2000 SERIES PA-30 / PA-39 STC NO. SA00233SE PA-24 STC NO. SA4150NM

Transcription

1 INSTALLATION REPORT NO Serial Number PRECISE FLIGHT, INC SERIES SPEEDBRAKE INSTALLATION MANUAL PA-30 / PA-39 STC NO. SA00233SE PA-24 STC NO. SA4150NM NOTE: READ THESE DIRECTIONS BEFORE STARTING! CHECK FOR EQUIPMENT THAT MAY INTERFERE WITH INSTALLATION BEFORE PROCEEDING! ALL WORK MUST BE DONE IN CONJUNCTION WITH APPLICABLE AIRCRAFT MAINTENANCE MANUAL! 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 06/20/01 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 TOOLS REQUIRED... 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) H. DOUBLER INSTALLATION I. SPEEDBRAKE CARTRIDGE INSTALLATION (TEMPORARY) I.1. FIGURE LOWER SUPPORT INSTALLATION J. EXTERIOR PANEL AND INTERIOR REMOVAL K. INSTALLATION OF THE ASSYMETRIC LOGIC CONTROL (ALC) K.1. FIGURE ALC INSTALLATION L. WIRING SPEEDBRAKE CARTRIDGES TO THE ALC L.1. FIGURE LEFT WING ROOT L.2. FIGURE LEFT WING WIRE HARNESS ROUTING (SPAR AFT MOUNT) M. WIRING THE ASSYMETRIC LOGIC CONTROL (ALC) N. CIRCUIT BREAKER AND SWITCH O. SPEEDBRAKE CARTRIDGE INSTALLATION (PERMANENT) O.1. FIGURE SPEEDBRAKE PERMANENT INSTALLATION P. PLACARDS Q. SPEEDBRAKE OPERATIONAL TEST R. DOCUMENTATION TROUBLE SHOOTING GUIDE SPEEDBRAKE CARTRIDGE FAILS TO OPERATE CORRECTLY DO NOT OPERATE THE SPEEDBRAKES BY HAND DO NOT USE SPRAY LUBRICANTS ON SPEEDBRAKES FOR ADDITIONAL TECHNICAL ASSISTANCE INSTRUCTIONS FOR CONTINUED AIRWORTHINESS APPENDIX A PARTS LIST ELECTRICAL LOAD ANALYSIS FORM INSTALLATION INSTRUCTION DRAWINGS S S S S S S S S S0014 REVISION B 06/20/01 PAGE 2

3 R E V I S I O N S REV NO. PAGE DESCRIPTION DATE NAME - All Initial release 01/18/00 STP A All Revise part numbers and procedures. PFS# 05/17/00 EWL B 16 Revise ALC Part Number to current Assembly 06/20/01 BDL REVISION B 06/20/01 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. Installing lower support brackets to support the SpeedBrake cartridges. 4. Wiring the SpeedBrakes will require removing all the seats and some cabin floor inspection bays. 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. 5. Reinstalling all removed panels and interior. 6. Functionally check SpeedBrakes. 7. Filling out necessary FAA paperwork to return the aircraft to service. Each section will include a list of tools and parts required. REVISION B 06/20/01 PAGE 4

5 B. LIST OF TOOLS REQUIRED Automatic center punch Bucking Bars Chip chaser Clecos: 3/32, 1/8, and side grip clamps Cleco pliers Copy of AC B Countersink Deburr tool Die grinder with abrasive cutter wheel Drills: numbered & decimal drill set, Unibit Drill motor Double back tape Felt marker: Ultra fine line Files: 1/4 inch round and 6 inch flat Inspection mirror Isopropyl Alcohol Masking tape: 3/4 inch Needle nose pliers Nutplate Jig 8-32 Pencil Pro-Seal: B1/2 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 Sockets: 3/8, 7/16 Soldering iron Solder: rosin core Tape measure: 12 feet minimum Volt-Ohm meter Wire crimper, cutter, and stripper Wrenches Zinc Chromate 3M adhesive or equivalent REVISION B 06/20/01 PAGE 5

