installation report no. 08095 aircraft serial · pdf fileremoving existing lower wing...

INSTALLATION REPORT NO. 08095 Document Number: 573SMAN0001

Aircraft Serial Number:

STC Number: SA00520SE PRECISE FLIGHT, INC. 63120 POWELL BUTTE ROAD BEND, OR 97701 800- 547-2558

REVISION: B January 8, 2008 PAGE i File: W:\Speedbrakes\573S\DOCS\Installation Manuals\573SMAN0001B.doc

PA-46-301P PIPER MALIBU / PA-46-350P MALIBU MIRAGE / PA-46R-350T MALIBU MATRIX

SPEEDBRAKE 2000 SERIES INSTALLATION MANUAL

AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

NOTICE The Airworthiness Limitations section (Section 4.0) is FAA Approved and Specifies maintenance required under Sections 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has

been FAA Approved.

These Documents must be Kept with the Aircraft Records

NOTE: READ THESE DIRECTIONS BEFORE STARTING!

NOTE:

CHECK FOR EQUIPMENT THAT MAY INTERFERE WITH THIS INSTALLATION BEFORE PROCEEDING! ALL WORK MUST BE DONE IN CONJUNCTION WITH

APPLICABLE AIRCRAFT MAINTENANCE MANUAL THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF PRECISE FLIGHT, INC. 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. IS STRICTLY FORBIDDEN.

PRECISE FLIGHT, INC. 63120 POWELL BUTTE ROAD

BEND, OR 97701 800- 547-2558

Installation Report: 08095

STC NO. SA00520SE - SPEEDBRAKE 2000 SERIES INSTALLATION MANUAL

REVISION: B January 8, 2008 PAGE ii File: � FILENAME \p W:\Speedbrakes\573S\DOCS\Installation Manuals\573SMAN0001B.doc

T A B L E O F C O N T E N T S

1.1. R E V I S I O N S iii 1.2. LIST OF ACTIVE PAGES iv

1. INSTALLATION OVERVIEW ......................................................................... 1-5 1.1. LIST OF TOOLS REQUIRED 1-2 1.2. 1-3 1.3. LIST OF SUPPLIES REQUIRED 1-3 1.4. LIST OF ABREVIATIONS 1-4

2. INSTALLATION INSTRUCTIONS ................................................................. 2-1 2.1. REMOVING EXISTING LOWER WING INSPECTION PANEL & DOUBLER 2-1 2.2. LOCATING NEW LOWER WING INSPECTION PANEL & DOUBLER 2-2 2.3. LOWER WING ACCESS COVER CUTOUT 2-3 2.4. UPPER WING CUTOUT 2-4 2.5. SPEEDBRAKE™ CARTRIDGE INSTALLATION (TEMPORARY) 2-7 2.6. UPPER DOUBLER BONDING 2-10 2.7. LOWER DOUBLER BONDING 2-12 2.8. PITOT TUBE INSTALLATION W/NEW ACCESS COVER PANEL 2-14 2.9. EXTERIOR PANEL AND INTERIOR REMOVAL 2-15 2.10. INSTALLING THE ASSYMETRIC LOGIC CONTROL (ALC) 2-16 2.11. FEEDTRHOUGH DOUBLER AND BULKHEAD FITTING INSTALLATION 2-17 2.12. WIRING THE SPEEDBRAKE™ CARTRIDGES TO THE ALC 2-19 2.13. WIRING THE ASSYMETRIC LOGIC CONTROL (ALC) 2-22 2.14. CIRCUIT BREAKER, SWITCH, AND ANNUNCIATOR 2-23 2.15. SPEEDBRAKE™ CARTRIDGE INSTALLATION (PERMANENT) 2-24 2.16. PLACARDS INSTALLATION 2-25 2.17. SPEEDBRAKE OPERATIONAL TEST 2-26 2.18. DOCUMENTATION 2-27

3. TROUBLE SHOOTING GUIDE....................................................................... 3-1 3.1. SPEEDBRAKE CARTRIDGE FAILS TO OPERATE CORRECTLY 3-1

4. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS .......................... 4-1

5. APPENDIX A ....................................................................................................... 5-4


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REVISION: B January 8, 2008 PAGE iii File: W:\Speedbrakes\573S\DOCS\Installation Manuals\573SMAN0001B.doc

R E V I S I O N S

REV PAGE DESCRIPTION EDITOR APP.

IR All Initial release DJC JNS

01/29/03 2/17/03

A All Updated Instructions for Continued Airworthiness, changed

document number to new numbering system.

JNS JNS

5/1/03 5/1/03

B All Added PA-46R-350t “Malibu Matrix” non-pressurized

aircraft.

JNS JNS

1/8/08 1/8/08


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REVISION: B January 8, 2008 PAGE iv File: W:\Speedbrakes\573S\DOCS\Installation Manuals\573SMAN0001B.doc

LIST OF ACTIVE PAGES

ORIGINAL ADDED PAGES

PAGE REV PAGE REV PAGE REV PAGE REV

i (Title) B

ii B

iii B

iv B

1-1 B

1-2 B

2-1 B

2-2 B

2-3 B

2-4 B

2-5 B

2-6 B

2-7 B

2-8 B

2-9 B

2-10 B

2-11 B

2-12 B

2-13 B

2-14 B

2-15 B

2-16 B

2-17 B

2-18 B

2-19 B

2-20 B

2-21 B

2-22 B

2-23 B

2-24 B

2-25 B

2-26 B

2-27 B

3-1 B

4-1 B

5-1 B


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REVISION: B January 8, 2008 PAGE v File: W:\Speedbrakes\573S\DOCS\Installation Manuals\573SMAN0001B.doc

1. INSTALLATION OVERVIEW

The installation of Precise Flight, Inc. SpeedBrakes™ consists of the following:

1. Debonding of existing inspection panel doubler in the bottom of each wing skin at WS

100.25.

2. Enlarging oval openings in the bottom of each wing skin using locating templates.

3. Cutting rectangular holes in the top wing skins using the templates and new doubler as

guides.

4. Installing / bonding new doublers to reinforce the new cutout in the upper wing skins.

5. Installing the SpeedBrake cartridges and side support brackets.

6. Installing / bonding new lower wing skin doublers to reinforce the enlarged areas.

7. Installing / bonding doublers and bulkhead fittings in each wing root through the pressure

vessel.

8. Wiring the SpeedBrakes™ will require removing pilot and co-pilot side panels, front seats,

and wing and wing spar inspection panels. Wires will then be run through the wing and

fuselage to a centrally located control unit.

9. Installing a circuit breaker to protect the system, a switch to actuate the system, and an

annuciator to indicate system function.

