DESCRIPTION
The AMI Model 104 Flap Asymmetry Tester is an intelligent hand-held electronic tester that is designed to facilitate the
testing and alignment of the left and right flap asymmetry switches on the Gulfstream GII, GIII, and GIV aircraft. Since it is
powered from the aircraft and requires no additional power source, it also tests the integrity of the flaps electrical system.
This tester has internal electronic logic that will automatically move and stop the flaps when the reference asymmetry
switch is aligned to the leading edge of the 'A' contact. This defines a solid reference point for setting the alignment of
both switches. It also has an extremely sensitive phase error detection indicator, and a circuit for detecting serious phase
errors that could lead to a FLAPS LOCKED condition.
IMPORTANT NOTE: Using this tester requires access to only one side of the aircraft (left or right), yet it allows
the technician the ability to observe and test both asymmetry switches from this one side. The switch accessed
is defined as the unit UNDER TEST, while the opposite switch (not accessed) is defined as the REFERENCE. The
rotation and position of both switches are displayed on the tester's ASYMMETRY SWITCH POSITIONS indicator.
SWITCHES & INDICATORS
POWER SWITCH Controls the application of power to the tester. Set to either the LEFT SWITCH, or RIGHT
SWITCH, depending on which side of the aircraft has been accessed.
AUTO SET SWITCH Moves the flaps & automatically stops when the position of the reference asymmetry
switch is set to the leading edge of the ‘A’ contact. This provides the technician with a
reference set point. Press & hold switch until flaps stop.
MANUAL RUN SWITCH Allows the technician to have manual control of the flaps with no interrupts.
Press & hold
switch to run.
FLAPS LOCKED INDICATOR Indicates a serious out of phase asymmetry condition that could cause the flaps to lock.
PHASE ERROR INDICATOR Indicates the asymmetry switches are not in perfect alignment (phase), as analyzed by
the tester's sensitive electronic phase comparator. Due to manufacturing tolerances,
absolute perfection may not be possible.
SWITCH POSITION INDICATORS Indicates the exact rotational position of each asymmetry switch.
FLAP ASYMMETRY TESTER
GII - GIII - GIV
MODEL 104
POWER SWITCH
AUTO SET/ MANUAL RUN
SWITCH
FLAPS LOCKED
INDICATOR
PHASE ERROR
INDICATOR
SWITCH POSITION
INDICATORS
TO SWITCH
TO AIRCRAFT
WARNING:
ANY PERSON OPERATING THIS TEST EQUIPMENT MUST BE FAMILIAR WITH THE APPLICABLE AIRCRAFT FLAP ASYMMETRY &
ELECTRICAL SYSTEMS. CURRENT AIRCRAFT MAINTENANCE MANUALS MUST BE AVAILABLE AS A GUIDE TO PROPER OPERATION OF
THE FLAP SYSTEM. THE FLAP ASYMMETRY SYSTEM WILL NOT PREVENT MOVEMENT WHEN THIS TEST BOX IS CONNECTED TO THE
SYSTEM. THE FLAPS WILL MOVE WHEN THE FLAPS SWITCH IS SELECTED & HELD IN THE “MANUAL RUN” POSITION REGARDLESS
OF THE STATE OF SYMMETRY.
OPERATION
THE FOLLOWING OPERATIONS REQUIRE THE USE OF HYDRAULIC AND ELECTRICAL POWER. REFER TO THE
AIRCRAFT MAINTENANCE MANUAL FOR INSTRUCTIONS AND SAFETY PRECAUTIONS.
SET UP
1. Gain access to either the right, or left flap asymmetry switch. Both switches will be tested from this side.
2. Connect the test box to the aircraft as indicated. Connect the ground clip to the aircraft frame (This clip is power
ground, so a good ground connection is required here). Secure cables to prevent damage. Check that all items
are clear of the flap drive system & that the harness will not be damaged when the flaps move.
