2000 SERIES SPEEDBRAKE INSTALLATION MANUAL STC NO. SA2602NM

Transcription

1 INSTALLATION REPORT NO Serial Number PRECISE FLIGHT, INC SERIES SPEEDBRAKE INSTALLATION MANUAL CESSNA 210G, T210G, 210H, 210J, 210K, T210J, 210L, T210L, 210M, T210M, 210N, P210N, T210N, P210R, T210R, 210R, T210H 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 C 04/16/2001 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 UPPER WING CUTOUTS...6 C.1. FIGURE UPPER WING TEMPLATE...6 D. RIVET REMOVAL...7 E. UPPER DOUBLER PLACEMENT...8 E.1. FIGURE UPPER DOUBLER PLACEMENT...8 F. UPPER WING CUTOUTS...9 F.1. FIGURE UPPER WING CUTOUT...9 G. LOCATING LOWER WING CUTOUTS...10 H. LOWER WING CUTOUTS...11 H.1. FIGURE LOWER WING CUTOUT...12 I. UPPER DOUBLER INSTALLATION (PRELIMINARY)...13 J. UPPER DOUBLER INSTALLATION...14 K. SPEEDBRAKE CARTRIDGE INSTALLATION (TEMPORARY)...15 L. LOWER DOUBLER ASSEMBLY & INSTALLATION...17 M. WING BAY STIFFNER ATTACHMENT...18 N. EXTERIOR PANEL AND INTERIOR REMOVAL...19 O. INSTALLING THE ASSYMETRIC LOGIC CONTROL (ALC) - NON PRESSURIZED...20 P. INSTALLING THE ASSYMETRIC LOGIC CONTROL (ALC) - PRESSURIZED...21 Q. WIRING THE SPEEDBRAKE CARTRIDGES TO THE ALC - NON PRESSURIZED...22 R. WIRING THE SPEEDBRAKE CARTRIDGES TO THE ALC - PRESSURIZED...24 V. SPEEDBRAKE CARTRIDGE INSTALLATION (PERMANENT)...30 W. PLACARDS...31 X. SPEEDBRAKE OPERATIONAL TEST...32 Y. DOCUMENTATION...33 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...34 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS...35 APPENDIX A...36 PARTS LIST...36 ELECTRICAL LOAD ANALYSIS FORMS...36 INSTALLATION INSTRUCTION DRAWINGS S S S S S S S S S0015 REVISION C 04/16/2001 PAGE 2

3 R E V I S I O N S REV NO. PAGE DESCRIPTION DATE NAME - A All All Initial release Added Attachment Angle P/N & Dwg. 10/26/99 11/19/99 STP EWL 211S0004 B All Revised P-210 Instructions 02/03/00 EWL C 35, 20,21 Revised Annual CONTA instructions Revised ALC Part Number 04/16/01 DJC REVISION C 04/16/2001 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. Cutting oval openings in the bottom of each wing skin using locating templates. 3. Installing doublers to reinforce the cutout areas, requiring removing and replacing existing rivets. 4. Installing stiffener angles to reinforce wing bays. 5. Wiring the SpeedBrakes will require removing co-pilot side panels, wing and wing spar inspection panels. 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. 6. Reinstalling all removed panels and interior. 7. Functionally check SpeedBrakes. 8. Filling out necessary FAA paperwork to return the aircraft to service. Each section will include a list of tools and parts required. REVISION C 04/16/2001 PAGE 4

5 B. LIST OF Automatic center punch Barrel sander: 2 Bucking bars Carbon paper: 8.5 x11 Chip chaser Clecos: 3/32, 1/8, and side grip clamps Cleco pliers Copy of AC B Countersink: 100 Die grinder with abrasive cutter wheel Drills: #40, #30, #19,.300, and 5/8 and ¾ capacity Unibit Drill motor Drill motor: Right Angle Felt marker: Ultra fine point Files: ¼ round and 6 flat Inspection mirror Masking tape: ¾ Needle nose pliers Pencil ProSeal: A1/2, B1/2 Rivet gun: with flush set, 1/8 inch set /8, 3/32 Rivet Squeezer Ruler: 12 (minimum) Screwdriver: Phillips #1 and #2 tip Snips: Prosnip offset snips 20SR, 20SL or equivalent Soldering iron Solder: rosin core Tape measure: 12 minimum Volt-Ohm meter Wire crimper, cutter, and stripper 3M adhesive or equivalent 11/32 Wrench PRESSURIZED ONLY Crimp Tool (P/N M22S ) Extraction Tool (P/N MS24256R20) Insertion Tool (P/N MS24256A20) Panel Punch: ¾ (Maximum Hole Size ¾ ) REVISION C 04/16/2001 PAGE 5