10. Functionally testing the SpeedBrake™ system.

11. Reinstalling all removed panels, interior, and touch-up painting if required.

12. Filling out necessary FAA paperwork to return the aircraft to service.


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REVISION: B January 8, 2008 PAGE 1-2 File: W:\Speedbrakes\573S\DOCS\Installation Manuals\573SMAN0001B.doc

LIST OF TOOLS REQUIRED

Each section will include a list of tools and parts required for the installation described in that

section. Table 1 includes a comprehensive list of the tools required for this installation.

Table 1 - List of Tools Required

FAA AC 43.13-1B: Acceptable Methods,

Techniques & Practices (or Later Revision)

Rivet Gun: 3/32 (#3)

Automatic Center Punch Rivet Squeezer: With Flush Set

Barrel Sander: 2” Ruler: 12” (Machinist Style)

Bucking Bars (Various) Scale: Ounce Or Gram

Chip Chaser Screwdriver: Phillips #1, #2 Tips, and Flat

Cleco Pliers Side Cutters

Clecos: 3/32” (#3), 1/8” (#4) Snips: Prosnip Offset Snips 20SR, 20SL or

Equivalent (Optional)

Countersink: 100° Wire Pin/Socket Extractor (Astro P/N

MS24256R20 or Equiv.)

Deburr Tool Soldering Iron (Optional – If Solder Type

Connector Contacts Are Used)

Die Grinder With Abrasive Cutter Wheel Solder: Rosin Core (Optional)

Drill Motor Tape Measure: 12’ Minimum

Drill Motor, Right Angle Volt-Ohm Meter

Drill Bits: #40, #30, #19, .300”, ¼” and ¾”

Capacity Welding Heat Control Crayons (250°F to

300°F Maximum)

Unibit Wire Pin/Socket Crimper (Daniels, Amp or

Astro Co. Models M22S20/2-01, M22S011-

01, Or Equivalent)

Files: ¼” Round And 6” Flat Wire Pin/Socket Insertion Tool (Astro P/N

MS24256A20 or Equivalent)

Infrared Thermometer (Optional - See Welding

Crayons)

Wire Terminal Crimper (Amp Model E9818 or

Equivalent)

Inspection Mirror Wire Cutter


BEND, OR 97701 800- 547-2558




Needle Nose Pliers Wire Stripper (18-24 GA)

Pencil Wrenches: 7/32”, 11/32”

Plastic Scraper

LIST OF SUPPLIES REQUIRED

Some supplies required for the installation of the SpeedBrake system are not included in the

installation kit and are listed here.

Table 2 - Supplies Required

Alodine Alumaprep Bon Ami cleaner Carbon paper: 8.5”x11” Distilled Water Double back tape, 3M or similar Felt marker: Ultra fine point

Hysol EA9309.3NA Adhesive

Isopropyl alcohol Masking tape: ¾” ProSeal: A1/2 or B1/2 Sandpaper: various grits Wax (Bee's wax or equivalent) Wax paper

Zinc Chromate


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LIST OF ABREVIATIONS

This section is to provide the reader with a complete state of the abbreviations used in this document and installation.

A/R As Required

AC Advisory Circular AMM Airplane Maintenance Manual BL Butt Line CB Circuit Breaker FAA Federal Aviation Administration FS Fuselage Station (Flight Station) IMC Instrument Meteorological Conditions In Inch IR Initial Release Lb, lbs Pounds PFI Precise Flight, Inc. N/A Not Applicable TCAS Traffic Alert & Collision Avoidance System VDC Volts Direct Current WS Wing Station


BEND, OR 97701 800- 547-2558




2. INSTALLATION INSTRUCTIONS

REMOVING EXISTING LOWER WING INSPECTION PANEL & DOUBLER

TOOLS REQUIRED

Heat Gun Isopropyl alcohol Infra-Red Thermometer (Opt.)

Plastic Scraper Sandpaper Welding Heat Crayons

PARTS REQUIRED

Part Number Qty Description PFI Number

573S0006-1 1 Lower RH Wing Template -

573S0006-2 1 Lower LH Wing Template -

NOTE: Use extreme care when de-bonding the doubler as excessive heat can debond

stringers next to the doubler!!

RIGHT WING

1. Referencing Template Drawing 573S0006, remove the right wing inspection panel located

at WS 100.25.

Using the welding heat crayons draw a thick line, inside and outside the wing, around the doubler

outside edge. Be sure to draw the line inside of the stringer edges.

2. Using a heat gun, carefully heat the inboard-inside edge of the doubler while applying

force on and between the doubler and wing skin. If available, use an infrared

thermometer to ensure the local temperature of the wing skin and doubler does not

exceed 300°°°°F.

3. As the doubler begins to debond, slowly apply heat and pressure around the doubler until

the doubler is removed.

4. Use isopropyl alcohol, plastic scraper, and sandpaper to remove the remaining adhesive in

the wing.

LEFT WING

5. Repeat steps 1 thru 5 on the left wing.


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LOCATING NEW LOWER WING INSPECTION PANEL & DOUBLER

TOOLS REQUIRED

Automatic Center Punch Carbon Paper Masking Tape

Pencil Tape Measure -

PARTS REQUIRED


573S0006-1 1 Lower RH Wing Template -

573S0006-2 1 Lower LH Wing Template -

573S0010-2 1* Access Cover, Right 04642

573S0010-3 1* Access Cover, Left 04653

573S0020-1 1* Alternate Access Cover, Left 04753

573S0020-2 1* Alternate Access Cover, Right 04754 * See Packing List

RIGHT WING

1. Using Template 573S0006-1, place the Template on lower right aircraft wing between

WS 93.00 and WS 107.50. Adjust Template so that the rows of rivets marked

“CRITICAL RIVET LINES” are aligned with the corresponding wing rivets. Once aligned,

place a piece of carbon paper between the wing and template, and secure the template to the

wing skin using masking tape.

NOTE: Use a pencil to highlight the rivet locations on the template. Adjust template so

template rivet lines match the existing rivet lines exactly. Actual rivet location (marked with

a”+”) does not need to match.

2. Place the Right Access Cover (P/N 04642 or 04754) on the template and align the screw

holes with the template. Using a pencil, trace around the access cover to transfer its

location (carbon paper) to the lower wing skin. Remove the template and set aside.

LEFT WING

3. Repeat steps 1 thru 2 on the left wing using Template 573S0006-02 and Left Access

Cover (P/N 04653 or 04753).

