CONTROL WHEELS INSTALLATION INSTRUCTIONS

Full document text

CONTROL WHEELS INSTALLATION INSTRUCTIONS CW-8001 Rev- 2.2 Sept 07, 2022 • Cast Aluminum • Cored in both grips for internal wiring. • Each wheel weighs approximately 2.7 lbs. each. (Excluding switches) CESSNA 150, 152, 170, 172, 175, 180, 185 & 182 (to 1961) with ¾” diameter control shaft. Removal of original control wheels. (Reference drawing CW-6001) Remove the nut and bolt securing the control shaft to the universal joint at the control column behind the instrument panel. Withdraw the shaft from the panel. Remove the two rivets holding the original Cessna control wheel to the shaft by drilling off the heads or tails. Carefully drive the rivet out with a punch. Try not to enlarge the rivet holes. Remove the wheels by twisting off the shaft. Clean the end of the shaft to remove any residual structural epoxy. Check fitting the shaft into the new hub to ensure that it can be easily assembled. Prepare the new control wheels: 1) Set the height of the control wheel relative to the control shaft to suit leg clearance requirements or your personal preference. (Except 180/185 1965-on see note below. There are four different heights allowing a height range of 2.5 inches. 2) Attach the control shaft hub to the control wheel using 4 x MS35207-264 screws. Apply Loctite thread locker to each screw, install and torque to 15 inch-lbs. 3) Apply Loctite thread locker to the inside of the hub and insert the control shaft into the new control hub. Install two bolts MS27309-1-16 to secure the original shaft to the new hub via the original rivet holes. Install MS21042-1032 nuts and tighten. Torque bolts to 32 inch-lbs. and allow the Loctite to harden prior to the next step. Re-Install Control Wheels: Install control wheel shaft through the control shaft guide on the panel and onto the universal joint on the control column. Re-install the nut and bolt and securely tighten. Repeat for the other wheel. Check that the control wheel has full and free motion and that the motion of the control column is not impeded in any way. Note: 1965 – on Cessna 180/185 aircraft The control wheel shaft/hub should be mounted in the best position on the Avion control wheel aircraft to provide adequate clearance between the Avion wheel LH bottom edge and the mixture control when the mixture is in idle-shutoff (fully out) and left aileron is fully applied. CESSNA 177, 182 (1962 0n), 205, 206, 207 & 210 With 1.25" diameter control shaft. Removal of original control wheels. (Reference drawing CW-6002) Remove plastic cover from rear of wheel with a screwdriver or the edge of a knife. The cover is held in place with a formed detent in the plastic. Slide the cover up the shaft to gain access to the three screws located 120 degrees apart around the shaft, these screws secure the wheel to the control shaft. Remove the three screws and remove the original control wheel by withdrawing out of the end of the control shaft. Disconnect the ribbon cables and remove the original control wheels. Prepare the new control wheels: 1) Set the height of the control wheel relative to the control shaft to suit leg clearance requirements or your personal preference. There are four different heights allowing a height range of 2.5 inches. 2) Attach the control shaft hub to the control wheel using 4 x MS35207-264 screws. Apply Loctite thread locker to each screw, install and torque to 15-inch pounds. Re-installation of control wheels. Reference drawing CW-6002 Re-install the control wheels onto the control shafts and re-install the three attaching screws. Add a drop of Loctite (Blue) to the three screw threats. Tighten securely to recommended torque setting. Repeat procedure for the other wheel. Wiring Access: The switch plates can be removed from each grip by removing the two #4-40 screws from each plate. Carefully drill necessary switch holes in the switch cover plates to install switches. Wiring is fed down the control wheel grip and out the bottom to be strain relieved on the rear of the wheel. A coiled cord can be secured to the rear of the wheel using any of the four available # 6-32 holes or # 8-32 unused mounting holes. The wiring can also be fed through the control shaft and exit in the same manner as the OEM installation. Switches: Avion does not supply PTT, A/P disconnect or Cygnet trim switches, but does recommend the following Otto P7-5 series Mil-Spec miniature push button switches. These switches are available with normally open or closed circuits and with either black or white actuators. A common PTT switch is the Otto P7-5A1122 Black Knob (normally open) and the Otto P7- 5A1121 Red Knob (normally closed) for the Auto Pilot Disconnect switch. The Otto switches are generally available at Mouser Electronics, Digikey, Newark Electronics and other electronics suppliers. Note: Cygnet supplies two # 2-56 cap head screws to secure the Cygnet trim switch to the control wheel switch plate, however Avion electric trim switch plates are tapped for # 4-40 threads. The # 2-56 screws should be replaced with # 4-40 flat head screws for more secure mounting when used with the Avion control wheel switch plate. The OEM Cygnet mounting holes can be counter sunk to accommodate the #4-40 flat head screws. INSTRUCTIONS FOR CONTINUING AIRWORTHINESS 14 CFR part 25, section 25.1529 Maintenance Requirements. “Modification of an aircraft by this supplemental type certificate obligates the aircraft operator to include the maintenance information provided by this document in the operator’s aircraft maintenance and operators scheduled maintenance program.” 1. Maintenance manual information, if any, is contained in Control Wheel Installation Instructions CW-8001 and should be placed in the operators appropriate Airplane Maintenance Manual. 2. There are no LRU’s associated with modifications made under this STC. 3. All wiring diagram changes, where applicable, are contained within the Control Wheel