6 C. LOCATING UPPER WING CUTOUTS Automatic center punch Masking tape Tape Measure 211S Upper Left Wing Template 211S Upper Right Wing Template LEFT WING 1. Using template 211S0005-1, place the template on the Left Aircraft Wing between Wing Stations and and align template with the critical rivet line. Adjust template so that the row of rivets marked CRITICAL RIVET LINE maintain a 2D edge clearance on doubler edge as shown on template. Once aligned, secure the template to the wing skin using masking tape. 2. Identify and mark the 16, #4 existing rivets to be removed. 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 right wing using Template 211S C.1. FIGURE UPPER WING TEMPLATE REVISION C 04/16/2001 PAGE 6

7 D. RIVET REMOVAL Drills: #30 Drill motor LEFT WING 1. On the left 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 two, #30 CORNER RIVET LOCATION holes. 4. Repeat steps 1 thru 3 on the right wing. REVISION C 04/16/2001 PAGE 7

8 E. UPPER DOUBLER PLACEMENT Clecos: 1/ Upper Doubler Cleco pliers 211S Left Template Drills: #30, S Right Template Drill motor Deburr tool Felt marker: Ultra fine line LEFT WING SKIN 1. On the upper left wing, cleco the Upper Doubler (P/N 04685) onto the wing skin using the 2 corner rivet location holes and 2, 1/8 clecos. See Template 211S 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. Using a #32 drill, drill through the 8 cartridge mounting holes in the doubler as shown on the template. 4. With an ultra fine felt marker or carbon paper trace the wing cutout onto the wing skin. This line will be used in making the cutout in the wing skin. 5. Remove the doubler and identify it as the Left Wing then set aside and deburr all holes. 6. Repeat steps 1 thru 4 on the right wing using upper doubler (P/N 04685). See Template 211S E.1. FIGURE UPPER DOUBLER PLACEMENT REVISION C 04/16/2001 PAGE 8

9 F. UPPER WING CUTOUTS Die grinder w/ abrasive cutter Upper Doubler Drill: ¼ Drill motor 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: LEFT 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-inch flat files. 6. Cleco the Upper Doubler on top of the wing skin and finish filing the opening to the doubler. 7. Repeat steps 1 thru 6 on the Right Wing. NOTE: The cutouts will be the finished product. Care must be taken when finishing these openings. F.1. FIGURE UPPER WING CUTOUT REVISION C 04/16/2001 PAGE 9

10 G. LOCATING LOWER WING CUTOUTS Automatic center punch Masking tape Tape Measure 211S Lower Left Wing Template Carbon Paper 8.5 x S Lower Right Wing Template LEFT WING 1. Using template 211S0006-1, place the template on the lower left aircraft wing between Wing Stations and and align template with the CRITICAL RIVET LINE. Once aligned, secure the template to the wing skin using masking tape. 2. Transfer the INSIDE OVAL to the wing skin using Carbon Paper and the Lower Doubler (P/N 04684). 3. Transfer the DRAIN HOLE location using an automatic centerpunch. 4. Remove the template partially and leave attached to the wing for accurate alignment later. 5. Repeat steps 1 thru 4 on the Right Wing using Template 211S REVISION C 04/16/2001 PAGE 10