Figure 0-1: LOWER WING TEMPLATE


BEND, OR 97701 800- 547-2558




LOWER WING ACCESS COVER CUTOUT

TOOLS REQUIRED

Deburr Tool Drum Sander: 2” Fine Point Felt Marker

Drill: .300" Files: ¼” Round & 6” Flat Snips: 20SR, 20SL

PARTS REQUIRED


573S0010-1 1 Lower Doubler 04641




573S0020-2 1* Alternate Access Cover, Right 04754

1000019 2 Clinch-nut, 8-32 07030

AN509-8R8 2 Screw, 8-32 x 1/2 FLH 01477 * See Packing List

Various methods may be employed to make the cutouts in the wings. Use Extreme Care! It has

been proven helpful to do the following:

RIGHT WING

1. Mask off the wing around the area to be cut.

2. Using a die grinder, abrasive cutters, or snips, enlarge the oval hole to the inside of the

traced line.

3. Install 2 Clinch-nuts (P/N 07030) into the Lower Wing Skin Doubler using a rivet

squeezer with flush dies per notes on drawing 573S0010.

4. Place the Lower Wing Skin Doubler (P/N 04641) inside the wing, center over the access

cover cutout, and verify it does not overlap the stringer edges. Adjust as necessary inside

the wing.

5. Place the Access Cover in the cutout and align with the lower doubler and clinch-nuts.

Check the cutout for proper alignment with the access cover. Two 8-32 Screws (P/N 01477) may be used to hold the Access Cover in place. Remark the cutout as necessary.

6. Remove the lower doubler and access cover and finish the cutout using a drum sander,

round and flat files. Use the Right Access Cover (P/N 04642 or 04754) to check cutout

size. Take Care! This will be the finished product!

7. Remove the lower doubler, mark it as the right wing, and set aside.

LEFT WING

8. Repeat steps 1 thru 7 on the left wing using Left Access Cover (P/N 04653 or 04753).

NOTE: These cutouts will be the finished product. Care must be taken when

finishing these openings.


BEND, OR 97701 800- 547-2558




UPPER WING CUTOUT

TOOLS REQUIRED

Cleco Pliers Clecos: #3, #4 Countersink, 100°

Deburr Tool Die Grinder with Abrasive Disc Double Back Tape

Drill Motor Drill Bits: #40, #35, 1/4" Unibit Files: 1/4" Round, 6" Flat

Fine Point Felt Marker Masking Tape -

PARTS REQUIRED


573S0009-1 1* Left Upper Doubler 04638

573S0009-2 1* Right Upper Doubler 04637

573S0009-4 1* Left Upper Doubler, Reinforced 04751

573S0009-5 1* Right Upper Doubler, Reinforced 04752

573S0005-1 1 Left Upper Template -

573S0005-2 1 Right Upper Template -

- 1 L SpeedBrake Cartridge 05115L

- 1 R SpeedBrake Cartridge 05114R

MS24693C3 16 Screw, 4-40 x 5/16 FLH SS 07026 * See Packing List

NOTE: The cutouts will be the finished product. Care must be taken when finishing

these openings.

RIGHT WING

1. On the underside of the right upper wing skin, use a machinist ruler and fine point felt

marker to measure a distance of 1" perpendicular from the inboard rib.

2. Using double back tape, place the Right Upper Wing Skin Doubler (P/N 04637 or 04752)

on the bottom of the upper wing skin. Place the inboard edge of the doubler, on the mark,

exactly 1" from the inboard rib where previously marked. See Figure 0-1: UPPER

DOUBLER PLACEMENT (LEFT SHOWN).

Figure 0-1: UPPER DOUBLER PLACEMENT (LEFT SHOWN)


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3. Center the doubler’s offset flanges between the forward and aft wing stringers. Use the

double back tape to hold the doubler in the proper position.

4. Using a #40 drill, drill two of the eight SpeedBrake mounting holes.

5. Remove the doubler and tape, and reinstall on the upper surface of the upper wing skin

using #3 clecos.

NOTE: Be sure to align the doubler in the proper location, inboard edge inboard, and

flanges down

6. Drill the remaining 6 holes using a #40 drill. Cleco as you drill to ensure no movement.

7. Transfer the SpeedBrake opening to the upper wing skin using a fine tip felt marker.

8. Using a #40 drill, drill the four corners of the SpeedBrake opening 1/8" in from the corner.

Use a Unibit to increase the hole size to the inside edge of the marked line.

9. Remove the Upper Doubler and mask off the wing around the area to be cut. See Figure

0-2: UPPER WING CUTOUT.

Figure 0-2: UPPER WING CUTOUT

10. Using a die grinder with an abrasive disc, or snips, cut a line between each of the four

holes, remaining inside of the marked line.

11. Install and cleco the upper doubler to the bottom of the upper wing skin.

12. Using 1/4" round, and 6" flat files, file the opening to the doubler edges until they appear as

one skin. Take Care! This will be the finished product!

13. Remove the clecos one at a time and re-drill the 8 mounting holes using a #30 drill and re-

cleco.

14. Use a 100° countersink to fit each of the screws holes. Remove the upper doubler and

deburr all holes.

15. Install the right SpeedBrake (P/N 05114R) and the upper doubler using 8 Stainless Steel

Screws (P/N 07026).


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16. Check for a .030" gap on all sides between the stainless SpeedBrake caps and the skin and

doubler cutout. This will ensure proper SpeedBrake function and prevent binding. If

needed open the cutout until a .030" gap exists on all sides.

17. Remove SpeedBrake and doubler and deburr doubler cutout. See Figure 0-3: FINISHED

UPPER WING SKIN CUTOUT.

Figure 0-3: FINISHED UPPER WING SKIN CUTOUT

LEFT WING

18. Repeat steps 1 thru 17 for the left wing, using (P/N's 05115L & 04638 or 04751).


BEND, OR 97701 800- 547-2558




SPEEDBRAKE™ CARTRIDGE INSTALLATION (TEMPORARY)

IMPORTANT: Reference Drawing 573S0003

TOOLS REQUIRED

Cleco Pliers Clecos: #4 Deburr Tool

Double Back Tape Drill Bits: #19, #30, .300" Drill Bit: 3/8" Unibit:

Drill Motor Machinist Ruler: 12" Screw Driver: Phillips #1, #2

Wrench: 11/32" Zinc Chromate -

PARTS REQUIRED


573S0003-1 1 Drawing (Sheet 1) -

573S0003-2 1 Drawing (Sheet 2) -

573S0011-1 4 Attachment Angle 04639

573S0012-1 2 Extruded Angle 04652

573S0013-1 4 Attachment Hinge 04644

573S0013-2 4 Cartridge Hinge 04645



MS21083-N08 36 Nut, 8-32 Nylock 07029

AN525-8R7 36 Screw, 8-32 x 7/16 WSHHD 01431

AN525-8R6 8 Screw, 8-32 x 3/8 WSHHD 00436

MS24693C3 16 Screw, 4-40 x 5/16 FLH 07026

AN960-8L 36 Washer, #8 00452

90174A114 4 Safety Pin 06024

- 2 Snap Bushing 06062 * See Packing List

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. 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 (flange faces aft) using 2 Screws (P/N 00436).