CONTROLLING FLAP MOVEMENT
1. Position the cockpit flap handle to the next flap position in the desired direction of movement. Set tester
POWER switch to either the LEFT or RIGHT position, depending on which asymmetry switch has been accessed.
(Upon initial application of power, all indicators will illuminate for two seconds. This is to test the indicators.)
2. Press & hold MANUAL RUN switch. Flaps will move until selected position is reached, or the switch is released.
LEFT SWITCH INTERFACE
Connect to LEFT or RIGHT asymmetry switch. Set
POWER switch accordingly. Press and Hold AUTO SET
switch to move reference to the next leading edge of A.
Adjust PHASE ERROR to minimum or nil.
FLAPS LOCKED shall remain off.
U
SWITCH
AIRCRAFT
(Under test) (Reference)
ERROR
PHASE
FLAPS
LOCKED
RIGHT SWITCH INTERFACE
AIRCRAFT FRAME - RIGHT WING
AIRCRAFT FRAME - LEFT WING
MANUAL RUN
RIGHT SWITCH
POWER
B
C
B
C
AA
ASYMMETRY SWITCH POSITIONS
MODEL 104
MOVE FLAPS
LEFT SWITCH
AUTO SET
FLAP ASYMMETRY TESTER
GII - GIII - GIV
OFF
OFF
PRESS & HOLD
PRESS & HOLD
LEFT
POWER
x x
x
x
x
x
x x
x
x
x x
x x
x
x
x
x
x x
x
x
x x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
ASYMMETRY
SWITCH
LEFT
ASYMMETRY
SWITCH
RIGHT
x x
x
x
x
x
x x
x
x
x x
x x
x
x
x
x
x x
x
x
x x
Connect to LEFT or RIGHT asymmetry switch. Set
POWER switch accordingly. Press and Hold AUTO SET
switch to move reference to the next leading edge of A.
Adjust PHASE ERROR to minimum or nil.
FLAPS LOCKED shall remain off.
ERROR
PHASE
FLAPS
LOCKED
Connect to LEFT or RIGHT asymmetry switch. Set
POWER switch accordingly. Press and Hold AUTO SET
switch to move reference to the next leading edge of A.
Adjust PHASE ERROR to minimum or nil.
FLAPS LOCKED shall remain off.
U
SWITCH
AIRCRAFT
(Under test) (Reference)
ERROR
PHASE
FLAPS
LOCKED
MANUAL RUN
RIGHT SWITCH
POWER
B
C
B
C
AA
ASYMMETRY SWITCH POSITIONS
MODEL 104
MOVE FLAPS
LEFT SWITCH
AUTO SET
FLAP ASYMMETRY TESTER
GII - GIII - GIV
OFF
OFF
PRESS & HOLD
PRESS & HOLD
RIGHT
POWER
x x
x
x
x
x
x x
x
x
x x
x x
x
x
x
x
x x
x
x
x x
Connect to LEFT or RIGHT asymmetry switch. Set
POWER switch accordingly. Press and Hold AUTO SET
switch to move reference to the next leading edge of A.
Adjust PHASE ERROR to minimum or nil.
FLAPS LOCKED shall remain off.
ERROR
PHASE
FLAPS
LOCKED
SWITCH
(Under test) (Reference)
AIRCRAFT
(Under test)
(Reference)
SWITCH
AIRCRAFT
AIRCRAFT
HARNESS
AIRCRAFT
HARNESS
POWER
GROUND
CLIP
POWER
GROUND
CLIP
NOTE POWER
SWITCH SETTING
"LEFT SWITCH"
NOTE POWER
SWITCH SETTING
"RIGHT SWITCH"
SET ASYMMETRY SWITCHES
1. Set the flaps to the full down position and set the flap handle to any other detent position. Press and Hold
the AUTO SET switch until flaps come to a complete stop. The AIRCRAFT (Reference) ‘A’ Switch Position
indicator should be illuminated (green) along with the previous position indicator.