11 H. LOWER WING CUTOUTS Die grinder w/ abrasive cutter Drum Sander: 2 211S Lower Left Wing Template Drill: ¼, #40,.300 Felt Marker: Ultra Fine Line 211S Lower Right Wing Template Drill motor: Right Angle Lower Doubler Files: ¼ round & 6 flat Access Cover Snips: 20SR, 20SL Deburr tool Carbon paper 8.5 x 11 Pencil Various methods may be employed to make the cutouts in the wings. Use Extreme Care! It has been proven helpful to do the following: LEFT WING 1. Mask off the wing around the area to be cut. 2. Drill a ¼ hole well inside all radiuses. 3. Using a die grinder and abrasive cutter, or snips, cut lines between the holes, staying well within the traced lines. 4. Place the Lower Doubler (P/N 04684) inside the wing and verify it does not overlap the stringer edges. Adjust as necessary inside the wing. 5. Clamp the Lower Doubler in place inside the wing and drill the TRANSFER RIVET LOCATIONS using a right angle drill and a #40 drill bit. 6. Cleco the Lower Doubler outside the lower wing skin and transfer the rest of the 16 rivet locations using the #40 drill. 7. Re-align the template on the hole pattern drilled in the previous step. Using carbon paper and a pencil or ultra fine line marker, transfer the final WING CUTOUT to the wing skin. 8. Finish the cutout using the die-grinder, drum sander, round and flat files. Use the Lower Doubler and Access Cover (P/N 04683) to check cutout size. Take Care! This will be the finished product! 9. Remove the Lower Doubler and identify it as the Right Wing and set aside. REVISION C 04/16/2001 PAGE 11

12 10. Drill the DRAIN HOLE using a.300 drill and deburr. 11. Repeat steps 1 thru 10 on the Right Wing. NOTE: The cutouts will be the finished product. Care must be taken when finishing these openings. H.1. FIGURE LOWER WING CUTOUT REVISION C 04/16/2001 PAGE 12

13 I. UPPER DOUBLER INSTALLATION (PRELIMINARY) Chip chaser Upper Doubler Clecos: 1/8 211S Upper Left Wing Cleco pliers Deburr tool Drills: #30 Drill motor Drills: #30 Felt marker: Ultra fine line Template 211S Upper Right Wing Template The upper doublers are positioned under the skin and on top of the stringers. LEFT WING 1. Reference drawing template 211S Insert the Upper Doubler (P/N 04685) into the wing through the lower cutout. 3. Position the Upper Doubler between the skin and stringers. 4. Orient the holes in the Upper Doubler with the holes in the wing skin and cleco in place. NOTE: The Upper Doubler may need to be trimmed to allow hole alignment. Insure that 2D rivet spacing is maintained after trimming. 5. Using a felt tip marker, transfer the rivet location for the stringers onto the doubler 6. Remove clecos and Doubler, confirm 2D edge distance on all holes. 7. Position the Upper Doubler again between the skin and stringers and cleco in place. 8. Using a #30 drill, drill through the skin into the Upper Doubler on all the rivets previously removed from the stringer. 9. Remove the Upper Doubler and deburr. Remove all bucked ends and any chips inside the wing. 10. Repeat steps 1 thru 9 on the Right Wing. Reference Drawing #211S REVISION C 04/16/2001 PAGE 13

14 J. UPPER DOUBLER INSTALLATION Bucking bars 211S Drawing Template Clecos: 1/8 211S Drawing Template Cleco pliers Upper Doubler Rivet gun Rivets Pro-Seal: B-1/ Rivets Isopropyl Alcohol LEFT WING Reference Drawings 211S & 211S Place a layer of Pro-Seal on the wing side of the upper doubler. 2. Insert the Upper Doubler (P/N 04685) through the opening in the lower wing skin. 3. Position the Upper Doubler between the upper wing skin and stringers. Orient with the cutout in the top skin and the previously drilled holes. 4. Cleco the Upper Doubler in place. 5. Rivet the Upper Doubler in place. Reference Drawing # 211S and 211S for correct rivets. 6. Clean the excess Pro-Seal with a rag and Isopropyl Alcohol. 7. Repeat steps 1 thru 6 on the right wing using. REVISION C 04/16/2001 PAGE 14