3. Enlarge 2 holes on a Cartridge Hinge (P/N 04645) using a #19 drill and deburr. Install

the cartridge hinge, hinge flange out and aft, on the aft side of the extruded angle using the

8-32 hardware provided (P/N 01431, 00452 & 07029).

4. 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).


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5. Place the right SpeedBrake cartridge and the right upper doubler through the lower wing

cutout and orient with the upper wing skin.

6. Install the SpeedBrake cartridge with the supplied 4-40 Screws (P/N 07026).

IMPORTANT NOTE: The supplied screws are the proper length - Use of

alternate screws to install the cartridges will interfere with proper

SpeedBrake operation and will compromise the component warranty.

7. Using a ruler, measure the approximate drain hole location so the drain hole will point

straight down from the cartridge. Mark the location on the outside of the bottom wing skin

and drill to .300".

8. Zinc chromate the drain hole and install a Snap Bushing (P/N 06062) from the bottom side

of the wing. Place the drain tube through the snap bushing.

9. Attach double back tape to the outside (rib-side) flanges of 2 Attachment Angles (P/N 04639) and forward-facing sides of 2 Attachment Hinges (P/N 04644).

10. Attach the Attachment Hinges (P/N 04644) to the cartridge hinges using Safety Pin (P/N 06024). Reference Drawing 573S0003 for correct alignment.

11. Using Drawing 573S0003-1 & -2 as reference, attach one attachment angle to the

outboard forward side of the attachment hinge and to the side of the rib. Be sure the

attachment angle remains flat against the rib and the attachment hinge remains flat against

the attachment angle. Press firmly to secure location with double back tape.

12. Use a fine point felt marker to mark the location of the attachment angle on the rib, and the

attachment hinge on the attachment angle. Slight trimming to the attachment angles for

clearance on the rib and attachment hinge is permitted.

13. Repeat steps 9 thru 12 for the inboard side/rib. See Figure 0-1: TEMPORARY SPEEDBRAKE

INSTALLATION (INBOARD LEFT SHOWN)

14. Remove the inspection panels to the left and right of the SpeedBrake access cover.

15. Remove the safety pins and remove the right SpeedBrake cartridge.

16. Using a #30 drill bit, drill and cleco the 5 holes in the attachment angles to the ribs.

17. Mark each Attachment Angle as Left or Right, and remove.

18. Using a #30 drill bit, drill and cleco the attachment hinges to the attachment angles.

19. Reinstall the attachment angles with clecos, and install the SpeedBrake cartridges with the

eight screws and safety pins.

Note: You should be able to install Safety Pins without great force. If needed for

alignment, the Safety Pin tips may be filed to a point.

20. If needed, adjust fit of angles and hinges until safety pins are installed without great force.


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21. Remove safety pins, SpeedBrake cartridge and upper doubler. Using a #19 drill, enlarge

the 10 attachment angle and rib holes.

22. Remove the attachment angles. Using a #19 drill, enlarge the 4 attachment hinge and

attachment angle holes.

23. Deburr all holes. Use zinc chromate to paint all holes in the ribs.

24. Install the attachment hinges to the attachment angles using 2 Screws, Washers, and Nuts

(P/N 01431, 00452 & 07029).

25. Install the attachment angle assemblies into the appropriate rib using 5 Screws, Washers,

and Nuts (P/N 01431, 00452 & 07029).

26. Install upper doubler and SpeedBrake cartridge with 8 4-40 Screws (P/N 07026) and 2

Safety Pins (P/N 06024). If fit remains acceptable, remove safety pins, SpeedBrake

cartridges, and upper doublers.

LEFT WING

27. Repeat Steps 1 thru 26 for the Left Wing.

Figure 0-1: TEMPORARY SPEEDBRAKE INSTALLATION (INBOARD LEFT SHOWN)


BEND, OR 97701 800- 547-2558




UPPER DOUBLER BONDING

TOOLS REQUIRED

Alumaprep & Alodine Bon-Ami: Surface Cleaner Cleco Pliers

Clecos: #4 Distilled Water Hysol EA9309.3NA

Isopropyl Alcohol Rivet Squeezer with Flush Set Scale: Ounces or Grams

Wax or Equivalent - -

PARTS REQUIRED


573S0009-1 1 Left Upper Doubler 04638

573S0009-2 1 Right Upper Doubler 04637 * See Packing List

RIGHT WING

1. Use Alumaprep (chromic acid etch) and Alodine to treat the Right Upper Doubler surface.

2. Using Bon-Ami, clean the underside of the right upper wing skin, and the upper doubler.

Use distilled water to perform a water break test. The water should distribute across the

wing and doubler surface evenly, not bead or crawl. Dry wing and doubler surface.

3. Apply wax or equivalent to the painted surfaces of the upper and lower wing surface to

prevent excess adhesive from bonding to the wing skin and paint.

4. Mix Hysol adhesive 22 parts to 100 parts by weight per Hysol instructions.

NOTE: Hysol must be mixed by Weight ONLY, not volume, including FL OZ.

5. Apply adhesive evenly across the upper doubler surface approximately 5-mil thick.

6. Carefully place doubler on wing skin and temporarily cleco in place.

7. Remove excess adhesive with Isopropyl alcohol.

8. Using 2 pieces of wood wrapped in wax paper (2x4 cut to fit), or equivalent method, clamp

the upper doubler and wing skin with approximately 4-psi of pressure (2x4's may be

screwed together through the cutout - clamping wing skin and doubler together). Check to

ensure a uniform bond and the upper doubler is flat with the lower surface of the upper

wing.

9. Remove excess adhesive with Isopropyl alcohol.

10. Cure bond for 5 days at 77°, or 1 hour at 150°.

NOTE: Do not exceed 200°°°° to ensure other bonded structures are not overheated.

11. After bond has cured, remove clamps and trim excess adhesive in cutout and countersunk

holes. Make sure underside of doubler is also clean so SpeedBrake cartridge will fit flush

with doubler surface.