6 C. LOCATING WING CUTOUTS TOOLS REQUIRED Automatic center punch Masking tape Tape Measure PARTS REQUIRED PART NUMBER QUANTITY DESCRIPTION 577S Template Right Wing 577S Template Left Wing RIGHT WING Reference Drawings 577S & 577S Using template 577S0006-1, place the template on the Right Wing and align template with the SKIN LAP REFERENCE. Adjust template so that the row of rivets marked CRITICAL RIVET LINE maintain 2D edge clearance on Doubler edge as shown on template. Once aligned, secure the template to the wing skin using masking tape. NOTE: The Aileron and Flap location are noted on the Template in the position they are from the overlapping skin. 2. Identify and mark the 24 #3 existing rivets to be removed. (Some Aircraft may differ in the number of rivets between the ribs.) 3. Locate the two points labeled CORNER RIVET LOCATION and center punch transfer these two locations. 4. Remove the template and set aside. 5. Repeat steps 1 thru 4 on the Left Wing using Template 577S C.1. FIGURE WING TEMPLATE REVISION B 06/20/01 PAGE 6

7 D. RIVET REMOVAL TOOLS REQUIRED Drills: #40, #30 Drill motor RIGHT WING PARTS REQUIRED PART NUMBER QUANTITY DESCRIPTION Reference Drawings 577S & 577S 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 06/20/01 PAGE 7

8 E. DOUBLER PLACEMENT TOOLS REQUIRED PARTS REQUIRED PART NUMBER QUANTITY DESCRIPTION Clecos: 1/ Upper Right Doubler Cleco pliers Upper Left Doubler Drills: #30 577S Right Wing Template Drill motor 577S Left Wing Template Felt marker: Ultra fine line RIGHT WING SKIN Reference Drawings 577S & 577S NOTE: Upper Left and Right Doublers (P/N 04692) are identical. The doublers are turned over so they are opposite. Refer to Drawings 577S & -2 for proper alignment and position. 1. On the upper Right Wing, cleco the upper doubler (P/N 04692) onto the wing skin using the 2 corner rivet location holes and 2, 1/8 clecos. See Template 577S 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 577S REVISION B 06/20/01 PAGE 8

9 F. WING CUTOUTS TOOLS REQUIRED PARTS REQUIRED PART NUMBER QUANTITY DESCRIPTION Die grinder w/abrasive cutter Upper Right Doubler Drill: ¼ Upper Left Doubler Drill motor Cover Plate Files: ¼ round & 6 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: NOTE: The cutouts will be the finished product. Care must be taken when finishing these openings. RIGHT WING 1. Mask off the wing around the area to be cut. 2. Drill a ¼ hole well inside all 4 radiused corners. 3. Using a ¼ 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 ¼ round and 6 flat files. 6. Cleco the doubler (P/N 04692) on top of the wing skin and finish filing the opening to the doubler. 7. Use the Cover Plate (P/N 04663) 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. F.1. FIGURE WING CUTOUT REVISION B 06/20/01 PAGE 9

10 G. DOUBLER INSTALLATION (PRELIMINARY) TOOLS REQUIRED PARTS REQUIRED PART NUMBER QUANTITY DESCRIPTION Bucking bars Upper Right Doubler Chip chaser Upper Left Doubler Clecos: 1/8 577S Right Wing Template Cleco pliers 577S Left Wing Template Deburr tool Drills: #30, #40 Drill motor Rivet gun: 1/8 The upper doublers are positioned under the skin and on top of the rib flanges with the outboard edge between the overlapping wing skins. RIGHT WING Reference Drawings 577S & 577S Reference drawing template 577S Insert the Doubler (P/N 04692) into the wing through the cutout. 3. Position the Doubler between the skin and stringer flanges. 4. Orient the holes in the doubler with the holes in the wing skin and cleco in place. NOTE: The doubler corners may need to be trimmed to allow for proper rivet spacing. Insure that 2D rivet spacing is maintained after trimming. See Drawing 577S Using a felt tip marker, transfer the rivet locations for the stringer onto the doubler. 6. Remove clecos and doubler, confirm 2D edge distance on doubler flange. 7. Position the Doubler again between the skin and stringer flanges. 8. Using a #30 and #40 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 #577S REVISION B 06/20/01 PAGE 10

