Chapter 27 Flight Controls
Contents
1. EXTRA 300 MAINTENANCE PRACTICES Rudder Rigging Replace the control cables and adjust the length per Chapter 27 21 04 if necessary Check if the rudder travel is within the given toler ances left right 30 2 If the rudder travel is out of limits contact the manu facturer for advice PAGE DATE 1 June 1996 CHAPTER 27 PAGE 22 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 27 30 00 ELEVATOR AND TAB Refer to Figure 16 The two control sticks 6 7 are connected by a push pull rod 8 inside the torque tube 5 The control movements are transferred from the rear con trol stick 7 to the elevator 2 by push pull rods 8 and bellcranks 9 9a The bell cranks have two sealed ball bearings The elevator is mounted at five points in spherical bearings pressed into aluminium hinge arms For lightning protection reason each hinge arm is grounded to the corre sponding attachment bracket at the elevator by bonding leads The travel stops 22 are located at the torque tube The mass balance weight 21 is mounted on the center bracket of the elevator extending into the fuselage An access panel is located at the right side of the rear fuselage Trim Tab The elevator trim control lever 16 is located at the right side in the rear cockpit Pitch trim is done by means of the trim tab 14 on the right elevator trailing edge operated by a bowden cable mechanism 15 The trim tab is mounted by two2. Rear Control Stick Removal Installation Remove the leather protection cuff Disconnect the electrical wiring Bring the control stick in the foremost position and dis connect the control stick from the control rods per Chap ter 27 10 01 Remove the control stick attachment bolt Remove the control stick Reverse procedure to install the control stick Replace the selflocking nuts Observe the first Note of Chapter 27 01 00 Check for potential chafing of the wiring after installa tion Torque Tube Removal Installation M Remove the respective access panels Remove the control sticks and rods per Chapters 27 01 01 and 27 01 03 04 Loosen the bolts of the front and rear bearing blocks Disassemble the bearing blocks and remove the torque tube Reverse procedure to install the torque tube Ensure that the lubrication hole of the rear bearing block is on the bottom Lubricate the rear bearing with Aeroshell grease 22C or equivalent MIL G 81322D PAGE DATE 31 January 1995 CHAPTER 27 PAGE 10 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 MAINTENANCE PRACTICES 27 01 06 NOTE IMPORTANT IMPORTANT Control Rod Length Adjustment The standard measurements are given in Chapter 27 00 02 1 Remove the respective access panels 2 Disconnect one rod end from the respective bellcrank 3 Loosen the check nut It might be necessary to adjust both rod ends to get the correct length In
3. SERVICE MANUAL EXTRA 300 MAINTENANCE PRACTICES 27 01 01 NOTE 27 01 02 Control Rod Removal Installation Refer to Figure 7 All control rods are attached to the control levers in the same way with AN bolts washers and self locking nuts The control rods inside the wing are intercon nected by ground bonding leads fastened to the rod ends by additional nuts So the rod ends have to be disassembled when the ground bonding leads shall be disconnected In this case also refer to Chapter 27 01 06 For the EXTRA 300 up to serial No 53 castle nuts and cotter pins are used instead of the selflocking nuts except the front control stick to control rod connection for which are also used a selflocking nut 1 Remove the respective access panels In case of removal of the control rod connecting the con trol sticks also observe the instructions given in the Chapters 27 01 03 and 04 2 Remove the M6 attachment bolts 1 3 Remove the control rod 4 Reverse procedure to install the control rod Replace the selflocking nuts Bellcrank Removal Installation Refer to Figure 7 1 Remove the respective access panels 2 Remove the adjacend control rods per Chapter 27 01 01 3 Remove the M5 attachment bolt 2 4 Remove the bellcrank 5 Reverse procedure to install the bellcrank using suffi cient washers min 2 at the nut side ofthe bolt to cover the shank except the rocker type bellcrank use only one washer on each si