BEND, OR 97701 800- 547-2558




LEFT WING

12. Repeat steps 1 thru 11 for the Left wing.


BEND, OR 97701 800- 547-2558




LOWER DOUBLER BONDING

TOOLS REQUIRED

Alumaprep & Alodine Bon-Ami Distilled Water

Hysol EA 309.3NA QT Isopropyl Alcohol Rivet Squeezer with Flush Set

Scale: Ounces or Grams Screwdriver: Phillips #2 -

PARTS REQUIRED


573S0010-1 1 Lower Doubler 04641

1000019 22 Clinch-nuts, 8-32 07030 * See Packing List

RIGHT WING

1. Use Alumaprep (chromic acid etch) and Alodine to treat the Lower Doubler surface.

2. Using Bon-Ami, clean the topside of the right lower wing skin, and the lower doubler. Use

distilled water to perform a water break test. The water should distribute across the wing

and doubler surface evenly, not bead or crawl. Dry wing and doubler surface.

3. Install the lower doubler into the right wing and position so the access panel is centered in

the hole.

4. Visually verify, from the cutout in the top wing, the lower doubler is in the correct position

(not overlapping stringers). Holding the doubler in place from the cutout, use a fine point

marker to trace a line on the lower doubler in the 3/32" gap.

5. Remove the access cover from the doubler.

6. Mix Hysol adhesive 22 parts to 100 parts by weight.

7. Apply adhesive evenly across the lower doubler surface approximately 5-mil thick.

8. Carefully place doubler on lower wing skin and center using the line traced above.

9. Using wood wrapped in wax paper, or equivalent method, clamp the lower doubler and

wing skin with approximately 4-psi of pressure. Note: Be careful to align doubler

correctly with the traced line so cover plate will fit correctly!

10. Remove excess adhesive with Isopropyl alcohol. Be sure to remove adhesive that appears

where the cover panel will be placed.

11. Cure bond for 5 days at 77°, or 1 hour at 150°.

NOTE: Do not exceed 200°°°° to ensure other bonded structures are not overheated.

12. After bond has cured, remove clamps and trim excess adhesive from doubler and wing.

Make sure that the cover plate will fit flush with doubler surface.


BEND, OR 97701 800- 547-2558




13. Install the remaining Clinch-nuts (P/N 07030) into the Lower Doubler using a rivet

squeezer with flush dies per notes on drawing 573S0010.

LEFT WING

14. Repeat steps 1 thru 13 for the Left wing.

Figure 0-1: BONDED LOWER DOUBLER (RIGHT SHOWN)


BEND, OR 97701 800- 547-2558




PITOT TUBE INSTALLATION W/NEW ACCESS COVER PANEL

TOOLS REQUIRED

Cleco Pliers Clecos: #3 Countersink (100°)

Drill: #40 Drill Motor Isopropyl alcohol

Pro-Seal: A1/2 or B1/2 Rivet Squeezer with Flush Set -

PARTS REQUIRED




AN426AD-3-

4

10 Rivet, #3 01350

* See Packing List

LEFT WING

1. Using a #40 drill, Remove the 10 #3 rivets securing the Pitot tube to the old inspection

panel.

2. Insert the Pitot tube into the Left Wing Access Cover (P/N 04653 or 04753). Use a #40

drill to match drill the Pitot tube to the access panel. Use #3 clecos as you drill.

3. Countersink the 10 rivet holes to match the supplied AN426AD3-4 Rivets (P/N 01350).

4. Clean the Pitot tube mating surface.

5. Apply a layer of Pro-Seal A1/2 or B1/2 to the mating surfaces of the Pitot tube and access

panel and cleco in place.

6. Using a rivet squeezer or rivet gun, buck the rivets to secure the Pitot tube.

7. Clean the excess Pro-Seal using Isopropyl alcohol.


BEND, OR 97701 800- 547-2558




EXTERIOR PANEL AND INTERIOR REMOVAL

TOOLS REQUIRED

Needle Nose Pliers Screw Drivers: Phillips #1,2 -

PARTS REQUIRED


- - - - * See Packing List

1. Disconnect all electrical power from aircraft.

2. Remove front seats.

3. Remove pilot and co-pilot’s side panel molding.

4. Remove instrument panel top closeout panel (eye-brow).

5. Remove inspection panels aft of the main spar out to the SpeedBrake cartridges.

6. Remove lower wing root fairings.


BEND, OR 97701 800- 547-2558




INSTALLING THE ASSYMETRIC LOGIC CONTROL (ALC)

TOOLS REQUIRED

AC 43.13-1B Chap. 11 Deburr Tool Drill Motor

Drill: #19 Screw Driver: Phillips #2 Wrench: 11/32"

PARTS REQUIRED


573S0014-1 1 Drawing -

- 1 ALC Assembly 05191

MS20365-832A 6 Nut, 8-32 00485

AN960-8L 6 Washer, #8 00452

AN525-8R7 6 Screw, 8-32 x 7/16 FLH 01431

MS21919DG8 2 Adel Clamp 07014

* See Packing List

FUSELAGE – CO-PILOT CABIN FLOOR

1. Remove the co-pilots floor panel at FS 120.00.

2. Referencing Drawing 573S0014-1, place the ALC (P/N 05191) unit at RBL 8.00 on the

underside of the panel.

3. Mark and drill the four ALC mounting holes in the floor panel using a #19 drill. Deburr as

necessary.

4. Mount the ALC to the floor panel using four Screws, Washers, and Nuts (P/N 01431, 00452 & 00485). Be sure to place the nuts on the ALC side of the panel.

5. Referencing Drawing 573S0014-1, drill 2 #19 holes and deburr. Install 2 Adel Clamps

(P/N 07014) using 2 Screws, Washers, and Nuts (P/N 01431, 00452 & 00485).

6. Temporarily install floor panel to ensure ALC clears all lines and existing equipment.

Remove panel for later installation.

Figure 0-1: FLOOR PANEL


BEND, OR 97701 800- 547-2558




FEEDTRHOUGH DOUBLER AND BULKHEAD FITTING INSTALLATION

TOOLS REQUIRED

Alumaprep & Alodine Automatic Center Punch Cleco Pliers

Clecos: #3 Deburr Tool Drill Motor

Drill: ¾”Unibit, #40, #30 Pro-Seal: A1/2, B1/2 Screw driver: #1 Phillips

Wrench: 7/32" Zinc Chromate -

PARTS REQUIRED


573S0015 1 Drawing -

573S0015-1 2 Feed-Through Doubler 04643

AN365-440A 8 Nut, 4-40 01291

AN960-4 8 Washer, #4 01312

AN526-4R10 8 Screw, 4-40 x 5/8 RDH 02073

MS3119-12-

10

2 Bulkhead Receptacle 02408

10-101949-12 2 Bulkhead Connector Gasket 02411

AN470AD3-3 7 Rivet, #3 07006

* See Packing List

RIGHT WING

1. Remove the right wing root inspection panel located at FS 154.50.

NOTE: Before drilling any holes, be sure that both sides of the bulkhead are clear of

obstacles and provide adequate room for each connector!