11 H. DOUBLER INSTALLATION TOOLS REQUIRED Bucking bars Clecos: 3/32, 1/8 Cleco pliers Rivet gun PARTS REQUIRED PART NUMBER QUANTITY DESCRIPTION 577S Right Wing Template 577S Left Wing Template Upper Right Doubler Upper Left Doubler Drill Bit: # Right Support Flange Drill motor Left Support Flange Rivets Rivets Rivets RIGHT WING Reference Drawings 577S & 577S Insert the Doubler (P/N 04692) through the opening in the wing skin. 2. Position the Doubler between the wing skin and the stringers. Align the doubler with the previously drilled holes and cutout. 3. Place a layer of Pro-Seal between the Doubler and wing skin ½ around the cutout. 4. Cleco the Doubler in place. 5. Rivet the Doubler in place. Reference drawing # 577S and 577S for correct rivets. 6. Repeat steps 1 thru 5 using P/N on the Left Wing. REVISION B 06/20/01 PAGE 11

12 I. SPEEDBRAKE CARTRIDGE INSTALLATION (TEMPORARY) TOOLS REQUIRED Clecos: 1/8 Cleco pliers Countersink Deburr tool Drill bits Drill motor: right angle Double back tape PARTS REQUIRED PART NUMBER QUANTITY DESCRIPTION Rivets Rivets Screw Cover Plate 05097L &05097R 2 OR Cartridge Assy. 12V 05115L &05114R 2 Cartridge Assy. 24V Lwr. Support Chnl. Nutplate Jig Snap Bushing Sharpie fine point pen #8 Washer Zinc Chromate Screw Screw driver: Phillips Support Flange Rt Support Flange Lt RIGHT WING Support Rod Assy. Upper Sprt. Chnl Nylock Nut #10 Washer Screw 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 07016). 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. Center the Lower Support Channel (P/N 04695) laterally in the SpeedBrake hole, with the channel feet in front of both stringers. Use Cleco clamps to hold the Lower Support Channel in place. 4. Match drill the 4-#40 holes through the Lower Support Channel into the stringers. Be sure that the holes are in the center of the stringer flange and clear of the stringer bulb. 5. Cleco the Lower Support Channel to the stringers. Re-drill the 4 holes using a drill. REVISION B 06/20/01 PAGE 12

13 6. Attach the Support Rod Assembly (P/N 05157) to the Lower Support Channel and adjust so the flange base sits square on the lower spar cap. Ensure 2D edge distance from any rivet. Using a fine point Sharpie pen, mark the lower spar cap through both nutplates on the Support Rod Flange Base. 7. Remove the Lower Support Channel and Support Rod Assemblies. Centerpunch both pen marks. Using a drill, drill both holes through the lower spar cap. IMPORTANT NOTE: Be sure that the drill is perpendicular to the lower spar cap! Failure to do so may cause the Support Rod Flange to not fit properly! 8. Deburr all holes and Zinc Chromate for corrosion protection. 9. Install the Lower Support Assembly in the wing using the hardware and positions located on Drawing # 577S0011. Be sure that each Rod End has a Stop Nut installed. 10. Tighten all hardware. Bias the Support Rod Assembly slightly so there is no slop in the stringers. IMPORTANT NOTE: Do not bias the Support Rod Assembly so that is deflects the stringers! 11. Cleco the Upper Doubler Support Flange (P/N 04693) in position. See Drawing # 577S0006 for reference. 12. Ensure that the drain tube in the SpeedBrake cartridge is aligned straight down, and that you have the right side SpeedBrake (check P/N for Left or Right indication) with the drain tube to the wing root (inboard). Place the SpeedBrake cartridge squarely in the SpeedBrake bay and identify where the drain tube contacts the lower wing skin. A small amount of grease on the drain tube is helpful in determining the contact point. Ensure that the contact point is at least 1 from the wing stringer. Centerpunch and drill the drain tube hole using a drill. Zinc Chromate hole for corrosion protection. Install Heyco Bushing (P/N 06062) from the bottom of the wing skin. 13. Apply Double Back Tape to the Upper Support Channel (P/N 04682). Place the SpeedBrake cartridge partially in the wing. Using the inspection hole on the bottom inboard side of the wing, place the Upper Support Channel on the center of the cartridge. Press the SpeedBrake cartridge squarely in the hole so that the cover plate lays flush in the wing. Ensure that the Double back tape has secured the Upper Support Channel to the Lower Support Channel. Remove the SpeedBrake cartridge. 14. Make sure that each of the 4 holes in the Upper Support Channel have at least a 2D edge distance on the Lower Support Channel. REVISION B 06/20/01 PAGE 13

