SECTION 7A ELECTRIC FLAP CONTROL SYSTEMS NOTE SEE SECTION 7 FOR HYDRAULIC FLAP CONTROL SYSTEMS TABLE OF CONTENTS Page FLAP CONTROL SYSTEMS... 2... Tat Operational Checkout. 2.) 21 2)! Ad ‘Trouble Shooting . . |: DTA2 Removal, Installation, and Adjustment of Flap Position Transmitter... . . TA-3 Removal, Repair, and Installation of ‘Motor and Transmission Assembly. . . 7A-3 Removal, Repair, and Installation of FLAP CONTROL SYSTEMS. Electrically operated wing flaps are used on all Models 205 and 206, and on the Model 210 begin- ning with the 210D, An electric motor and trans mission assembly, located in the right wing is con nected to the right flap drive pulley which operates the flap control system, ‘The Model 210D and on, and the Model 206 series, are equipped with larger sspan flaps than the Model 205 series, and these flaps ‘require an extra set of flap tracks and two inte connected belleranks operating two push-pull rods at each flap. ‘The systems are illustrated in figures acl and TA? Prior to the Serial No. 208-0196, the front ‘cargo door must be either in full’ open or full closed position before operating wing flaps, or damage will result. All other airplanes with ‘cargo doors contain a flap interrupt switch, ‘mounted on the front cargo door frame, which prevents flap operation while the front cargo door is open. As noted in Service Letter 65-1, the switch and electrical wiring may be installed on earlier serials. If the airplane is operated Drive Pulleys... 2 e . TAS Removal, Repair, and Installation of Outboard Belleranks ... . 2 TAS Replacement of Flap Cables and Pulleys. | 7A-3 Rigging - Model 205 Series... DA8 Rigging - Model 206 Series, and BM0Dand On... ee es TAMLO Flap Motor Brake Adjustment | |)? TA-10 with cargo doors removed, a spoiler kit (AK206- 1) must be installed. The kit contains a switch depressor to retain use of the flaps. ‘1A-3, OPERATIONAL CHECKOUT OF FLAP CON- ‘TROL SYSTEM. ‘4, Operate flaps through full range of travel, ob- serving for uneven or jumpy motion, binding and Jost motion in system. Make sure flaps are moving together through full range of travel, 'b, Deliberately overrun motor at each end of stroke to make sure transmission is free wheeling. c. Check to see that flaps are not sluggish in oper- ation, Inflight at 100 mph, indicated airspeed, the flaps should take approximately 8, 7 seconds to ex- tend and 7, 6 seconds to retract, On the ground with engine running, the flaps take approximately 6.5 seconds to extend or retract, ‘d. Raise flaps and check to see that they are com- pletely up. Check flap position indicator to see that it reads 0°, Mount an inclinometer on one flap and set to 0°, 'e. Lower flaps to extreme down position and check ‘lap down angle with inelinometer. “Down angle is £. Open the flap drive pulley and bellerank access ‘openings and attempt to rock pulley or bellerank to disclose internal bearing play. 8. Examine rollers and tracks for defective parts. m1‘A-4. ‘TROUBLE SHOOTING THE FLAP CONTROL SYSTEM, PROBABLE CAUSE ‘BOTH FLAPS FAIL TO MOVE. Popped clreuit breaker. Defective switch. Defective motor. Broken or disconnected wires. Defective or disconnected transmission, Defective flap interrupt switch (used with cargo doors). ISOLATION PROCEDURE Check circuit breaker. Place jumper across switch, Remove and bench test motor. Run continuity check of wiring. ‘Check to see transmission is connected to flap system, If connected, remove for bench test, Check continuity. REMEDY Reset circuit breaker, Replace switch. Replace motor. Connect or repair wiring, Connect or replace transmission. Replace switch. LEFT FLAP FAILS TO MOVE, [Disconnected or broken cable. [Disconnected push-pull rod. Check cable tensions. ‘Check push-pull rod attachment, Connect or replace cable, ‘Attach push-pull rod. BINDING IN SYSTEM AS FLAPS ARE RAISED AND LOWERED. [Cables not riding on pulleys. Broken or binding pulleys. Frayed cable, Bind in drive pulleys. Flaps binding on tracks. INCORRECT FLAP TRAVEL. Incorrect rigging. Open access covers and observe pulleys. Check pulleys for free rotation or breaks. Check condition of cables. Check drive pulleys in motion. Observe