CIRRUS AIRPLANE MAINTENANCE MANUAL Flaps System CHAPTER 27-50: FLAPS SYSTEM GENERAL 27-50: FLAPS SYSTEM 1. General This section describes that portion of the flight control system which controls the position and movement of the flaps. Included are the flap assembly, flap actuator assembly, torque tube assembly, flap switch assembly, flap switch panel, and flap relays. Flap control is achieved via a flap activation switch mounted on the center console. Indicator lights identify flap position. A linear actuator, located under the baggage floor, drives a torque tube interconnect between the left and right flaps. A load limiting clutch on the actuator prevents flap deployment at high speeds. Proximity sensors on the flap linear actuator identify flap position and surface travel. In the event of a sensor failure, torque tube/actuator geometry prevents the flaps from causing an uncontrollable flight condition. Electromagnetic Interference Suppression (EMI) cores are integral to the flap system wire harness. 1
CHAPTER 27-50: FLAPS SYSTEM 2. Maintenance Practices CIRRUS AIRPLANE MAINTENANCE MANUAL A. Flap Actuator Assembly (See Figure 27-50-1) (See Figure 27-50-2) (1) Removal - Flap Actuator Assembly CAUTION To prevent damage to flap hinges and flaps, tape flaps to wing prior to disconnecting flap actuator. (a) Pull FLAPS circuit breaker. (b) Remove passenger seats. (Refer to 25-10) (c) Remove carpet. (Refer to 25-10) (d) Remove access panels CF4C and CF5. (Refer to -00) (e) Serials w/ Air Conditioning: Remove condenser. (Refer to 21-50) (f) Remove cotter pin, nut, washers, and bolt securing flap actuator to torque tube coupler. (g) Disconnect flap actuator electrical connector. (h) Remove retainer rings and pin securing flap actuator assembly to mounting bracket. (i) Remove flap actuator assembly from airplane. (j) If replacing flap actuator with new assembly, remove screws securing collar at flap actuator shaft. Retain collar and screws. (2) Disassembly - Flap Actuator Assembly (a) (b) (c) (d) Loosen jam nut securing rod end to flap actuator end fitting. Remove rod end and jam nut. Loosen jam nut securing flap actuator end fitting to flap actuator. Remove end fitting. 2
CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 27-50: FLAPS SYSTEM (3) Assembly - Flap Actuator Assembly (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Threadlocker Loctite 242 Any Source Lock threads. (b) Back jam nut to bottom of flap actuator and install end fitting on actuator. (c) Bottom out end fitting onto flap actuator to ensure maximum thread engagement. (d) Apply threadlocker to jam nut thread area. (Refer to 20-40) (e) Torque jam nut 140.0 to 155.0 in-lb (15.8 to 17.5 Nm). (Refer to 20-0) (f) Bottom out jam nut onto rod end. (g) Install rod end into actuator end fitting and bottom out. Leave jam nut loose at this time. (4) Installation - Flap Actuator Assembly (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Threadlocker Loctite 242 Any Source Lock threads. (b) If secured, cut cable ties securing proximity sensor wiring to flap actuator. (c) Position flap actuator assembly to mounting bracket and secure with pin and retaining rings. (d) Manually extend actuator to approximately 50% full deployment. (e) Connect flap actuator electrical connector. (f) Reset FLAPS circuit breaker. (g) Turn flap switch to UP. (h) Set BAT 1 switch to ON position. (i) After flap actuator stops, turn flap switch to 50%. (j) Set BAT 1 switch to OFF position. (k) Loosen adjustment screws and reposition full up proximity sensor to within 1.0 inch (2.5 cm) of middle proximity sensor. 3
CHAPTER 27-50: FLAPS SYSTEM CIRRUS AIRPLANE MAINTENANCE MANUAL (l) Loosen adjustment screws and reposition full down proximity sensor to within 1.0 inch (2.5 cm) of middle proximity sensor. NOTE Stack-up order may be altered to allow for better alignment between flap actuator and torque tube coupler. (m) Install bolt and washers connecting rod end to torque tube coupler and secure with new nut. Do not install cotter pin at this time. (n) Remove tape securing flaps to wing. (o) If removed, position collar so that screws are seated against flats on flap actuator rod. Tighten screws securing collar to flap actuator rod. (p) Reset FLAPS circuit breaker. (q) Perform Adjustment/Test - Flap Travel. (Refer to 27-50) (r) If jam nut was loosely installed during flap actuator assembly: 1 Apply threadlocker to jam nut thread area. (Refer to 20-40) NOTE By design, the collar will deform when specified torque is applied to screws. 