AC B Chapter 11 for reference. NOTE: For switch and light locations other than that shown, obtain separate FAA engineering approval. REVISION B 03/19/2001 PAGE 18

19 O. SPEEDBRAKE CARTRIDGE INSTALLATION (PERMANENT) Screw driver: Phillips # Screws 05097L & 05097R 2 Cartridge assembly 12V OR 05115L & 05114R 2 Cartridge assembly 24V 541S DWG RIGHT WING 1. Attach the wiring harness to the cartridge. Drop cartridge into wing opening insuring that the drain tube is fed through the grommet and the cartridge is seated firmly on the lower support. 2. Screw the Speed Brake and Cover Plate Assembly to the upper support flange in the wing, using 14 Screws (P/N 01477). 3. Trim drain tube 1/4 inch from wing skin at an angle away from the direction of airflow. 4. Repeat Step 1 through 3 for the left wing. REVISION B 03/19/2001 PAGE 19

20 P. PLACARDS Placard Placard Placard 1. Install Placard (P/N 00456) in full view of the pilot. SPEEDBRAKE EQUIPPED: FOR OPERATING INSTRUCTIONS & LIMITATIONS SEE SUPPLEMENT IN OWNERS MANUAL OR OPERATING HANDBOOK. 2. Install Placard (P/N 00455) at SpeedBrake circuit breaker and next to SpeedBrake switch. SPEEDBRAKE SPEEDBRAKE 3. Install Placard (P/N 01750) on wing skin aft of SpeedBrake cartridges. Electrically Actuated - DO NOT MANUALLY OPERATE REVISION B 03/19/2001 PAGE 20

21 Q. DOCUMENTATION Before performing flight tests it is recommended you complete the calculations for weight and balance and revise the equipment list showing installation of Precise Flight SpeedBrakes at 9-lbs. at in. FAA Form 337, section 8 Description of work accomplished. Installed Precise Flight 2000 Series SpeedBrakes serial # accordance with STC # and Installation Report # Amended weight and balance and aircraft equipment list. in Add the FAA approved Flight Manual Supplement to the aircraft Flight manual. Keep all Precise Flight 2000 Series SpeedBrakes papers with aircraft records. Fill out and return warranty card. REVISION B 03/19/2001 PAGE 21

22 TROUBLE SHOOTING GUIDE 1. SPEEDBRAKE CARTRIDGE FAILS TO OPERATE CORRECTLY a. Check circuit breaker b. Check cannon plugs for security c. Check cannon plug (P/N 01726) for correct wiring (See Drawing No. 541S0015 for electrical installation procedures.) d. If Speedbrake doors open, check that doors stop approximately ¼ before being fully vertical. There should be no gap between the Speedbrake doors. If doors open beyond this position call Precise Flight, Inc. 2. DO NOT OPERATE THE SPEEDBRAKES BY HAND While electrical power is on. Damage to cartridges and personal injuries may result! 3. DO NOT USE SPRAY LUBRICANTS ON SPEEDBRAKES Damage to cartridges and Speedbrake clutch may result! 4. FOR ADDITIONAL TECHNICAL ASSISTANCE Please call Precise Flight, Inc.. REVISION B 03/19/2001 PAGE 22

23 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS MOONEY SPEEDBRAKE 2000 TM EACH 5000 HOURS EACH 1000 HOURS ANNUALLY EACH 100 HOURS EACH 50 HOURS 1. Check Cap Strip Cover screws for security, if loose, remove screws and apply Locktite 242, retorque to 8 in-lbs. Check SpeedBrake top attachment screws for security, if loose, remove screws and apply Locktite 242, retorque to 8 in-lbs. 2. Check drain tubes for debris 3. a.) Remove inspection plates b.) Disconnect electrical plugs c.) Remove SpeedBrakes TM from aircraft d.) Clean and Inspect unit for damage, corrosion, looseness & proper operation e.) Lubricate worm and worm gear with Lubriplate. DO NOT USE SPRAY LUBRICANTS! f.) Reinstall SpeedBrakes TM in aircraft g.) Connect electrical plugs h.) Install inspection plate i.) Check for proper placards 4. a.) Remove inspection plates b.) Disconnect electrical plugs c.) Remove SpeedBrakes TM from aircraft d.) Return SpeedBrakes TM to Precise Flight Inc. for Clutch Lubrication and Spring Replacement e.) Reinstall SpeedBrakes TM in aircraft f.) Connect electrical plugs g.) Install inspection plate 5. a.) Remove inspection plates b.) Disconnect electrical plugs c.) Remove SpeedBrakes TM from aircraft d.) Return SpeedBrakes TM to Precise Flight Inc. for Drive Assembly Replacement e.) Reinstall SpeedBrakes TM in aircraft f.) Connect electrical plugs g.) Install inspection plate REVISION B 03/19/2001 PAGE 23

24 APPENDIX A PARTS LIST ELECTRICAL LOAD ANALYSIS FORM INSTALLATION INSTRUCTION DRAWINGS REVISION B 03/19/2001 PAGE 24

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