2. While still connected, manually adjust the asymmetry switch until the PHASE ERROR indicator is off and both
ASYMMETRY SWITCH POSITIONS indicators are matched. Refer to the Aircraft Maintenance Manual for
instructions on adjusting asymmetry switch.
CHECK OPERATION
1. Allow flaps to operate by pressing and holding the MANUAL RUN switch.
2. Verify that the ASYMMETRY SWITCH POSITIONS indicators are matched. Monitor the PHASE ERROR and
FLAPS LOCKED indicators while flaps are in motion.
3. If the FLAPS LOCKED indicator illuminates at any time during the testing, this indicates a severe misalignment of
the switches leading to a complete loss of the asymmetry signal. In this condition the flaps will not run when the
asymmetry system is reconnected. Repeat the SET ASYMMETRY SWITCHES procedure. If this does not
correct the problem, refer to the Aircraft Maintenance Manual for additional troubleshooting procedures.
4. The PHASE ERROR indicator will illuminate whenever both asymmetry switches are not in precise
synchronization. This indicator may still pulse slightly under normal conditions. The shorter the pulse is, the
closer the alignment.
Due to manufacturing tolerances, however, absolute synchronization may not be possible.
TROUBLESHOOTING
CONDITION ACTION
All indicators on tester Illuminate momentarily when
POWER is first turned on.
This is normal. The test box performs a self test
each time it is turned on.
PHASE ERROR indicator flashes when the flaps
are moved, but the ASYMMETRY SWITCH POSITIONS
indicators match.
Due to mechanical tolerances between the switches
and within the flap drive system it may not be possible
to adjust to a zero Phase Error.
PHASE ERROR indicator flashes when the flaps are
moved, and the ASYMMETRY SWITCH POSITIONS
indicators DO NOT match.
Indicates an out of symmetry condition.
Perform SET ASYMMETRY SWITCHES procedure.
FLAPS LOCK indicator is illuminated. Indicates a serious out of symmetry condition.
Perform SET ASYMMETRY SWITCHES procedure
Nothing happens when the POWER switch is turned on. Check all connections. Check ground clip is connected
properly. Check tester fuse. Verify that the POWER
switch is set correctly to RIGHT or LEFT. Make sure that
Flap handle is selected to another detent position.
AUTO SET does not stop flap movement on AIRCRAFT
(Reference) 'A' indicator.
Make sure that you PRESS & HOLD AUTO SET
switch until flaps come to a complete stop.
Warranty & General Disclaimer
AirMech Innovations (AMI) warrants this product to be free from defects in materials and workmanship
for a period of TWO (2) years.
During the warranty period, AMI will repair or replace, at its option, free of charge, any unit returned to AMI, freight
prepaid. Written authorization from AMI must be obtained prior to returning any unit for warranty work.
This warranty shall be void if the unit has been modified, altered, repaired, or re-calibrated, by anyone other than
an authorized AMI technician.
AMI will not be liable for any consequential damages, loss, or expense arising in connection with the use of,
or the inability to use its goods for any purpose whatsoever. AMI’s maximum liability shall not in any case exceed the
contract price for the goods claimed to be defective or unsuitable.
Products will be considered accepted by customer, unless written notice to the contrary is given to AMI
within ten (10) days of such delivery to customer.
AMI shall not in any case be liable for any event occurring, or defect discovered, with regard to said products unless
written notice thereof is given to AMI within ONE (1) year of such products delivery to customer.
Except for the warranty that the products are made in accordance with the specifications therefore supplied or agreed to
by customer, AMI makes no warranty expressed or implied, and any implied warranty of merchantability or fitness for a
particular purpose which exceeds the foregoing warranty is hereby disclaimed by AMI.
AMI’s products are not designed for and should not be used, without the specific prior written consent of AMI, in any life
support systems, nuclear-facility applications, aircraft-control applications or any other applications in which use or failure
of the product, in any way, could result in personal injury, harm to life, property, or the environment.
This warranty and general disclaimer is in lieu of all other warranties and claims, expressed or implied
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