4. APTER 27 PAGE 18 EXTRA FLUGZEUGBAU GmbH RUDDER SERVICE MANUAL EXTRA 300 2 ES g Son n oo Ss Ta BoA e0 S t dua 3 g 5 X IER B 55355443 STESSE Fes baa oo este em D de e Rudder Control Figure 15 PAGE DATE 31 January 1995 CHAPTER 27 PAGE 19 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 27 21 00 MAINTENANCE PRACTICES IMPORTANT If airplane is factory equipped or retrofitted with elec tric actuated rudder pedal adjustment perform checks 10 11 of Flight Controls presented in Chapter 05 20 04 after each maintenance work affecting the rudder control cables 27 21 01 Rudder Removal Installation 1 Disconnect the rudder control cables from the bottom hinge bellcrank 2 Loosen the hinge bolts and the ground bonding leads and remove the bolts 3 Install in reverse sequence of removal Observe the sec ond Note of Chapter 27 01 00 27 21 02 Bottom Hinge Bracket Removal Installation 1 Remove the rudder per Chapter 27 21 01 2 Loosen the attachment bolts 3 Remove the bottom hinge bracket with the travel stop plate 4 Install in reverse sequence of removal 27 21 03 Bottom Hinge Bellcranks Removal Installation 1 Remove the rudder per Chapter 27 21 01 2 Loosen the attachment bolts 3 Remove the bottom hinge bellcranks 4 Install in reverse sequence of removal PAGE DATE 1 June 1996 CHAPTER 27 PAGE 20 EXTRA FLUGZEUGBAU GmbH MAINTENANCE PRAC
5. EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 Chapter 27 Flight Controls PAGE DATE 31 January 1995 CHAPTER 27 PAGE 1 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 Chapter 27 00 00 27 00 01 27 00 02 27 01 00 27 01 01 27 01 02 27 01 03 27 01 04 27 01 05 27 01 06 27 10 00 27 11 00 27 11 01 27 11 02 27 11 03 27 20 00 27 21 00 27 21 01 27 21 02 27 21 03 27 21 04 27 21 04 27 21 05 27 21 06 27 30 00 27 31 00 27 31 01 27 31 02 27 31 03 27 31 04 TABLE OF CONTENTS Title GENERAL tette 3 Free Play in the Control System ssl 3 Control Rod Lengths u sss 5 MAINTENANCE PRACTICES s 6 Control Rod Removal Installation 7i Bellcrank Removal Installation 7 Front Control Stick Removal Installation aaa 9 Rear Control Stick Removal Installation 10 Torque Tube Removal Installation 10 Control Rod Length Adjustment 3 11 ATDER CONS us eade uta ua guau uma umu L ni 12 MAINTENANCE PRACTICES ll 14 Aileron Removal Installation aa 14 Aileron RiggIng lea 15 Spade Rigging s 16 RUD DPR aaa o EARN 18 MAINTENANCE PRACTICES ll 20 Rudder Removal Installation aaa 20 Bottom Hinge Bracket Removal Installation 0 20 Bottom Hinge Bellcranks Removal Installation 20 Control Cable Removal 20A Control Cable Installation 20A Fairlead Removal Installation aaa 21 Rudder BIg BSIDB odiis D Red b d ERR Om 21 ELEVATOR AND TAB 23 MAINTENANCE PRACTICES l
6. PAGE DATE 1 June 1995 CHAPTER 27 PAGE 17 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 27 20 00 IMPORTANT RUDDER Refer to Figure 15 The rudder pedals 4 are connected via a cable system 17 to the bottom hinge bellcrank 13 The cables are guided by fairleads 11 Springs 20 keep the cables under tension when they are not operated Adjust ment 18 is made via multihole sheet metal connections to the rear pedals The rudder 3 is mounted at three points in spherical bearings pressed into a aluminium hinge resp into aluminium hinge arms For lightning protection reason each hinge arm is grounded to the corresponding attach ment bracket at the rudder by bonding leads A travel stop plate is located at the bottom hinge bracket If airplane is factory equipped or retrofitted with electric actuated rudder pedal adjustment a second safety stop is located atthe rudder pedal bearing having the only purpose of protecting the lower brake system fitting in case of rudder cable failure This second stop must not be reached under normal operation conditions Missallignment or exessive elon gation of the rudder cabels will result in misuse of this second stop and a subsequent overload of the rudder bearing An subsequent inflight failure of the footrest could occur To prevent flutter the rudder is mass balanced The mass balance weight ofthe rudder is installed in the rudder horn PAGE DATE 1 June 1996 CH