flap tracks and rollers, Route cables correctly over pulleys, Replace defective pulleys. Replace defective cable. Replace drive pulley. Replace defective parts, Rig flaps correctly. SHOP NOTES: 7A-2A-5, REMOVAL, INSTALLATION, AND ADJUST- MENT OF FLAP BOSITION TRANSMITTER. (See figure TA-1.) ‘a, Remove access covers from bottom of right ‘wing below right drive pulley (6). b, Remove two bolts (10) which secure flap posi- tion transmitter (11), ‘c. Remove cotter pin (14) and pin (13) which secure wire rod (12) to arm (15), 4. Disconnect two wires at the quick-disconnects and remove the transmitter from the wing. e. Installation of flap position transmitter may be accomplished by reversing the steps listed above, after which it should be adjusted as described in paragraph 7A-I1, Reinstall all parts removed for access, 7A-6, REMOVAL, REPAIR, AND INSTALLATION QF MOTOR AND TRANEMIBHION ASSEMBLY. (Gee figure 7A~ a. Transmission (3), motor (1), tube (4), and hinge (2) are removed as one assembly if standard fuel tanks are installed, With long range tanks in- stalled, it is necessary to detach the assembly from hinge (2) before removing motor and transmission from wing and to attach them to the hinge after posi- tioning them in wing. b, Remove access covers from bottom of right wing under drive pulley and motor assembly. c. Remove bolt securing tube (4) to drive pulley (6). 4d. Remove bolt securing hinge (2) to the wing, or if long range fuel tanks are installed, remove bolt securing transmission to the hinge. ‘e. Disconnect electrical wires at quick-disconnects and remove screw securing ground wire. Remove assembly from wing. {, Repair of the transmission and motor assembly consists of replacement of the motor (1), transmis- sion (3) or tube (4). Bearings in hinge (2) may be replaced, &. Installation may be accomplished by reversing the preceding steps and rigging the flap control sys~ tem in accordance with paragraph TA-11 or para~ graph 7A-12. A-7._ REMOVAL, REPAIR, AND INSTALLATION OF DRIVE PULLEYS. (See figure TA-1.) NOTE ‘The right drive pulley (6) must be removed to detach flap position transmitter arm (15) from the drive pulley assembly. a, Remove access covers under right drive pulley. b. Remove the bolts securing push-pull rod (7) to drive pulley (6) and lower flap gently. On the Model 206 series and on the Model 210 series beginning with the 210D, also disconnect the outboard push-pull rods from the outboard belleranks. ‘c. Remove bolt securing tube (4) to drive pulley (6). d. Remove pin (13) to disconnect flap position trans- mitter rod (12) from arm (15). e. Loosen turnbuckles (21 and 23) and detach cables (8 and 9) from drive pulley by removing bolts and pins. 4. Remove bolt securing drive pulley (6) to wing and remove drive pulley. On the Model 208 series and on the Model 210 series beginning with the 210D, also remove boll attaching synchronizing push-pull tube (2, figure TA-2) to the drive pulley. &. To remove a left drive pulley, use this same procedure, omitting steps "o" and "d,"\ for the left side, h, "Repair of drive pulleys is limited to replacement of needle bearings. 1, Installation may be accomplished by reversing the preceding steps and rigging per paragraph TA~11 or 7A-12. Cables may be attached to drive pulleys before installing them in the wings. NOTE ‘Transmitter arm (15) must be attached to right drive pulley (6) before installing the drive pulley. 4-8. REMOVAL, REPAIR, AND INSTALLATION OF OUTBOARD BELLCRANKS — MODEL 206 SERIES, AND 210D AND ON. (See figure 7A-2.) ‘a, Remove access covers under outboard belleranks. b, Remove bolt securing outboard push-pull rod (7) to bellerank (17), Also remove bolt attaching inboard push-pull rod (7) to drive pulley (6). Lower flap gently. ©. Remove bolt attaching synchronizing push-pull tube (2) to bellerank (17). NOTE ‘To remove synchronizing push-pull tube (2), disconnect it at both ends and position it through lightening holes until it can be re- moved through the access hole. 4, Remove bellerank pivot bolt and remove bell- crank through access hole. fe. Repair of belleranks is Limited to replacement of needle bearings. {. Installation