2. From the inside of the aircraft, use a center punch and 3/4" Unibit, drill a 3/4" hole in the

fuselage. Reference drawing 573S0015 for proper location.

3. From the inside of the aircraft, place and center the Feed-Through Doubler (P/N 04643) over the hole. Match drill and cleco the 7 #40 holes.

4. Using a deburr tool, or equivalent method, increase the size of the fuselage hole to match

the doubler (Approximately 0.810")

5. Using a #30 drill, drill the 4 remaining bulkhead adapter holes. Remove the doubler and

deburr as necessary. See Figure M.1.

6. Alumaprep (chromic acid etch) and Alodine the feed-through doubler.

7. Zinc chromate the fuselage hole edges for corrosion protection.


BEND, OR 97701 800- 547-2558




8. From inside the aircraft, using Pro-Seal A-1/2 or B-1/2 between the doubler and fuselage

surface, cleco the doubler in place. Buck rivets using Rivets (P/N 07006). Install each

rivet wet with Pro-Seal.

9. Reference drawing 573S0015. Install Bulkhead Receptacle (P/N 02408) with Gasket

(P/N 02411) through the doubler. Be sure that the long portion of the receptacle is placed

through the doubler. The Bulkhead Receptacle, when installed, will have Pin contacts

inside the aircraft and Socket contacts outside. Use 4-40 hardware (P/N’s 02073, 01312 & 01291) to secure receptacle to the doubler.

10. Use Pro-Seal A-1/2 or B-1/2 to seal around the edges of the bulkhead receptacle and around

each of the four screws.

LEFT WING

11. Repeat steps 1 thru 10 for the left wing.

Figure 0-1: FEEDTHROUGH DOUBLER INSTALLATION (LEFT SHOWN)


BEND, OR 97701 800- 547-2558




WIRING THE SPEEDBRAKE™ CARTRIDGES TO THE ALC

TOOLS REQUIRED

AC 43.13-1B Chap. 11 Crimp Tool: M22S20/2-01 or M22S2011-01, (AMP E9818)

Extraction Tool: MS24256R20

Insertion Tool: MS24256A20 Ruler: 12 inch Screwdriver: #1 Phillips, Flat

Volt-Ohm Meter Wire Crimper, Cutter, Stripper -

PARTS REQUIRED




010S0041-1 2 Wire harness 05093

66506 16* Pin Contact, Crimp style 02413

66570 16* Pin Contact, Solder style 01725

206062-1 2 Wire Holder 01727

205841-2 2 Receptacle 01729

91067-2 1 Pin Insertion Tool 01773

MS3126F12-

10S

2 Cannon Plug Assy. 02409

MS3126F12-

10P

2 Cannon Plug Assy. 02410

9421 A/R 8-Conductor 22 Ga Cable 02029 * See Packing List. Crimp or Solder style may be used

NOTE: Be sure to keep wiring harness clear of control cables, and clear of fuel lines. Secure

the wire according to AC 43.13-1B, Chapter 11.

RIGHT WING

1. From the SpeedBrake access hole in the right wing, run Wire Harness (P/N 05093) through the center of the existing wing stringers, to the wing root bulkhead connector, with

the installed wire harness plug on the SpeedBrake end.

2. Secure the wire harness with Adel clamps if necessary.

3. At the wing root, strip the wiring harness jacket back exposing 5/8” of conductors.

4. Insert the ends through the strain relief of Cannon Plug (P/N 02410).

5. Remove 1/8” of insulation from all conductors.

6. Crimp the end of each wire to the short end of a pin (M39029/31-240), supplied with

Cannon Plug (P/N 02410).

7. Referring to drawing 573S0004 for color to pin code, insert the pins into their respective

holes in the Cannon Plug (P/N 02410) using MS24256 insertion tool.


BEND, OR 97701 800- 547-2558




8. Attach the wire holder to the plug. Tighten the strain relief to the jacket. Check for pin

continuity with a Volt-Ohm meter.

9. Connect the Cannon Plug and Bulkhead Receptacle together.

LEFT WING

10. Repeat steps 1 thru 9 for the left wing.

RIGHT WING

11. On the cabin side of the right wing root, at the Bulkhead Receptacle, route the 8-Conductor

22 GA Cable (P/N 02029) along the existing wire harness, along the co-pilot’s sidewall

wiring harness forward to the ALC.

12. At the Bulkhead Receptacle, strip the 8-conductor cable jacket back, exposing 5/8” of

conductors.

13. Insert the ends through the strain relief in Cannon Plug (P/N 02409).


15. Crimp the end of each wire to the short end of a socket (LP-597820-355), supplied with

Cannon Plug (P/N 02409).

16. Referring to drawing 573S0004 for color to pin code, insert the sockets into their

respective holes in the plug in Cannon Plug (P/N 02409).

17. Attach the wire holder to the plug. Tighten the strain relief to the jacket. Check for contact

continuity with a Volt-Ohm meter.

18. Connect the Cannon Plug and Bulkhead Receptacle together.

19. On the ALC end of the right 8-Conductor Cable, strip the jacket back exposing 5/8” of

conductors.

20. Insert the ends through the Wire Holder (P/N 01727).


22. Crimp the end of each wire to the short end of a Pin (P/N 01725).

23. Referring to drawing 573S0004 for color to pin code, insert the sockets into their

respective holes in the Receptacle (P/N 01729). Use the red end of the Pin Insertion Tool

(P/N 01773) to insert contacts, use the white end to extract contacts from the housing.

24. Attach the Wire Holder (P/N 01727) to the Receptacle (P/N 01729). Tighten the strain

relief to the jacket. Check for contact continuity with a Volt-Ohm meter.

LEFT WING

25. Repeat steps 12-24 for the left wing. For Step 11 route the 8-Conductor Cable along

existing wiring harnesses, across the instrument panel, or across the aft side of the forward

wing spar under the floorboards, to the co-pilot's side panel. Then route the cable along the

co-pilot's sidewall with the other SpeedBrake wire harness to the ALC.


BEND, OR 97701 800- 547-2558




NOTE: Be sure to keep wiring harness clear of control cables and fuel lines.