7. R 27 PAGE Control Surface Deflections Figure 2 PAGE DATE 31 January 1995 EXTRA FLUGZEUGBAU GmbH GENERAL SERVICE MANUAL EXTRA 300 27 00 02 Control Rod Lengths The measurements given in this chapter refer to the dis tances between the centers of the rod end bearings see Figure 3 7 FH Q given measurements Control Rod Measurement Figure 3 Refer to the following Figure 4 for identification of the control rods Control Rod Identification Figure 4 0 970 mm 1 787 mm 2 645 mm 3 832 mm 4 873 mm 5 409 mm 6 532 mm 7 1884 mm 8 420 mm PAGE DATE 31 January 1995 CHAPTER 27 PAGE 5 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 27 01 00 NOTE NOTE MAINTENANCE PRACTICES When installing a bellcrank or control stick the spacer sleeve inside the bearing could be displaced as shown in Figure 5 Use a mandrel to adjust the spacer sleeve M uL bearings spacer sleeve Spacer Sleeve Displaced Figure 5 When installing a control surface use mandrels as shown in the following Figure 6 to preset the control surface Then press out each mandrel by pushing a bolt into the bearing a Ad Aileron Su Control Surface Mounting Aid Figure 6 PAGE DATE 31 January 1995 CHAPTER 27 PAGE 6 EXTRA FLUGZEUGBAU GmbH
8. TICES SERVICE MANUAL EXTRA 300 Control Cable Installation 9 Slip the 771095 shrinking sleeve and the NICOPRESS National Telephone Supply Co Cleveland Ohio 18 3 M sleeve on the cable end 10 Move the cable around the thimble and tighten IMPORTANT Clamping has to be performed in accordance with the Service Bulletin 300 1 93 and the Instruction No 32 of the National Telephone Supply Co Cleveland Ohio 11 Clamp the sleeve Consider to let a distance of 1 mm between the thimble and the sleeve 12 Cut the free end ofthe cable 20 mm behind the sleeve 13 Slip the shrinking sleeve on the cable end and heat up with a heat gun 14 Follow the steps 5 to 13 for the LH control cable 15 Remove rudder and rudder pedals securing devices 16 Check free travel of rudder 27 21 05 Fairlead Removal Installation 1 Remove the fairlead retaining clip 2 Pull the fairlead halves out of the sleeve 3 Reverse procedure to install the fairlead 27 21 06 Rudder Rigging NOTE Inspect the control cables the fairleads and the bottom hinge assembly with the travel stop plate for signs of wear or damage before beginning any adjustments Replace parts if necessary 1 Secure the rudder pedals in neutral position 2 Check if the rudder is in 0 position Rudder horn lead ing edge in alignment with the leading edge of the ver tical stabilizer PAGE DATE 1 June 1996 CHAPTER 27 PAGE 21 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL
9. de Replace the selflocking nuts PAGE DATE 31 January 1995 CHAPTER 27 PAGE 7 EXTRA FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 300 Observe the first Note of Chapter 27 01 00 To ensure installation of the elevator rocker type bellcrank and the aileron central bellcrank in correct direction these bellcranks are marked by an F which indicates the front side refer to Detail A of Figure 7 Detail A Control Levers and Rods Removal Installation Figure 7 PAGE DATE 31 January 1995 CHAPTER 27 PAGE 8 EXTRA FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 300 27 01 03 Front Control Stick Removal Installation Refer to Figure 8 1 Remove the leather protection cuff 2 Disconnect the electrical wiring 3 Remove the control stick attachment bolt 1 4 Disconnect the control stick from the control rod per Chapter 27 01 01 Use the control stick to move the control rod attachment bolt within the mounting hole area 2 Front Control Stick Removal Installation Figure 8 5 Remove the control stick 6 Reverse procedure to install the control stick Replace the selflocking nuts Observe the first Note of Chapter 27 01 00 7 Check for potential chafing of the wiring after installa tion PAGE DATE 31 January 1995 CHAPTER 27 PAGE 9 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 MAINTENANCE PRACTICES 27 01 04 27 01 05