may be accomplished by reversing the preceding steps and rigging per paragraph 7A-12, A-9._ REPLACEMENT OF FLAP CABLES AND PULLEYS may be accomplished while using figure ‘TA-1 or 7A-2 as a guide, Refer to paragraph TA-11 or TA-12 for proper cabie attachment. NOTE To ease rerouting of cables, a length of wire ‘may be attached to the end of the cable before it is withdrawn from the alreraft, Leave the wire in place, routed through the structure; then attach it to the new cable and use it to pull cable into plac 7A-10, REMOVAL, REPAIR, AND INSTALLATION OF FLAPS. Figures 7A-3 and 7A-4 show details of flap installations and may be used as guides during removal and installation of the flaps. If flap push- pull rod adjustment is not disturbed, it should not be necessary to rerig the flap system. Check flap 7A-3FLAP TRAVE] 0° 040", 43 CABLE TENSION: 20to 40 Pounds |. Motor Hinge Assembly | Transmission | Tube Assembly Bolt Drive Pulley Assembly : Push-Pull Rod Direct Cable Retract Cable Bolt Flap Position Transmitter Wire Rod Pin Cotter Pin Flap Transmitter Arm Washer Set Screw Nut and Ball Assembly A-1, Flap Control system (Model 205 Series) Pulley Bushing . Turnbuckle Drive Pulley Assembly | Turnbuckle Flap Position Indicator Flap Switch60to 80 Pounds . Flap Motor }. Push-Pull Rod . Set Screw 1; Synchronizing Push-Pull Tube 3. Direct Cable Nut And Ball Assembly Flap Motor Hinge 9. Retract Cable Flap Position Indicator ‘Transmission Flap Position Transmitter Flap Switch .. Flap Motor Actuating Tube Wire Rod Bellerank Drive Pulley Assembly 12. Flap Position Transmitter Arm Figure 7A-2. Flap Control System (Model 206 Series and Model 210D & On) a5Bushings (4), rollers (9), and spacers (8) are first positioned through slots in flap tracks, then are secured to the flap roller supports with attaching bolts, washers, and nuts, Nylon plug buttons (18) prevent wing flap from chafing wing trailing edge. . Cover Plate 1. Upper Skin . Spacer |. Push-Pull Rod Spar | Washer: Bracket, Rod End |. Leading Bdge Skin Lower Skin Rib Plug Button Figure 7A-3, Flap Installation (Model 205 Series) A-6|. Wing Flap Wing Structure | Outboard Flap Track Access Cover Bushings (10), rollers (11), and spacers (14) are first positioned through slots in flap tracks, then are secured to the flap roller supports with at- taching bolts, washers, and nuts. Nylon plug buttons (15) prevent wing flap from chafing wing trailing edge. ‘Beginning with Serial No, P206-0037, 206-0327, and 21058553, stiffeners are installed along the flap trailing edges. . Center Flap Track 11, Roller . Inboard Actuating Bracket 12. Washer Inboard Flap Track Nut |. Outboard Actuating Bracket Bolt Spacer 1. Bushing Nylon Plug Buttons Figure 7A-4, Flap Installation (Model 206 Series and 210D & On) TA-1travel and rerig if necessary. Repair of a damaged flap may be accomplished in accordance with instruc~ tions contained in Section 19. TA-L1, RIGGING FLAP CONTROL SYSTEM — MODEL 205 SERIES. (See figure 74-1. ) NOTE Before using this procedure, disconnect flap cables at turnbuckles above cabin headliner, disconnect flap push-pull rods at drive pulleys in both wings, and disconnect tube (4) from drive pulley (6). a, If cables are not connected to drive pulleys, tube (4), left and right push-pull rods (7), and the flap transmitter arm must be disconnected before installing the cables, If drive pulleys are not in- stalled, attach cables before installing drive pulleys in wings. >. Connect the 3/82" retract cable (9) to forward side of the right drive pulley (6) and to aft side of left drive pulley (22). ©. Connect the 1/8" direct cable (8) to aft side of right flap drive pulley (6) and to forward side of left drive pulley (22). 