14 15. Match drill the 4-#40 holes. Rivet the Upper Support Channel to the Lower Support Channel using the rivets provided (P/N 00600). Check that the SpeedBrake lays flush in the hole, with the bottom supported by the support channels. Remove the Upper Doubler Support Flange. 16. Repeat Steps 1 through 15 on the Left Wing. I.1. FIGURE LOWER SUPPORT INSTALLATION REVISION B 06/20/01 PAGE 14

15 J. EXTERIOR PANEL AND INTERIOR REMOVAL TOOLS REQUIRED Screw drivers: Phillips #2, #1 Sockets: 3/8, 7/16 Wrenches: 3/8, 7/16 Needle Nose Pliers PARTS REQUIRED PART NUMBER QUANTITY DESCRIPTION 1. Disconnect all electrical power from aircraft. 2. Remove all seats. 3. Remove the aft floor panels and the co-pilot s floor panel. 4. Remove the tail-cone access panel. REVISION B 06/20/01 PAGE 15

16 K. INSTALLATION OF THE ASSYMETRIC LOGIC CONTROL (ALC) TOOLS REQUIRED PARTS REQUIRED PART NUMBER QUANTITY DESCRIPTION Copy of AC B Chp S Drawing Drills: # TY-RAP Drill motor Washer #8 Screw driver: #2 Phillips Deburr tool Nut 8-32 Adel Clamp Wrench 11/ Screw ALC-12V/24V Assembly TAIL-CONE RADIO TRAY 1. Reference drawing 577S0014. 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 #19 drill, and deburr. 3. Install the ALC as shown using the four 8-32 screws, #8 washers, 8-32 nuts, and one or two Adel clamps. (P/N s 01431, 00452, 00485, 01402) 4. Be sure to route all three cable assemblies through the Adel clamp(s). 5. Check to ensure that ALC unit and cable assembly installation does not interfere with any other aircraft system. K.1. FIGURE ALC INSTALLATION REVISION B 06/20/01 PAGE 16