10. g as shown in Figure 13 PAGE DATE 31 January 1995 CHAPTER 27 PAGE 15 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 MAINTENANCE PRACTICES Aileron Rigging Aileron Wing 10 11 12 13 Trailing Edge Alignment Figure 13 If necessary adjust the length of the control rods con necting the aileron center linkage to the outer wing bellcrank per Chapter 27 01 06 Check if the left aileron travel is within the given tol erances up down 30 2 Use a conventional pro tractor Adjust the travel stops if necessary Follow step 8 for the right aileron If the travel of the right aileron exceeds the given tol erances contact the manufacturer Check if the movement of the control sticks is free over the whole travel range and check if the rear control stick travel is symmetrically to each side If it is not contact the manufacturer PAGE DATE 31 January 1995 CHAPTER 27 PAGE 16 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 MAINTENANCE PRACTICES 27 11 03 Spade Rigging For roll trim the spade rigging angle of incidence has to be changed Insert washer s between the spade and the mount ing plate refer to Figure 14 For example When the aircraft rolls to the left insert washer s at the front attach ment bolt of the right spade spade arm mounting plate washer s e Spade Spade Rigging Figure 14
11. i 25 Elevator Removal Installation 25 Trim Tab Removal Installation 25 Elevator Rigging u acti recon aene red EORR leas 25 Trim Tab Rigging 27 PAGE DATE 1 June 1996 CHAPTER 27 PAGE 2 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 27 00 00 GENERAL Refer to Figure 1 The EXTRA 300 is standard equipped with full dual primary flight controls including conven tional control sticks and adjustable rudder pedals The control surfaces are operated by a direct mechanical link age The control surface deflections are shown in Figure 2 From Ser N 64 there isa rubber plugged hole in the bottom fuselage cover for rear torque tube bearing lubrication 27 00 01 measured at the trailing edge and max chord Controls Figure 1 Free Play in the Control System With controls stick and rudder pedals locked the free play measured at the control surfaces must not exceed the values listed Aileron 1 mm Elevator 1 mm Trim tab 2 mm The rudder has a direct cable connection with retracting springs and is therefore always under tension PAGE DATE 1 June 1996 CHAPTER 27 PAGE 3 GENERAL EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 50 uwop scr 99UEJ9 0 oST UMOP oS C AN Do 93UEJO O 0 yel s 99UBI9 0 IOIBA9IH SUOJ9 IV 00 3491 oCF 99ULI9 O xa OPPOY oSIY umop a qe ul oS I 4 CHAPTE
12. nstall in reverse sequence of removal Elevator Rigging 1 Remove the respective access panels Before beginning any adjustments inspect control rods levers and hinges for signs of wear or damage and check if control rod lengths correspond with the measurements given in Chapter 27 00 02 Replace parts and correct lengths if necessary per Chapter 27 01 06 PAGE DATE 31 January 1995 CHAPTER 27 PAGE 25 EXTRA FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 300 Elevator Rigging 2 Remove the control stick leather protection cuff 3 Secure the control stick in the neutral position Verti cal back edge of the torque tube parallel to the control stick like shown in Figure 17 parallels Neutral Position of the Rear Control Stick Figure 17 4 Check if the elevator is in 0 position Trailing edge on chord line Fasten a lath to the tip rib of the horizontal tail per Figure 18 using adhesive tape lath on chord line elevator 0 position adhesive tape Lath on Chord Line Figure 18 PAGE DATE 31 January 1995 CHAPTER 27 PAGE 26 EXTRA FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 300 Elevator Rigging 5 Ifnecessary adjust the length of the middle tail control rod per Chapter 27 01 06 6 Check if the elevator travel is within the given toler ances up down 25 2 Use a conventional protrac tor 7 Adj