4. “Connect flap position transmitter rod (12) to ‘right flap drive pulley arm (15). ©. Adjust push-pull rods (7) to 8 11/16 + 1/8 inches, between center of rod end bearings and tighten jam nuts on both ends. Install push-pull rods on flaps and on drive pulleys (6 and 22). NOTE ‘Temporarily connect the flap cables at turn- buckles above cahin headliner, and test flaps by hand to see that flaps extend together. If they will not, cables are incorrectly attached to drive pulleys. Also see that right drive pulley rotates clockwise, when viewed from below, as flaps are lowered. Disconnect turn- buckles above cabin headliner again, £. Using care not to cause damage, run flap motor to fully retract actuating tube (4) on motor (fall up position). g. Loosen set screw (17) and while manually hold- ing right flap full up, rotate nut and ball assembly (18) in or out as required to align tube (4) with attach- ing hole in drive pulley, tighten set screw and attach tube to drive pulley. NOTE Apply Loctite Sealant Grade C (American Sealant Co., Hartford 11, Conn.) to threads of set screw (17) after final adjustments have been made. 1h. If tube (4) does not retract enough to connect to the right drive pulley with flap full up, disconnect push-pull rod at flap drive pulley and connect tube (4) to flap drive pulley. 4, With flap motor full up, manually hold right flap up and readjust push-pull rod to align with 1A-8 attaching hole in drive pulley. Connect push-pull rod and tighten lock nuts. NOTE ‘The right flap and motor must be correctly rigged before the flap cables and left flap can be rigged. J. Operate flap motor to place right flap full up, ‘manually hold left flap full up and connect flap cables at turnbuckles above headliner. k. With flaps full up tighten flap cable turnbuckles to obiain 3010 pounds cable tension on each cable. ‘Adjust retract (8/32 inch) cable first, NOTE ‘When tightening cable turnbuckles be sure the cables are in the pulley grooves and cable ends are correctly positioned at the drive pulleys. 1. Disconnect push-pull rod at left drive pulley. Run motor to extend flaps approximately 20° and check tension on each flap cable. If necessary re- adjust turnbuckles to maintain 30:10 pounds cable tension on each cable and safety turnbuckles. NOTE Rig cable tension to the average temperature for the area. m. Fully retract right flap. Manually holding left flap up, readjust left push-pull rod to align with attaching hole in left drive pulley and connect push- pull rod to drive pulley. Tighten locknuts. n. With flaps up, mount an inclinometer on right flap and set to 0°.” Fully extend flaps and check flap down angle. See figure 7A-1 for wing flap travel. Repeat check on left flap. NOTE Since flap rollers may not bottom in flap tracks with flaps fully extended, some free play may be noticed in this position. (©. Raise flaps to full up position and adjust flap position transmitter to make indicator read 0°. Slotted holes in the transmitter bracket are pro- vided for adjustment. If necessary, transmitter rod may be formed slighily for additional adjustment, . Perform an operational checkout of the flap control system, check all locknuts for tightness, check that all turnbuckles are safetied, and install all parts removed for access. NOTE ‘An inclinometer for measuring control surface travel is available from the Cessna Spare Parts Department. (See figure 6-10.)MODEL 206 SEI JAND 210D & ON Figure 7A-5. Flap System Schematics 470-13 Temporary Change 1 A-9 30 January 1978‘A-12. RIGGING FLAP CONTROL SYSTEM — ‘MODEL 206 SERIES AND MODEL 210D AND ON. (Bee figure 7A-2.) Before using this procedure, disconnect flap cables at turnbuckles above cabin headliner, and disconnect flap push-pull rods at drive pulleys and belicranks in both wings. If cables are not connected to drive pulleys, it 4s necessary to discomect parts attached to each drive pulley so it may be rotated beyond its normal ange of travel to permit cable attachment, If drive alleys are not installed, attach cables before in- stalling the drive pulleys in the wings. 'b, The 3/32" retract cable connects to the forward side of the right hand drive palley and to the aft side of the left hand drive pulley. c. ‘The 1/8" direct cable connects to the aft side of the right hand drive pulley and to the forward aide of the left hand drive palley. 