17 L. WIRING SPEEDBRAKE CARTRIDGES TO THE ALC TOOLS REQUIRED Copy of AC B Chp. 11 Ruler: 12 Deburr tool Screw driver: #2 Phillips Soldering Iron Solder: rosin core PARTS REQUIRED PART NUMBER QUANTITY DESCRIPTION 577S Drawing Adel Clamp #8 Washer 8-32 Nut Heyco Bushing 8-32 Screw Needle nose pliers Pins Volt-Ohm meter Plug (Sockets) Wire crimper, cutter, stripper Wire holder Wrench: 11/ Sockets Zinc Chromate Plugs (Pins) Pin Extractor Wire Harness 3M TyWrap Mount TyWrap RIGHT WING LOWER 1. Locate the inspection panels between the SpeedBrake bay and the wing root. Remove the panels closest to the trailing edge including the dirt cover in the wheel well. From inside of each inspection panel, drill a.310 hole through each rib for the Wire Harness to pass through. NOTE: Be sure not to route the Wire Harness across any cables or fuel lines. Maintain 2D edge distance from any fastener or edge. An existing hole may be used. Reference AC B for wire routing guidelines. 2. Zinc Chromate the holes for corrosion protection. Install a Heyco Bushing (P/N 06062) in each hole. 3. Route the Wire Harness from the SpeedBrake bay, through the Heyco Bushings, behind the wheel well dirt cover, through the wing root, and into the cabin through the existing wiring harness grommet. See Figure L.1. for Wire Harness routing through wheel well. 4. Once in the cabin, route the Wire Harness into the tail-cone and onto the radio tray, utilizing existing wire harnesses and Adel Clamps beneath the cabin floor. Secure the Wire Harness in accordance with AC B. 5. Secure the Wire Harness with Adel Clamps (P/N 00355) in the wheel well to ensure security around all cables and fuel lines. Use the 8-32 hardware provided. (P/N 01431, 00485, 00452) See Figure L To hold the Wire Harness in position, install an Adel Clamp (P/N 00355) on the inboard wing rib in the SpeedBrake bay. Maintain a 2D edge distance from all fasteners and edges. Use a REVISION B 06/20/01 PAGE 17

18 #19 drill, deburr tool, Zinc Chromate, and the 8-32 hardware provided. (P/N 01431, 00452, 00485). An existing tooling hole in the rib may be used. 7. Route the Wire Harness through the Adel Clamp and tighten. Leave sufficient slack to connect the SpeedBrake cartridge. 8. On the SpeedBrake end of the Wiring Harness strip the jacket back exposing 5/8 of conductors. 9. Remove ¼ of insulation from all conductors. 10. Solder the end of each wire to the short end of a Socket (P/N 01728). 11. Insert the ends through the Wire Holder (P/N 01727). 12. Referring to Drawing #577S0004 for color to pin code, insert the sockets into their respective holes in the Plug (P/N 01726). 13. 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. 14. On the ALC end of the Wiring Harness, strip the jacket back exposing 5/8 of conductors. 15. Repeat Steps 10 thru 15 on the ALC end of the Wiring Harness using (P/N 01729, 01725, 01727). Connect the Wire Harness to one of the ALC Plugs 16. Check to ensure that the harness installation does not interfere with any other aircraft system. 17. Repeat Steps 1 thru 16 on the Left Wing. NOTE 1: It may be necessary to route the Left Wing Wire Harness across the rear of the wing spar to join the existing aircraft wire bundles. If so, use the 8-32 hardware provided, Adel clamps, TyWraps, and 3M TyWrap mounts provided to support the wire harness across the rear of the spar. DO NOT drill holes in the spar for the Adel clamps, USE ONLY existing tooling holes! See Figure L.2. NOTE 2: Reference AC B Chapter 11 for all wire routing. Wires must be secure when crossing fuel lines and must not pass within 2 of fuel line unless hard mounted!! See Figure L.2. REVISION B 06/20/01 PAGE 18

19 Heyco Bushing P/N Adel Clamps P/N Wire Harness P/N L.1. FIGURE LEFT WING ROOT LEFT WING WIRE HARNESS ROUTING L.2. FIGURE LEFT WING WIRE HARNESS ROUTING (SPAR AFT MOUNT) REVISION B 06/20/01 PAGE 19

20 M. WIRING THE ASSYMETRIC LOGIC CONTROL (ALC) TOOLS REQUIRED PARTS REQUIRED PART NUMBER QUANTITY DESCRIPTION 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 tail-cone, under the floorboards, and behind the instrument panel, utilizing existing wire bundles and 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 of conductors. 3. Remove ¼ 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 #577S0004 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. Connect the Wire Harness to the ALC. REVISION B 06/20/01 PAGE 20