13. o the rear control stick 7 To reduce pilot s hand forces the hinge line of the ailerons is positioned at 25 of the aileron chord Furthermore the ailerons are equipped with spades To prevent flutter the ailerons are mass balanced in the overhanging leading edge Two access panels are located at the bottom surface of each side of the wing PAGE DATE 31 January 1995 CHAPTER 27 PAGE 12 EXTRA FLUGZEUGBAU GmbH AILERONS SERVICE MANUAL EXTRA 300 o bn g Su J 5 9 O 2 o no ga 2 L24202 Bee OL PP d sai t2 Soyonoasd Osun HOD n 8 e lt QDs S2 555355328 sS 8 Sd b e sols Q in O A ca TA Aileron Control Figure 10 PAGE DATE 31 January 1995 CHAPTER 27 PAGE 13 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 27 11 00 MAINTENANCE PRACTICES 27 11 01 Aileron Removal Installation 1 Disconnect the actuator rod from the aileron center link age 2 Disassemble the spade if necessary observing the quan tity and location of washers 3 Loosen the hinge bolts and the ground bonding leads and remove the bolts 4 Install in reverse sequence of removal Ensure that the spade is installed with the same quantity and location of washers Observe aileron to linkage connection re fer to Figure 11 and spade to mounting plate connec tion refer to Figure 14 From Serial No 41 the wash ers of the aileron to linkage connection have been omit ted Also observe the sec
14. ond Note of Chapter 27 01 00 aileron washers linkage spade arm Aileron to Linkage Connection Figure 11 PAGE DATE 31 January 1995 CHAPTER 27 PAGE 14 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 MAINTENANCE PRACTICES 27 11 02 Aileron Rigging Before beginning any adjustments inspect control rods levers and hinges for signs of wear or damage check if the control rod lengths correspond with the measurements given in Chapter 27 00 02 If necessary replace parts and correct lengths per Chapter 27 01 06 1 2 Secure the control stick in the neutral position Remove the back rest of the front seat and check if the central bellcrank is in middle position bolts in the same distance from the central tube as shown in Figure 12 Front view Front seat back rest removed central tube M bolts central bellcrank Central Bellcrank Middle Position Figure 12 If necessary adjust the control rod connecting the torque tube and the central bellcrank per Chapter 27 01 05 Reinstall the front seat back rest Check if the control rods connecting the central bellcrank and the inner wing bellcranks have a length of 532 mm Refer to Chapter 27 00 02 Adjust length if necessary per Chapter 27 01 06 Check if the ailerons are in 0 position The trailing edge bottom of the aileron is in alignment with the trailing edge bottom of the win
15. piano hinges The trim tab is not mass balanced PAGE DATE 31 January 1995 CHAPTER 27 PAGE 23 HDVd LC UWHLdVHO vc S661 renuef Tc AIVA HDVd 9 24n314 1041u0 quy UA pun 40 D42 T A a J li elevator torque tube front seat stick rear seat stick push pull rod bellcrank rocker type bellcrank elevator actuator arm trim tab trim control bowden cable mechanism trim tab control lever mass balance travel stops 00 VALXH TVANVIN HOIAUHS HQUD5 NVEONAZON TA VALXA 8V L ANV YOLVAYTA EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 27 31 00 27 31 01 27 31 02 27 31 03 IMPORTANT MAINTENANCE PRACTICES Elevator Removal Installation Before the removal of the elevator the vertical stabilizer has to be disassembled 1 Remove the respective access panels 2 Remove the rudder per Chapter 27 21 01 3 Remove the vertical stabilizer per Chapter 55 21 01 4 Loosen the bowden cables from the trim tab If a re placement is necessary order new cable 5 Disconnect the elevator actuator arm from the push pull rod 6 Loosen the hinge bolts and the ground bonding leads and remove the bolts 7 Install in reverse sequence of removal Observe the sec ond Note of Chapter 27 01 00 Trim Tab Removal Installation 1 Loosen bowden cables If a replacement is necessary order new cable 2 Disconnect the safety cotter pins and remove the hinge pins 3 I