2 Tighten jam nut securing rod end to actuator end fitting. Torque jam nut 0.0 to 70.0 in-lb (.8 to 7.9 Nm). (Refer to 20-0) (s) Torque bolt securing rod end to torque tube coupler. (Refer to 20-0) (t) Install new cotter pin at attaching hardware securing rod end to torque tube coupler. (Refer to 20-70) (u) Install cable ties securing proximity switch wiring to flap actuator. (v) Set BAT 1 switch to ON position. (w) Rotate FLAPS switch to 100% position. (x) Rotate FLAPS switch to UP position. (y) Set BAT 1 switch to OFF position. (z) Serials w/ Air Conditioning: Install condenser. (Refer to 21-50) (aa) Install access panels CF4C and CF5. (Refer to -00) (ab) Install carpet. (Refer to 25-10) (ac) Install passenger compartment seats. (Refer to 25-10) 4
CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 27-50: FLAPS SYSTEM (5) Adjustment/Test - Flap Travel NOTE When in the 0% position, a minimum 0.05 inch (1.27 mm) clearance must be maintained between end fitting and torque tube coupler. When adjusting position proximity sensors, it may be necessary to lengthen actuator to achieve full 0% position. Accomplish by backing out rod end, but do not exceed 2 turns maximum. (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose WS 40 Wing Template 13057-101/-102 Cirrus Design Flap rigging. WS 132 Wing Template 13057-107/-108 Cirrus Design Flap rigging. Inclinometer PRO30 Macklanburg Duncan Deflection angle determination. NOTE Flap may exhibit a slight twist from root to tip. Average the inboard and outboard angle to set the neutral point. (b) Remove passenger compartment seats. (Refer to 25-10) (c) Remove carpet and access panels CF4C and CF5. (Refer to -00) (d) If secured, cut cable ties securing proximity sensor wiring to flap actuator. (e) Set BAT 1 switch to ON position. (f) Turn flap switch to UP. (g) Mark WS 132 reference line for left and right wing templates as follows: 1 From wing cuff, measure 1.75 inches inboard and mark. 2 From flap outboard edge, measure 10.7 inches inboard and mark. 3 Draw WS 132 reference mark line from leading edge to trailing edge. (h) Mark WS 40 reference line for left and right wing templates as follows: 1 From flap inboard edge, measure 1.75 inches outboard and mark. 2 From wing cuff, measure 90 inches inboard and mark. 3 Draw WS 40 reference mark line from leading edge to trailing edge. (i) Position WS 40 and WS 132 template on left and right wing to verify flaps are in full up position. 5
CHAPTER 27-50: FLAPS SYSTEM CIRRUS AIRPLANE MAINTENANCE MANUAL (j) If flaps are not in full up position, adjust flap actuator proximity sensor. 1 Turn flap switch to 50%. 2 Set BAT 1 switch to OFF position. NOTE For best results in determining proximity sensor location, do not move sensor more than 0.10 inch (2.5 mm) per positioning attempt. 3 Adjust full up proximity sensor by loosening screw and repositioning sensor on flap actuation extension tube. 4 Set BAT 1 switch to ON position. 5 Turn flap switch to UP. Using the templates, verify flaps are in full up position. 7 If necessary, repeat repositioning of proximity switch until flaps are in full up position. (k) Fasten inclinometer to inboard side of left flap and set at 0. (l) Turn flap switch to 100%. (m) Verify flap exhibits a 35.5 angle change. (n) If flaps are not in 100% deployed position, adjust flap actuator proximity sensor. 1 Turn flap switch to 50%. 2 Set BAT 1 switch to OFF position. NOTE For best results in determining proximity sensor location, do not move sensor more than 0.10 inch (2.5 mm) per positioning attempt. 3 Adjust 100% proximity sensor by loosening screw and repositioning sensor on flap actuation extension tube. 4 Set BAT 1 switch to ON position. 5 Turn flap switch to 100%. If necessary, repeat repositioning of proximity switch until flaps are in 100% deployed position. (o) Turn flap switch to UP. After flaps stop, turn flap switch to 50%. (p) Verify flap exhibits a 1 angle change. (q) If flaps are not in 50% deployed position, adjust flap actuator proximity sensor. 1 Turn flap switch to UP. 2 Set BAT 1 switch to OFF position.
CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 27-50: FLAPS SYSTEM NOTE For best results in determining proximity sensor location, do not move sensor more than 0.10 inch (2.5 mm) per positioning attempt. 3 Adjust 50% proximity sensor by loosening screw and repositioning sensor on flap actuation extension tube. 4 Set BAT 1 switch to ON position. 5 Turn flap switch to 50%. If necessary, repeat repositioning of proximity switch until flaps are in 50% deployed position. (r) Remove inclinometer from flap. (s) Verify operation of flaps circuit. 1 Activate flaps circuit from 0% position to 50% position and press Push-to-Talk Switch while flaps are in transit. Flaps shall travel to 50% position without hesitation and stop. 2 Activate flaps circuit from 100% position to 50% position and press Push-to-Talk Switch while flaps are in transit. Flaps shall travel to 50% position without hesitation and stop. 3 Activate flaps circuit from 50% position to 0% position. (t) Verify torque tube clearance. 1 Push torque tube all the way to the left. 2 Verify gap between left end of torque tube and nearest part of flap assembly, hinge, or linkage is at least 0.1 inch (2.54 mm). 3 Push torque tube all the way to the right. 4 Verify gap between right end of torque tube and nearest part of flap assembly, hinge, or linkage is at least 0.1 inch (2.54 mm). (u) Install cable ties securing proximity switch wiring to flap actuator. (v) Install carpet and access panels CF4C and CF5. (Refer to -00) (w) Install passenger compartment seats. (Refer to 25-10) 7
CHAPTER 27-50: FLAPS SYSTEM CIRRUS AIRPLANE MAINTENANCE MANUAL () Inspection/Check - Flap System Rigging (See Figure 27-50-1) NOTE The gap and overlap inspection of the following procedure need only be performed after the installation of a replacement (new or different) flap. If the following flap leading edge gap and overlap inspections do not fall within the specified clearances, contact Cirrus Design Customer Service for disposition. (Refer to AMM-Intro-00) (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose 90 Square - Any Source Flap rigging. (b) (c) (d) (e) Replacement Flap Installation Only: Verify flap gap and overlap. 1 Using 90 square with flaps fully extended, verify maximum gap between crown of flap and trailing edge of wing is 0.917±0.200 inch (2.33±0.50 cm) at root of the flap, and 0.958±0.200 inch (2.43±0.50 cm) at tip of flap. 2 Using 90 square with flaps fully extended, verify maximum overlap between leading edge of flap and trailing edge of wing is 1.512±0.200 inch (3.84±0.50 cm) at root of flap, and 0.52±0.200 inch (1.43±0.50 cm) at tip of flap. Verify flap UP, 50%, and 100% deployment positions. Verify minimum rod end thread engagement of 0.312 inch (0.79 cm). Verify proper installation of safety wires and cotter pins on all fasteners and engagement of all jam nuts through complete flap control system. 8
CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 27-50: FLAPS SYSTEM Figure 27-50-1: Flap Gap and Overlap Inspections SQUARE LEADING EDGE GAP OVERLAP Max. at Root of Flap Min. at Root of Flap Max. at Tip of Flap Min. at Tip of Flap Leading Edge Gap Overlap 1.117" 0.717" 2.83 cm 1.83 cm 1.712" 4.34 cm 1.312" 3.34 cm 1.158" 0.758" 2.93 cm 1.93 cm 0.72" 1.93 cm 0.32" 0.93 cm SR22_MM27_4484 9
CHAPTER 27-50: FLAPS SYSTEM CIRRUS AIRPLANE MAINTENANCE MANUAL B. Torque Tube Assembly (See Figure 27-50-2) (1) Removal - Torque Tube Assembly (a) Remove nuts, washers, spacers, and bolts securing torque tube thrust collar and end fitting to flap torque tube. (b) Remove passenger compartment seats. (Refer to 25-10) (c) Remove carpet and access panel CF4C. (Refer to -00) (d) Remove cotter pin, nut, washers, and bolt securing flap actuator push/pull rod to torque tube coupler. (e) Remove nuts, washers, spacers, and bolts securing torque tube coupler and torque tubes. (f) Withdraw torque tube from outboard tube bushing. (g) Withdraw torque tube coupler from inboard tube bushing. (2) Installation - Torque Tube Assembly (a) Insert torque tube coupler into inboard tube bushing. (b) Insert LH torque tube through outboard bushing into torque tube coupler. (c) Insert RH torque tube through outboard bushing into torque tube coupler. (d) Install bolts, washers, spacers, and nuts securing torque tube coupler and torque tubes. (e) Install bolts, washers, spacers, and nuts securing torque tube thrust collar and end fitting to flap torque tube. (f) Install bolt, washers, nut, and new cotter pin securing flap actuator push/pull rod to torque tube coupler. (g) Perform Adjustment/Test - Flap Travel. (Refer to 27-50) (h) Install access panel and carpet. (Refer to -00) (i) Install passenger compartment seats. (Refer to 25-10) 10
CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 27-50: FLAPS SYSTEM Figure 27-50-2: Flap Actuator and Torque Tube Installation (1 of 3) 17 14 1 18 15 12 5 12 1 14 11 12 4 12 13 A1 11 0% A1 2 FUSELAGE SKIN (REF) 50% 100% 8 7 3 12 9 10 11 NOTE Refer to sheet 2 for continuation. Collar Installation. Stack-up order may be altered to allow for better alignment between flap actuator and torque tube coupler. LEGEND 1. Flap Actuator 2. Proximity Sensor 3. Connector 4. Actuator End Fitting 5. Rod End. Washer 7. Bracket 8. Bushing 9. Pin 10. Retainer Ring 11. Screw 12. Nut 13. Collar 14. Bolt 15. Cotter Pin 1. Spacer 17. Torque Tube 18. Torque Tube Coupler SR22_MM27_4485 11
CHAPTER 27-50: FLAPS SYSTEM CIRRUS AIRPLANE MAINTENANCE MANUAL Figure 27-50-2: Flap Actuator and Torque Tube Installation (2 of 3) 8 14 20 AFT FLOOR LONGERON (REF) 21 17 17 14 21 FUSELAGE (REF) (LEFT SIDE SHOWN) 18 1 20 14 8 19 12 NOTE Refer to sheet 1 for continuation. LEGEND. Washer 8. Bushing 12. Nut 14. Bolt 1. Spacer 17. Torque Tube 18. Thrust Collar 19. Torque Tube End Fitting 20. Bushing Mount 21. Backing Plate SR22_MM27_448 12
CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 27-50: FLAPS SYSTEM Figure 27-50-2: Flap Actuator and Torque Tube Installation (3 of 3) 18 ACTUATOR SEAL (REF) 5 4 11 4 100% POSITION 2 18 13 5 4 4 NOTE Position collar so that screws are seated against flats on flap actuator rod. 0% POSITION VIEW A1 1 LEGEND 1. Flap Actuator 2. Proximity Sensor 4. Actuator End Fitting 5. Rod End 11. Screw 13. Collar 18. Torque Tube Coupler SR22_MM27_4487 13
CHAPTER 27-50: FLAPS SYSTEM CIRRUS AIRPLANE MAINTENANCE MANUAL C. Flap Switch Panel (See Figure 27-50-3) (1) Removal - Flap Switch Panel (a) (b) (c) (d) Pull FLAPS circuit breaker. Remove screws securing flap switch panel to engine control panel. Disconnect flap switch connector. Remove flap switch panel from airplane. (2) Installation - Flap Switch Panel (a) Connect flap switch connector. (b) Position flap switch panel to engine control panel and secure with screws. (c) Reset FLAPS circuit breaker. (d) Perform Operational Test - Flap Switch Panel. (Refer to 27-50) (3) Operational Test - Flap Switch Panel (a) (b) (c) (d) Set BAT 1 switch to ON position. Before testing the flaps system, verify flaps and flaps actuator are connected and no obstructions to movement are present. Set flaps switch to same position as current flaps position. Set flaps switch to "UP" position. Verify flaps position is up with "UP" LED illuminated. (e) Set flaps switch to "50%" position. Verify flaps position stops at 50% with "50%" LED illuminated. (f) Set flaps switch to "100%" position. Verify flaps position stops at 100% with "100%" LED illuminated. (g) Set flaps switch to "50%" position. Verify flaps position stops at 50% with "50%" LED illuminated. (h) Set flaps switch to "UP" position. Verify flaps position stops at up position with "UP" LED illuminated. 14
CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 27-50: FLAPS SYSTEM (i) (j) (k) Set flaps switch to "100%". While flaps are passing 50%, verify 50% LED only flashes once. Set flaps switch to "UP". While flaps are passing 50%, verify 50% LED only flashes once. Set BAT 1 switch to OFF position. 15
CHAPTER 27-50: FLAPS SYSTEM CIRRUS AIRPLANE MAINTENANCE MANUAL Figure 27-50-3: Flap Switch Panel Installation 1 3 2 ENGINE CONTROL PANEL (REF) LEGEND 1. Flap Switch Panel 2. Screw 3. Connector SR22_MM27_4488 1
CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 27-50: FLAPS SYSTEM D. Flap Relays (See Figure 27-50-4) (1) Removal - Flap Relay (a) Pull FLAPS circuit breaker. (b) Remove access panel CF3R. (Refer to -00) (c) Remove relay from socket. (2) Installation - Flap Relay (a) Position relay to socket and push firmly to install. (b) Install access panel CF3R. (Refer to -00) (c) Reset FLAPS circuit breaker. 17
CHAPTER 27-50: FLAPS SYSTEM CIRRUS AIRPLANE MAINTENANCE MANUAL Figure 27-50-4: Flap Relay Installation A RH LONGERON (REF) 3 ROLL RELAY (REF) 5 3 8 4 1 GROUND BUS (REF) 3 5 7 3 2 DETAIL A LEGEND 1. Mounting Plate, Forward 2. Screw 3. Washer 4. Spacer 5. Nut. Bolt 7. Relay Socket 8. Flap Relay SR22_MM27_4489 18