Figure 0-1: CONNECTOR PINOUTS, REFERENCE ONLY


BEND, OR 97701 800- 547-2558




WIRING THE ASSYMETRIC LOGIC CONTROL (ALC)

TOOLS REQUIRED

AC 43.13-1B Chap. 11 Crimp tool: AMP E9818 Needle Nose Pliers

Screwdriver: #1 Phillips, Flat Wire Crimper, Cutter, and Stripper

PARTS REQUIRED



205838-1 1 Plug 01726

206062-1 1 Wire Holder 01727

66504 8* Socket Contact, Crimp style 02414

66569 8* Socket Contact, Solder style 01728

91067-2 1 Pin Insertion Tool 01773

9421 A/R 8-Conductor 22 GA Cable 02029 * See Packing List. Crimp or Solder style may be used.

1. Route the remaining 8-Conductor 22 GA Cable (P/N 02029) from the ALC mount in the

co-pilot cabin floor, along the co-pilot’s side-wall, behind the instrument panel through

existing wire bundles, and into the circuit breaker panel on the pilot's side-wall. Leave

sufficient slack behind the instrument panel to connect the circuit breaker, switch, and

annuciator. Cut the 8-Conductor Cable and save the scrap. Secure the wire according to

AC 43.13-1B, Chapter 11.

2. On the ALC end of the 8-Conductor wiring harness strip the jacket back exposing 5/8” of

conductors.


4. Crimp 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 573S0004 for color to pin code, insert the sockets into their

respective holes in the Plug (P/N 01726) using the Pin Insertion Tool (P/N 01773).

7. Attach the Wire Holder (P/N 01727) to the Plug (P/N 01726). Tighten the strain relief to

the jacket. Check for contact 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.


BEND, OR 97701 800- 547-2558




CIRCUIT BREAKER, SWITCH, AND ANNUNCIATOR

TOOLS REQUIRED

AC 43.13-1A Chap. 11 Drill Bits: 7/16” & 5/8” Capacity Unibit

Drill Motor Needle Nose Pliers Solder: Rosin Core

Soldering Iron Wire Crimper, Cutter, & Stripper

PARTS REQUIRED




7277-2-3 1 Circuit breaker, 3A 01270

- 1* Placard, Switch 08436

9803-11 1* Switch, 2PDT Toggle 02412

7101J61ZQE22 1* Switch, Lever 02637

5821A0B0C3F4L5N1

(A) P11,13

SPEED,BRAKE

1 Annunciator 02404

* See Packing List

1. At the circuit breaker panel, install and wire the Circuit Breaker (P/N 01270). Reference

Drawing 573S0004 for proper wiring.

2. Install switch option in accordance with Drawing 573S0002-1, or -2. See packing list for

part numbers actually ordered.

3. Install the Annunciator (P/N 02404) within full view of the pilot. Use Drawing

573S0002-1 for reference.

4. Using the wire run in the previous section, wire the Annunciator, circuit breaker, ground,

and switch using Drawing 573S0004 for reference.

5. Ring out all harnesses and wiring to ensure good connections.

NOTE 1: Wire may be separated or pulled from the wire harness outer shielding and run to

the individual items. Use heat shrink to seal separated shielding.

ALTERNATIVELY, new wire may be run to the individual items.

NOTE 2: For switch and light locations other than shown, obtain separate FAA engineering

approval, or provide a deviation statement on the 337 submitted for approval.


BEND, OR 97701 800- 547-2558




SPEEDBRAKE™ CARTRIDGE INSTALLATION (PERMANENT)

TOOLS REQUIRED

Screw driver: Phillips #2 Side-cutters -

PARTS REQUIRED


573S0003-1 1 Drawing -

573S0019-1 1 Drawing -




573S0020-2 1* Alternate Access Cover, Right 04754

90174A114 4 Safety Pin 06024

MS24693C3 16 Screw, 4-40 x 5/16 FLH SS 07026

MS24694S5 24 Screw, 8-32 x 1/2 FLH 01477



* See Packing List

RIGHT WING

1. Clean any metal filings, chips, and tools 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 07026).

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 43.13-1B Chapter 11.

5. Trim drain tube ¼” from wing skin. Reference Drawing 573S0019.

6. Reinstall all inspection panels.

7. Reinstall SpeedBrake Access Covers (P/N 04642 or 04754) using 8-32 Screws (P/N

01477).

LEFT WING

8. Repeat Step 1 through 6 for the left wing. Note: Reference Piper Maintenance Manual

when reinstalling Pitot tube and Access Cover (P/N 04653 or 04753).

9. Check to ensure that cable routing does not interfere with any other aircraft system.


BEND, OR 97701 800- 547-2558




SPEEDBRAKE

PLACARDS INSTALLATION

TOOLS REQUIRED

Isopropyl alcohol - -

PARTS REQUIRED


- 1 Placard, SB Equipped 00456

- 1 Placard, Speedbrake 00455

- 2* Placard, Elect. Act. – Large 08416

- 2* Placard, Elect. Act. – Small 01750 * See Packing List

NOTE: Use Isopropyl alcohol to prepare surface before applying placard.

1. Install Placard (P/N 00456) in full view of the pilot.

2. Install Placard (P/N 00455) at SpeedBrake circuit breaker.

3. Install Placard (P/N 08416) on wing skin aft of SpeedBrake cartridges.

Or alternate Placard (P/N 01750)

SPEEDBRAKE EQUIPPED: FOR OPERATING INSTRUCTIONS & LIMITATIONS SEE SUPPLEMENT IN OWNERS MANUAL OR OPERATING HANDBOOK.

Electrically Actuated - DO NOT MANUALLY OPERATE

Electrically Actuated - DO NOT MANUALLY OPERATE


BEND, OR 97701 800- 547-2558




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 annuciator has illuminated and dimming works as required.

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 annuciator 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 cycle the SpeedBrake switch. Observe

that the SpeedBrakes deploy to the fully opened position.

10. Repeat Steps 6 and 7.

11. Turn off aircraft master power switch.

12. If any problems occur, consult the TROUBLE SHOOTING GUIDE section.

13. Install all interior and exterior panels, and aircraft interior.


BEND, OR 97701 800- 547-2558




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™

Complete FAA Form 337 and submit to the FAA as required.

1. Complete calculations for Weight and Balance for SpeedBrakes™ installation at 8-lbs. at

178.0 in. and Precise Flight ALC at 1-lbs. at 120.00 in.

2. Update aircraft equipment list with the installation of the Precise Flight SpeedBrakes™

3. Add the FAA approved Flight Manual Supplement to the aircraft Flight manual.

4. Record installation in appropriate aircraft maintenance records (See Figure 1.18-1 FAA

Form 337) and ensure Flight Manual Supplement is properly annotated in Aircraft Flight

Manual.

8. Description of Work Accomplished

(If more space is required, attach additional sheets. Identify with aircraft nationality and registration mark and date work completed.)

A. The following components were installed:

PRECISE FLIGHT 2000 Series Electric SpeedBrake TM

Kit per STC SA00520SE, installation Kit # __________.