21 N. CIRCUIT BREAKER AND SWITCH TOOLS REQUIRED PARTS REQUIRED PART NUMBER QUANTITY DESCRIPTION Copy of AC A Chp S Drawing Drills: 7/16, 5/8 Unibit 577S 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 # 577S0002 & 577S At the instrument panel, install and wire the Circuit Breaker (P/N 01270). Reference Drawing # 577S0004 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 # 577S0002, 577S0004, and AC B Chapter 11 for reference. 4. If installing the Yoke Mount Switch, attach Bracket (P/N 04689) to the existing Autopilot Disconnect switch mount, nut, and lock-washer. NOTE: For switch and light locations other than that shown, obtain separate FAA engineering approval. REVISION B 06/20/01 PAGE 21

22 O. SPEEDBRAKE CARTRIDGE INSTALLATION (PERMANENT) TOOLS REQUIRED Screw driver: Phillips #2 PARTS REQUIRED PART NUMBER QUANTITY DESCRIPTION 577S Drawing Screws Rivets Support Flange Rt Support Flange Lt L &05097R 2 Cartridge Assy. 12V OR 05115L &05114R 2 Cartridge Assy. 24V RIGHT WING 1. Install the Upper Doubler Support Flange (P/N 04693) using rivets (P/N 00528). 2. Attach the wiring harness to the cartridge. Drop cartridge into wing opening insuring that the drain tube is fed through the Heyco Snap Bushing and the cartridge is seated firmly on the lower support. 3. Screw the Speed Brake and Cover Plate Assembly to the upper support flange in the wing, using 14 Screws (P/N 01477). 4. Trim drain tube ¼ from wing skin at an angle away from the direction of airflow. 5. Repeat Step 1 through 4 for the left wing using (P/N 04694). 6. Reinstall interior and all inspection panels. Check to be sure all tools and debris have been removed from the aircraft! O.1. FIGURE SPEEDBRAKE PERMANENT INSTALLATION REVISION B 06/20/01 PAGE 22

23 P. PLACARDS TOOLS REQUIRED PARTS REQUIRED PART NUMBER QUANTITY DESCRIPTION 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 06/20/01 PAGE 23

24 Q. SPEEDBRAKE OPERATIONAL TEST 1. Reconnect all electrical power. 2. Turn on aircraft master power switch. 3. Check that SpeedBrake Circuit Breaker is pushed in. 4. Press SpeedBrake switch and check that both SpeedBrake cartridges fully deploy and remain open. 5. Check that the SpeedBrake annunciator has illuminated. 6. Press SpeedBrake switch and check that both SpeedBrake cartridges have returned to the fully closed position and remain closed. 7. Check that the SpeedBrake annunciator has turned off. 8. Depress the SpeedBrake switch, and pull the SpeedBrake Circuit Breaker just as the SpeedBrakes begin to leave the cartridge. Check that the SpeedBrakes drop promptly to the closed position. 9. Push the SpeedBrake Circuit Breaker back in, cycle the SpeedBrake Switch, and observe the SpeedBrakes deploy to the fully opened position. 10. Repeat Steps 6 and Turn off aircraft master power switch. 12. If any problems occur, consult the TROUBLE SHOOTING GUIDE section. REVISION B 06/20/01 PAGE 24

25 R. 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 8-lbs. at._-in., and Precise Flight ALC at 1-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 06/20/01 PAGE 25

26 TROUBLE SHOOTING GUIDE 1. SPEEDBRAKE CARTRIDGE FAILS TO OPERATE CORRECTLY a. Check circuit breaker b. Check cannon plugs for security c. Check all cannon plugs for correct wiring (See Drawing No. 577S0004 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 and will void warranty! 3. DO NOT USE SPRAY LUBRICANTS ON SPEEDBRAKES Damage to cartridges and Speedbrake clutch may result and will void warranty! 4. FOR ADDITIONAL TECHNICAL ASSISTANCE Please call Precise Flight, Inc.. REVISION B 06/20/01 PAGE 26

27 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS PIPER PA-24 / PA-30 / PA-39 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 inlbs. 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 graphite. 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 APPENDIX A REVISION B 06/20/01 PAGE 27

28 PARTS LIST ELECTRICAL LOAD ANALYSIS FORM INSTALLATION INSTRUCTION DRAWINGS REVISION B 06/20/01 PAGE 28