15 K. SPEEDBRAKE CARTRIDGE INSTALLATION (TEMPORARY) Clecos: 1/8 Cleco pliers 211S Drawing 8-32 Screws Drill bits: #19, #30 Drill motor #8 Washer 8-32 Nut Double back tape Safety Pin Deburr tool Cartridge Hinge Screw driver: Phillips #2 Zinc Chromate L &05097R 05115L &05114R OR 2 Extruded Angle Attachment Angle Attachment Angle Cartridge Assy. 12V Cartridge Assy. 24V REVISION C 04/16/2001 PAGE Screws Snap Bushing LEFT WING IMPORTANT: Reference Drawing #211S 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 left wing installation. 2. Enlarge the 4 holes in one Extruded Angle (P/N 04652) using a #19 drill and deburr. Install on the outboard end of the cartridge using 2 screws (P/N 00436). Enlarge 2 holes on a Cartridge Hinge (P/N 04645) using a #19 drill and deburr. Install on the Extruded Angle using the 8-32 hardware provided (P/N 00436), (P/N 00452), (P/N 00485). 3. Enlarge 2 holes on another Cartridge Hinge (P/N 04645) using a #19 drill and deburr. Install on the inboard end of the cartridge using 2 screws (P/N 00436). 4. Place the SpeedBrake cartridge through the lower wing cutout and orient with the Upper Doubler. 5. Zinc Chromate the drain hole and install a Snap Bushing (P/N 06062). 6. Install the SpeedBrake cartridge with the supplied 4-40 screws (P/N 07021). IMPORTANT NOTE: The supplied screws are the proper length - Use of alternate screws to attach the install the cartridges will interfere with proper SpeedBrake operation and will compromise the component warranty. 7. Attach the Attachment Hinges (P/N 04644) to the Cartridge Hinges using Safety Pin (P/N 06024). Reference Drawing #211S0003 for correct alignment.

16 8. Attach double back tape to the outside flanges of the Attachment Angles (P/N & P/N 04688). Using Drawing # 211S0003 as reference, attach Attachment Angles (P/N 04690) to the outboard trailing edge Attachment Hinge and to the side of the rib. Using a #30 drill, drill 2 holes through the Attachment Angle into the rib. Be sure to maintain a 2D edge distance with holes. Cleco in place. Mark the 2 holes where the Attachment Hinge contacts the Attachment Angle. 9. Remove the outboard Attachment Angle (P/N 04690) and drill the 2 holes using a #30 drill. Replace the outboard Attachment Angle and cleco in place. 10. Place the inboard Attachment Angle (P/N 04688) so that it covers 2 of the existing rivets running vertical on the rib. Check to ensure that 2D edge distance is maintained. Mark the 2 rivets and remove using the appropriate drill size. 11. Using Drawing #211S0003 as reference, attach the inboard Attachment Angle to the inboard trailing edge Attachment Hinge and to the side of the rib, covering the 2 removed rivets. Mark the 2 removed rivet locations on the Attachment Angle. Mark the two holes where the Attachment Hinge contacts the Attachment Angle. 12. Remove the inboard Attachment Angle and drill the 4 holes using a #30 drill. Replace the inboard Attachment Angle and cleco in place. 13. Enlarge the 4 holes in each Attachment Angle and 2 holes in each rib with a #19 drill and deburr. 14. Enlarge the 2 holes in each double tabbed Cartridge Hinge with a #19 drill and deburr. 15. Zinc Chromate the two holes in each rib to prevent corrosion. 16. Using Drawing #211S0003 as reference for position and hardware, install the Attachment Hinges and Attachment Angles as shown. 17. Remove the Safety Pins (P/N 06024) and remove the SpeedBrake from the wing. 18. Repeat Steps 1 thru 16 for the right wing. REVISION C 04/16/2001 PAGE 16

17 L. LOWER DOUBLER ASSEMBLY & INSTALLATION Bucking bars or Rivet Sqzr Lower Doubler Clecos: 3/ Access Cover Cleco pliers Rivets Rivet gun Rivets Countersink Tool: Nutplates LEFT WING Reference Drawings 211S0006-1, 211S0006-2, & 211S Countersink the 12 rivet holes that hold the nutplates in the Lower Doubler (P/N 04684). 2. Rivet the nutplates (P/N 07035) onto the Lower Doubler using the provided rivets (P/N 00486). 3. Place the completed Lower Doubler in the wing and cleco in place. 4. Check that the Lower Doubler opening is large enough for the Access Cover (P/N 04683). 5. Rivet the Lower Doubler in place using the provided rivets (P/N 07006) 6. Repeat steps 1 thru 5 on the right wing. REVISION C 04/16/2001 PAGE 17