16. r hole of the pedal link rod 3 Fix rear pedals in vertical position 90 relative to the upper longeron Use a lath which can be fastened to the steel tube frame ofthe front seat back rest by means of clips 4 Secure the rudder in 0 position 5 Mount the shackle of the pre assembled control cable end to the RH pedal link rod 6 Thread the other end through the fairleads and the hole in the fabric to the tail 7 Slip 800 mm teflon protective hose on the control ca ble end The protective hose should extend to the front of the first fairlead inside the fuselage 8 Pre install the LN9355 06 20 bolt the DIN 125 M6 washers 2 washers outside 4 washers inside the DIN 937 M6 castle nut the DIN 94 cotter pin and the thim ble to the bottom hinge bellcrank PAGE DATE 1 June 1996 CHAPTER 27 PAGE 20A
17. this case the free thread of both rod ends should have the same length Observe that the rod ends joined to the rocker type bellcrank should be adjusted long enough not to obstruct the travel Ensure that the threaded rod is visible in the check hole Figure 9 in any case check hole Control Rod Check Hole Figure 9 4 Turn the rod end in the desired direction to change the length 5 Ensure that the rod end is in proper alignment with the respective control lever and tighten the check nut 6 Reinstall the control rod per Chapter 27 01 01 7 Ensure that the control rods don t jam when the control sticks are moved between the extreme positions PAGE DATE 31 January 1995 CHAPTER 27 PAGE 11 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 27 10 00 AILERONS Refer to Figure 10 The aileron 1 is direct mechanical linked to the control sticks 6 7 by the aileron center linkage 10 with spade arm push pull rods 8 bellcranks 9 and the torque tube 5 The bell cranks have two sealed ball bearings Each aileron is mounted at three points in spherical bearings pressed into aluminium hinge arms For lightning protection reason each hinge arm is grounded to the corresponding attachment bracket at the aileron by bonding leads The rod end bearings of the push pull rods located in the wing are also interconnected by bonding leads The travel stops 22 are located at the torque tube next t
18. ust the travel stops if necessary 8 Check if the rear control stick travel is symmetrically 9 If itis not contact the manufacturer 27 31 04 Trim Tab Rigging Refer to Figure 19 1 Secure the control stick in normal position 2 Secure the trim control lever 1 in horizontal position 3 Adjust the fuselage bellcrank 2 in middle position Use new selflocking nuts 3 Trim Tab Rigging Figure 19 4 Bring the trim tab in 0 position Use new selflocking nuts 4 5 Bring the trim lever in extreme positions and check if trim tab travel is 15 tolerance 2 If it is not check free travel of the trim levers fuselage bellcrank and bowden cables PAGE DATE 31 January 1995 CHAPTER 27 PAGE 27 EXTRA FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 300 27 21 04 Control Cable Removal 1 Remove the respective access panels 2 Remove the cable to pedal link rod attachment bolts 3 Remove the cable to rudder bellcrank attachment bolts 4 Cut the control cable behind the front shrinking sleeve 5 Remove the control cable by pulling it out to the back 27 21 04 Control Cable Installation Use only control cables manufactured by EXTRA FLUGZEUGBAU GmbH Those cables are prepared for simply installation 1 Remove the respective access panels per Chapter 51 2 Install rudder pedals in the 5th count from the rear hole of the bottom pedal attachment sheet and in the 6th count from the rea
Download Pdf Manuals
Related Search