B. Installed the Precise Flight SpeedBrake system in accordance with SpeedBrake® 2000 Installation

Instructions for the PA-46 PIPER MALIBU / MALIBU MIRAGE / MALIBU MATRIX (STC

SA00520SE), Precise Flight Installation Report 08095, Revision Initial Release, or later FAA approved

revision. Guidance in FAA Advisory Circulars AC43.13-1B Chapter 11, and AC43.13-2A Chapters 1 and

2.

C. An electrical load analysis was performed and the revised continuous load of the aircraft electrical bus

(generator or other supply) does not exceed 80% of capacity or in accordance with the procedures in FAA

AC43.13-1B Chapter 11.

D. A complete operational test was performed according to the SPEEDBRAKE Installation Report 08095.

The equipment performed satisfactorily and did not adversely affect existing components or systems in the

aircraft, as required by FAR 23.1301, FAR 23.1431.

E. The aircraft equipment list was revised to reflect these changes; weight and balance data was revised and

placed in the aircraft records. A Precise Flight Inc. SPEEDBRAKE Aircraft Flight Manual Supplement

dated ______was placed in the aircraft. Installed weight includes 8lbs at STA 178.0in, and 1lbs at STA

120.0in.

2.18-1 FIGURE – Suggested FAA FORM 337 Description of Work

5. Keep all Precise Flight 2000 Series SpeedBrakes™ papers with aircraft records.

6. Fill out and return warranty card to Precise Flight, 63120 Powell Butte Road, Bend,

Oregon 97701.


BEND, OR 97701 800- 547-2558




3. TROUBLE SHOOTING GUIDE

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 573S0004 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.

e. Check that system voltage is adequate. The ALC is designed to disengage the

SpeedBrake blades should either cartridge fail to deploy within a few seconds or

to stay up. Low voltage or corroded connectors may cause the ALC to retract the

SpeedBrake blades. Low voltage may cause other problems.

f. The wing harness connectors, J2 or J3, may be reversed at the ALC to isolate a

problem to the cartridge or the ALC. (This would cause the right cartridge to

indicate as the left if separate annunciation is used.)

g. A SpeedBrake cartridge may be removed from the wing and plugged directly into

the ALC at connector P2 or P3 to isolate a harness failure.

DO NOT OPERATE THE SPEEDBRAKES™ BY HAND While electrical power is on. Damage to cartridges and personal injuries may result,

and will void warranty!

DO NOT USE SPRAY LUBRICANTS ON SPEEDBRAKES™ Damage to cartridges and SpeedBrake clutch may result and will void warranty!

FOR ADDITIONAL TECHNICAL ASSISTANCE Please call Precise Flight, Inc. 800-547-2558 Additional information and products are available on the web, at

www.preciseflight.com or email us at [email protected]


BEND, OR 97701 800- 547-2558




4. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

4.1 INTRODUCTION

The contents of this section provides the instructions for continued airworthiness for the

SpeedBrake®

2000 Series System Installation. Because a majority of the installation does not

affect the standard airworthiness of the aircraft, only the key items that exist different are noted in

this section. All structure and general maintenance must be performed in accordance with

existing approved maintenance practices, or the aircraft maintenance manual.

4.2 SYSTEM DESCRIPTION

The Series 2000 SpeedBrake®

Option consists of wing mounted electric SpeedBrake®

Cartridges.

Each SpeedBrake Cartridge is interconnected electronically by a central logic-switching unit and

the yoke mounted SpeedBrake actuator switch. The SpeedBrake®

Cartridges receive electrical

power from the aircraft electrical buss through a disconnect type circuit breaker.

Precise Flight SpeedBrake®

2000 System is installed to provide expedited descents at low cruise

power, glide path control on final approach, airspeed reduction and an aid to the prevention of

excessive engine cooling in descent. The SpeedBrakes can be extended at aircraft speeds up to

Vne.

The SpeedBrake Annunciator switch is located near the airspeed indicator. The switch is

depressed on position to fully deploy and is positioned off to retract the SpeedBrakes. The

switch includes annunciation to indicate deployment if both SpeedBrake®

units are deployed. A

failure of a single cartridge drive unit will prevent the annunciator light from illuminating.

FIGURE 1-1 SPEEDBRAKE ANNUNCIATOR SWITCH

The Annunciator will light after the SpeedBrake®

Switch is toggled ON and both brakes are in

the up position. If the annunciator fails to light and both brakes do not extend after the switch is

depressed, it indicates a failure of one SpeedBrake®

cartridge and the SpeedBrake®

switch should

be depressed off. The system can be checked again for proper operation, but after the second

attempt, the SpeedBrake®

switch should be left off. When the SpeedBrake®

Switch is depressed

OFF, the annunciator will extinguish when both brakes are fully stowed in the wing.


BEND, OR 97701 800- 547-2558




4.3 SPECIAL TOOLS REQUIRED

Refer to Table 1 and Table 2 of this document for a list of special tools and materials required for

installation and maintenance of the SpeedBrake®

2000 system.

4.4 Maintenance Instructions

Maintain aircraft structure, and wiring in accordance with aircraft maintenance manual, and FAA

AC 43.13. Access to the SpeedBrake installation is through the lower access panel installed per

section 2 of this document.

4.5 Trouble Shooting Guide

Refer to Section 3 of this document for trouble shooting guide.

4.6 Airworthiness Limitations

None – The operation of the SpeedBrake®

System does not impact the airworthiness

limitations and is not required for normal flight.

4.7 Scheduled Maintenance Intervals and Inspections for Continued Airworthiness

This section includes the inspection intervals, and requirements, for maintenance of the

SpeedBrake®

2000 system when installed in the Piper Malibu / Malibu Mirage Aircraft. The

breakdown of required inspections is listed in Table 3.


BEND, OR 97701 800- 547-2558




Table 3 - Schedualed Maintanance Intervals and Inspections

EACH 5000 HOURS

EACH 1000 HOURS

ANNUALLY

EACH 100 HOURS

EACH 50 HOURS

PIPER MALIBU / MALIBU MIRAGE / MALIBU MATRIX

SPEEDBRAKE 2000 TM

1.

Check Cap Strip Cover screws for security, if loose, remove screws and apply Loctite 242, re-torque to 8 in-lbs. Check SpeedBrake top attachment screws for security, if loose, remove screws and apply Loctite 242, re-torque 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 SpeedBrakesTM 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 SpeedBrakesTM from aircraft d.) Return SpeedBrakes

TM to Precise Flight Inc. for

Drive Assembly Replacement e.) Reinstall SpeedBrakesTM in aircraft f.) Connect electrical plugs g.) Install inspection plate

•


BEND, OR 97701 800- 547-2558




5. APPENDIX A

1.1.1. PARTS LIST

1.1.2. ELECTRICAL LOAD ANALYSIS FORMS

1.1.3. INSTALLATION INSTRUCTION DRAWINGS