18 M. WING BAY STIFFNER ATTACHMENT Copy of AC B Chp. 11 Tape Measure Deburr Tool 211S S Left Template Right Template Rivets Rivet gun Stiffener Angle Automatic centerpunch Bucking bars Clecos: 1/8 Cleco Pliers Drills: #30 Drill motor RIGHT WING Reference Drawing #211S & 211S Using template 211S0007-2, place the template on the Right Wing between Wing Stations and and align template with the critical rivet line. Once aligned, secure the template to the wing skin using masking tape. 2. Identify and mark the 3, new rivet holes to be drilled. 3. Center punch transfer the hole closest to the leading edge and drill using a #30 drill. 4. Cleco the Stiffener Angle (P/N 04691) to the wing skin with the flange towards the wing root. 5. Align the Stiffener Angle with the remaining holes on the template. Use the Stiffener Angle as a drill guide and drill the remaining 2 #30 holes and deburr. Remove all chips inside the wing. 6. Remove the template and set aside. 7. Place the Stiffener Angle through the inspection panel on the bottom of the wing and cleco in place with the flange towards the wing tip using 1/8 clecos. 8. Rivet the Stiffener Angle in place using rivets (P/N 00480). Cherry-Max 4-3 rivets may be substituted since limited space is available to buck the rivets. 9. Repeat steps 1 thru 8 on the left wing using Template 211S REVISION C 04/16/2001 PAGE 18

19 N. EXTERIOR PANEL AND INTERIOR REMOVAL Screw drivers: Phillips #2, #1 Needle Nose Pliers 1. Disconnect all electrical power from aircraft. 2. Remove the front seats. For a P210 remove the mid seats. 3. Remove co-pilot s side panel molding. 4. Remove the main spar inspection panels out to the SpeedBrake cartridges. 5. Remove the inspection panels aft of the main spar out to the SpeedBrake cartridges. 6. Remove the lower wing root fairings. 7. Remove the headliner only as necessary in the following steps. REVISION C 04/16/2001 PAGE 19

20 O. INSTALLING THE ASSYMETRIC LOGIC CONTROL (ALC) - NON PRESSURIZED Copy of AC B Chp S Drawing Drills: # ALC Assembly Drill motor Nut Screw driver: Phillips # Screw Zinc Chromate #8 Washer RIGHT WING LARGE INSPECTION PANEL 1. Reference drawing 211S Place the ALC (P/N 05191) in place at Wing Station Mark holes with felt marker and dimple with automatic center punch. 2. Drill 4 holes using a #19 drill, and deburr. 3. Zinc Chromate the 4 holes for corrosion protection. 4. Install the ALC as shown using the four 8-32 screws, #8 washers, and 8-32 nuts (P/N s 00722, 06048, 00485) 5. Check to ensure that ALC unit installation does not interfere with any other aircraft system. REVISION C 04/16/2001 PAGE 20

21 P. INSTALLING THE ASSYMETRIC LOGIC CONTROL (ALC) - PRESSURIZED Copy of AC B Chp S Drawing Isopropyl Alcohol ALC Assembly Scotch Brite Nut Screw driver: Phillips # #8 Washer Zinc Chromate Click Bond Studs Click Bond Epoxy FUSELAGE AFT CABIN FLOOR 1. Place the Click Bond Studs (P/N 06071) on the ALC using the four #8 washers and 8-32 nuts (P/N s 06048, 00485). 2. Reference drawing 211S Place the ALC (P/N 05191) in place on the cabin floor at Fuselage Station 100. Be sure that the ALC clears all rivets and screws. Trace around the Click Bond Studs with an ultra fine line marker. Remove the ALC. 3. Using Scotch Brite and Isopropyl Alcohol, remove the paint inside the traced lines being sure that the Click Bond Studs will not come in contact with any paint. 4. Place the ALC in position and trace again around the Click Bond Studs. 5. Remove the Click Bond Studs from the ALC and place in the 3M plastic holders. Bond the studs to the cabin floor using the bonding instructions and Epoxy (P/N 06072) provided with the studs. Be sure to place the studs within the traced lines. Allow proper bonding time before installing ALC. 6. Install the ALC as shown using the four #8 washers and 8-32 nuts (P/N s 06048, 00485) 7. Check to ensure that ALC unit installation does not interfere with any other aircraft system. REVISION C 04/16/2001 PAGE 21