4. Adjust synchronizing push-pull tube in right wing to 48, 69" between centers of rod end holes, tighten jam nuts, and install, If outboard bellerank 18 not ‘installed, the tube and bellcrank must be positioned {n the wing and the tabe attached to the bellcrank be- fore the bellcrank is installed, Using care not to cause damage, run flap motor to fully retract actuating tube (5) on motor (full up position). Loosen set screw (13) and rotate nut and ball assembly (14) in or out as required to position right flap drive pulley 80 that centerline of bolt hole for flap inboard push-pull rod attachment 8 3.95 inches aft of the fuel well bulkhead. Tighten set screw (13). NOTE Apply Loctite Sealant Grade C (American Sealant Co., Hartford 11, Conn.) to threads of set screw (18) after Tiral adjustments have been made. {, Manually holding right flap full up, adjust right inboard push-pull rod to align with attaching holes, fand install the push-pull rod. Tighten push-pull rod fend lockmut. : f., Repeat step "T" for the right outboard push-pull NOTE ‘The right wing flap and motor must be cor rectly rigged before the flap cables and left ‘wing flap can be rigged. 1. Adjust synchronizing push-pull tube in the left wing to 48,69 inches between centers of rod end holes, tighten lock nut, and install tube. If outboard bell- rank is not installed, the tube and belicrank must bbe positioned in the wing and the tube attached to the bellerank before the bellcrank is installed. 1. Connect flap cables at turnbuckles above cabin headliner. Adjust turnbuckles to position left wing flap drive pulley so the centerline of the bolt hole A-10 for flap inboard push-pull rod attachment is 4. 20 inches aft ofthe fuel well bulkhead, maintaining 70 10 pounds cable tension. NOTE When tightening cable turnbuckles be sure the cables are in the pulley grooves and cable ends ‘are correctly positioned at the drive pulleys. Rig cable tension to the average temperature for the area. J. Manually holding left wing flap up, adjust left inboard push-pull rod to align with attaching holes and install the push-pull rod. Tighten push-pall rod end lock aut. ik. Repeat step "" for the left outboard push-pull rod. 1. Check cable tension at intermediate flap post {Hons to see that cable tension is within limits. Re- tract cable tension may increase to 90 pounds when flaps are fully retracted. Check that drive pulleys are in the positions specified in steps "e"" and "1." Check that all locknuts are tight and all turnbuckles are safetied. NOTE Since flap rollers may not bottom in flap tracks with flaps fully extended, some free play may be noticed in this position. m, With flaps up, mount an inclinometer on the right wing flap and set to 0°. Operate flaps to full down position and check flap down angle. ‘See figure ‘TA-2 for wing flap travel. Repeat check on left flap. 1a, (See figure 7A-2.) Connect wing flap position transmitter rod (11) to arm (12) on right wing drive palley (6). ‘0. Raise wing flaps to full up position and adjust ‘lap position tranamitter to make position indicator read 0°. Slotted holes in the transmitter bracket are provided for adjustment, If necessary, trans- mitter rod may be formed slightly for additional adjustment. 'p. Perform an operational checkout of the wing flap control system, check all locknuts for tight- ness, check that all turnbuckles are safetied, and reinstall all parts removed for access. NOTE ‘An inclinometer for measuring control surface travel is available from the Cessna Spare Parts Department. (Gee figure 6-10. ‘IA-13._ FLAP MOTOR BRAKE ADJUSTMENT. Re- {er to figure 7A-6 for adjustment of the flap motor ‘solenoid-released brake assembly.NOTE Adjust brake assembly, with solenoid actuated, so minimum clearance be- tween brake lining and any part of the coupling is .001" and maximum is 010", Do not bend spring (9). Brake assembly not used on Model 205 Series prior to 205-0200, ENLARGE HOLES AS REQD ‘TO .250 INCH MAXIMUM: NOTE Alignment of flap motor shaft and transmission shaft is important, After reassembly, brake drum and coup- ling assembly must turn freely with brake released. It is permissible to enlarge the holes illustrated to a max- imum of . 250" to obtain proper alignment. 1. Motor 5. Coupling: |. Spring Assembly 2. Motor Shaft Hinge Brake Lining 3. Brake Drum ‘Transmission Solenoid 4. Setscrew | Transmission Shaft Bracket Figure 7A-6. Flap Motor Brake TAM