22 Q. WIRING THE SPEEDBRAKE CARTRIDGES TO THE ALC - NON PRESSURIZED Copy of AC B Chp. 11 Tape Measure Needle nose pliers 211S S Drawing Drawing Pin Screw driver: Phillips #1, # Plug Soldering iron Solder: rosin core Drill motor Wire holder Sockets Plug Drills: Pin extractor Volt-Ohm meter inches Wire harness Wire crimper, cutter, & stripper Sockets Snap Bushings Deburr tool Zinc Chromate RIGHT WING LOWER Reference Drawing # 211S0003, 211S In the forward main spar inspection panel directly in front of the SpeedBrake bay, drill a.310 hole in the center of the main spar web. Use existing holes if possible. 2. Deburr and Zinc Chromate the hole for corrosion protection. 3. Install a Snap Bushing (P/N 06062) in the hole. 4. Route the Wire Harness (P/N 02029) from the Right SpeedBrake cutout in the wing, through the main spar, and inboard to the ALC mount in the Right Wing root. Allow for routing through the wing with sufficient slack at both ends, and cut the Wiring Harness (P/N 02029). Save the scrap. Secure the wire according to AC B, Chapter On the ALC end of the Wiring Harness strip the jacket back exposing 5/8 of conductors. 6. Remove ¼ of insulation from all conductors. 7. Solder the end of each wire to the short end of a Pin (P/N 01725). 8. Insert the ends through the Wire Holder (P/N 01727). 9. Referring to Drawing #211S0004 for color to pin code, insert the Pins into their respective holes in the Plug (P/N 01729). REVISION C 04/16/2001 PAGE 22

23 10. Attach the Wire Holder (P/N 01727) to the Plug (P/N 01729). Tighten the strain relief to the jacket. 11. Connect the ALC Plug and Wire Harness Plug together. On the SpeedBrake end of the Wiring Harness, strip the jacket back exposing 5/8 of conductors. 12. Repeat Steps 6 thru 10 on the SpeedBrake end of the Wiring Harness using (P/N 01728), (P/N 01726), (P/N 01727). 13. For the Left SpeedBrake cartridge, repeat Steps 1 thru 13, routing the wire through the cabin in front of the main spar and above the headliner to the ALC location. 14. Check to insure that cable routing does not interfere with any other aircraft systems. REVISION C 04/16/2001 PAGE 23

24 R. WIRING THE SPEEDBRAKE CARTRIDGES TO THE ALC - PRESSURIZED Copy of AC B Chp. 11 Ruler: 12 inch Screw driver: #2 Phillips Soldering iron Solder: rosin core Needle nose pliers 211S S S Volt-Ohm meter Plug Drawing Drawing Drawing 4-40 Nuts #4 Washer Pin Wire crimper, cutter, stripper Drill:.300 Drill Motor: Right Angle Wire holder Socket Plug Panel Punch: ¾ Pin extractor LEFT WING SPEEDBRAKE Reference Drawing # 211S0001, 211S0004, 211S inches Wire harness 4-40 Screw Blkhd Receptacle Cannon Plug Assy. Cannon Plug Assy Sockets Snap Bushings 1. In the forward main spar inspection panel directly in front of the SpeedBrake bay, drill a.300 hole in the center of the main spar. 2. Zinc Chromate the hole for corrosion protection. 3. Install a Snap Bushing (P/N 06062) in the hole. 4. Carefully measure the distance from the Right SpeedBrake cutout in the wing, to the Right Wing Root Bulkhead Receptacle. Allow for routing through the wing with sufficient slack at both ends, then cut the Wiring Harness (P/N 02029). Save the scrap. 5. Repeat Steps 1 through 4 for the Left Wing. 6. Reference Drawing # 211S0015. Using the appropriate size drill, drill a hole for the panel punch bolt. NOTE: Before drilling any holes, be sure that both sides of the bulkhead are clear of obstacles and provide adequate room for each connector! Make the bulkhead receptacle hole using a ¾ Panel Punch. NOTE: Be sure that the panel punch makes a final REVISION C 04/16/2001 PAGE 24

25 hole size of ¾! Use a deburring tool to enlarge the hole size enough that the Bulkhead Receptacle can be inserted. 7. Reference Drawing # 211S0015. Install Bulkhead Receptacle (P/N 02408) with gasket through the Bulkhead at the Right Wing root from the cabin side. Be sure that the long portion of the receptacle is placed through the Bulkhead. Use 4-40 hardware (P/N s 02073, 01312, 01291) to secure Receptacle to the Bulkhead. Use Pro-Seal A-1/2 on the inside and outside of the Bulkhead Receptacle to seal the cabin. 8. Repeat Steps 6 and 7 on the Left Wing Root. Reference Drawing # 211S Route the Wiring Harness from the Bulkhead Receptacle along the existing wire harness in the main spar inspection panels, and through the snap bushing into the SpeedBrake bay. Allow sufficient slack at both ends. Secure the wire according to AC B, Chapter On the SpeedBrake end of the Wiring Harness strip the jacket back exposing 5/8 of conductors. 11. Remove ¼ of insulation from all conductors. 12. Solder the end of each wire to the short end of a Socket (P/N 01728). 13. Insert the ends through the Wire Holder (P/N 01727). 14. Referring to Drawing #211S0004 for color to pin code, insert the sockets into their respective holes in the Plug (P/N 01726). 15. 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. 16. At the wing root, strip the wiring harness jacket back exposing 5/8 of conductors. 17. Remove ¼ of insulation from all conductors. 18. Crimp the end of each wire to the short end of a Pin in (P/N 02410). 19. Insert the ends through the Strain Relief in (P/N 02410). 20. Referring to Drawing #211S00015 for color to pin code, insert the sockets into their respective holes in the Plug in (P/N 02410). 21. Attach the Wire Holder to the Plug. Tighten the strain relief to the jacket. Check for pin continuity with a Volt-Ohm meter. 22. Connect the Bayonet Plug and Bulkhead Wire Receptacle together. 23. On the cabin side of the Right Wing root, at the Bulkhead Receptacle, route the remaining wire harness along the existing wire harness, down the doorpost, along the co-pilot s side wall wiring harness back to the ALC. NOTE: Be sure to keep wiring harness clear of aileron cable and pulley, and clear of fuel lines. Secure the wire according to AC B, Chapter At the Bulkhead Receptacle, strip the wiring harness jacket back exposing 5/8 of conductors. 25. Remove ¼ of insulation from all conductors. REVISION C 04/16/2001 PAGE 25

26 26. Crimp the end of each wire to the short end of a Socket in (P/N 02409). 27. Insert the ends through the Strain Relief in (P/N 02409). 28. Referring to Drawing #211S00015 for color to pin code, insert the sockets into their respective holes in the Plug in (P/N 02410). 29. Attach the Wire Holder to the Plug. Tighten the strain relief to the jacket. Check for pin continuity with a Volt-Ohm meter. 30. Connect the Bayonet Plug and Bulkhead Wire Receptacle together. 31. On the ALC end of the Right Wing Wiring Harness strip the jacket back exposing 5/8 of conductors. 32. Remove ¼ of insulation from all conductors. 33. Solder the end of each wire to the short end of a pin (P/N 01725). 34. Insert the ends through the Wire Holder (P/N 01727). 35. Referring to Drawing #211S0004 for color to pin code, insert the sockets into their respective holes in the Plug (P/N 01729). 36. 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. 37. Repeat Steps 8-35 for the Left wing. For Step 23 route the Wire Harness down the door post and behind the instrument panel utilizing an existing wire harness to secure. Then route the Wire Harness along the co-pilot s sidewall with the other SpeedBrake Wire Harness. NOTE: Be sure to keep wiring harness clear of aileron cable and pulley, and clear of fuel lines. Secure the wire according to AC B, Chapter 11. REVISION C 04/16/2001 PAGE 26

27 S. WIRING THE ASSYMETRIC LOGIC CONTROL (ALC) NON-PRESSURIZED Copy of AC B Chp S Drawing Needle nose pliers Plug Wire crimper, cutter, & stripper Wire Holder Soldering iron Solder: rosin core inches Socket Wire Harness 1. Route the remaining Wire Harness Cable (P/N 02029) from the ALC mount in the Right Wing, through the wing root, into the cabin behind the headliner and with the existing wire harness, down the co-pilot s side panel, and behind the 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 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 #211S0004 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. 8. Connect the ALC Plug and Wire Harness Plug together. On the Instrument Panel end of the Wiring Harness, strip the jacket back exposing 5/8 of conductors. 9. Check to ensure that cable routing does not interfere with any other aircraft system. REVISION C 04/16/2001 PAGE 27

28 T. WIRING THE ASSYMETRIC LOGIC CONTROL (ALC) - PRESSURIZED Copy of AC B Chp S Drawing Needle nose pliers Plug Wire crimper, cutter, & stripper Wire Holder Screwdriver: Soldering iron Solder: rosin core inches 1 1 Socket Wire Harness Cannon Plug Assy. Cannon Plug Assy. 1. Route the remaining Wire Harness Cable (P/N 02029) from the ALC mount in the aft cabin to the back of the instrument panel. Route the Wire Harness along the co-pilot s side wall. Leave sufficient slack behind the instrument panel to connect the circuit breaker, switch, and annunciator. 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 #211S0004 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. 8. Connect the Wire Harness Plug and ALC Plug together 9. Check to ensure that cable routing does not interfere with any other aircraft system. REVISION C 04/16/2001 PAGE 28

29 U. CIRCUIT BREAKER AND SWITCH Copy of AC A Chp S Drawing Drills: 7/16, 5/8 capacity Unibit 211S Drawing Drill motor Soldering iron Solder: rosin core Volt Bulb 12 Volt Bulb Circuit breaker Needle nose pliers Lens Wire crimper, cutter, & stripper Mylar Placard Reference Drawing #211S0002 & 211S0004 Switch Option I Switch Kit 1. At the instrument panel, install and wire the Circuit Breaker (P/N 01270). Reference Drawing # 211S0004 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 # 211S0002, 211S0004, and AC B Chapter 11 for reference. NOTE: For switch and light locations other than that shown, obtain separate FAA engineering approval. REVISION C 04/16/2001 PAGE 29

30 V. SPEEDBRAKE CARTRIDGE INSTALLATION (PERMANENT) Screw driver: Phillips #2 211S Drawing Access Cover Safety Pins Screws Screws 05097L &05097R 2 Cartridge Assy. 12V OR 05115L &05114R 2 Cartridge Assy. 24V LEFT WING 1. Clean any metal filings and chips from the wing. 2. Attach the wiring harness to the cartridge. Insert cartridge into the lower wing opening insuring that the drain tube is fed through the snap bushing. Insert Safety Pins (P/N 06024) into the outboard and inboard hinges. 3. Install the SpeedBrake cartridge with the supplied 4-40 screws (P/N 07021). 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. 4. Secure the wiring harness in accordance with AC B Chapter Trim drain tube ¼ from wing skin. 6. Reinstall all inspection panels and SpeedBrake Access Cover (P/N 04683). 7. Repeat Step 1 through 6 for the right wing. 8. Check to ensure that cable routing does not interfere with any other aircraft system. 9. Reinstall interior. REVISION C 04/16/2001 PAGE 30

31 W. 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 C 04/16/2001 PAGE 31

32 X. 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, 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 C 04/16/2001 PAGE 32

33 Y. 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 64.3 in. and Precise Flight ALC at 1-lbs. at 69.0 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 C 04/16/2001 PAGE 33

34 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. 211S0016 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 C 04/16/2001 PAGE 34

35 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS CESSNA 210/P210 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 C 04/16/2001 PAGE 35

36 APPENDIX A PARTS LIST ELECTRICAL LOAD ANALYSIS FORMS INSTALLATION INSTRUCTION DRAWINGS REVISION C 04/16/2001 PAGE 36