Chapter 27 FLIGHT CONTROLS

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1 Chapter 27 FLIGHT CONTROLS 27-Title Page 1 January 23, 2012

2 INTENTIONALLY LEFT BLANK 27-Title Page 2 January 23, 2012

3 LIST OF EFFECTIVE PAGES Chapter Section Page No. Date Title 1 January 23, January 23, LOEP 1 January 23, January 23, January 23, January 23, TOC 1 January 23, January 23, July 7, July 7, July 7, July 7, July 7, July 7, July 7, July 7, July 7, July 7, July 7, July 7, July 7, July 7, July 7, July 7, LOEP Page 1 January 23, 2012

4 LIST OF EFFECTIVE PAGES Chapter Section Page No. Date July 7, July 7, July 7, July 7, July 7, July 7, July 7, July 7, July 7, July 7, July 7, July 7, LOEP Page 2 January 23, 2012

5 TABLE OF CONTENTS Chapter Section Title 27 Flight Controls 27-Title Title Page 27-LOEP List of Effective Pages 27-TOC Table of Contents General Co-Pilot Control Column Control Column (2C3 & 2C4) Control Wheel (2C3 & 2C4) Aileron System Aileron Rigging Rudder System Rudder Rigging Electric Rudder Trim Removal & Installation Trim Tab Travel Limits System Function Check Elevator System Elevator Rigging Horizontal Stabilizer Stabilizer Trim Actuator System Trim Control Wheel Trim Indicator Trim Actuator Stabilizer Rigging Plain Flaps Flap Rigging Fowler Flap General Maintenance Requirements Flap Limit Switches Flap Motor and Actuator Flap Indicator Fowler Flap Rigging Continuity Tests Flight Control Static Balancing Required Equipment Aileron Balance Procedure Elevator Balance Procedure Rudder Balance Procedure Alternate Method for Balancing Control Surfaces Control Lock 27-TOC Page 1 January 23, 2012

6 TABLE OF CONTENTS Chapter Section Title Control Cable Replacement Table and Figures 27-TOC Page 2 January 23, 2012

7 27 FLIGHT CONTROLS GENERAL The aircraft flight control systems are comprised of conventional aileron, elevator and rudder control surfaces. The pitch trim system is the horizontal stabilizer. In addition to the pitch trim system, the 2C3 & 2C4 utilize an electric rudder trim system. All of the primary control systems use variations of sprockets, chains, cables, pulleys, bellcranks and pushrods to move the control surfaces. Aileron and elevator movement is through a control wheel which is mounted to a central control column. The 2C3 and 2C4 include a dual control system as standard equipment, while the dual control system is an option on the 2C1 and 2C2. The rudder movement is through the rudder pedals of which there is a set in the left hand and optional right hand positions Page 1 July 7, 2011

8 INTENTIONALLY LEFT BLANK Page 2 July 7, 2011

9 27-01 CO-PILOT CONTROL COLUMN (2C1 & 2C2) The aircraft may be equipped with an optional Co-Pilot Control Column. The control column provides inputs to both the elevator and aileron systems. For additional details see sections Aileron System and Elevator System. It is permissible to operate the aircraft without the Co-Pilot Control Column installed. Co-Pilot Control Column Removal Step 1. Disconnect P.T.T. switch and remove associated wire. Be certain to secure the copilot P.T.T. wires per AC43-13 to avoid unwanted transmitter keying. See Figure Figure Co-Pilot P.T.T. Wire Removal Page 1 July 7, 2011

10 Step 2. Remove the dust cap from the end of the co-pilot control column. See Figure Step 3. Remove, if set, the cotter pin securing the control arm nut. See Figure Step 4. Remove the control arm nut using FAC tool TF1726 or equivalent. See Figure Step 5. Loosen the Pinch Screws securing the control arm sleeve. See Figure Figure Control Arm Removal Step 6. Rotate the control yoke until the Master Link is accessible. See Figure Step 7. Remove the Master Link and separate the chain. See Figure Step 8. Remove the control sleeve. See Figure Page 2 July 7, 2011

11 MASTER LINK ASSEMBLY CLIP MUST BE ON FWD FACE OF CHAIN REMOVE YOKE AND CONTROL SLEEVE Figure Control Sleeve Removal Step 9. Remove the bolt securing the control arm to the center section. See Figure Step 10. Remove the control arm. (Note: The control arm fit will be tight.) Page 3 July 7, 2011

12 Figure Control Arm Removal Step 11. Remove the double safety wire securing the roll pin which secures the aft sprocket inside the center section. See Figure Step 12. Drive out the roll pin using a 5/16 drift punch. This will allow the sprocket to rotate. Step 13. Carefully remove the co-pilot control chain. See Figure Step 14. Replace the roll pin and double safety wire it in place using S.S. wire. Step 15. Cover the resultant hole with a dust cover, Spaenaur P/N B-1565N, or equivalent. See Figure Page 4

13 Figure Control Chain Removal Figure Dust Cover Install Page 5

14 Co-Pilot Control Column Installation Step 1. Remove dust cap from center section of control column. See Figure Step 2. Remove the double safety wire from the roll pin of the aft sprocket. See Figure Step 3. Using a 5/32 drift punch, drive out the roll pin. See Figure Step 4. Fish the co-pilot control chain over the aft sprocket. Step 5. Pull the chain out evenly following the approximate line of the control arm. See Figure Step 6. Using the pilots control yoke and the co-pilot control chain align the holes in the aft sprocket and control shaft. Step 7. Install the roll pin. Double lock wire it with S.S. wire. See Figure Step 8. Next install the control arm as shown in Figure Ensure the control chain is routed both over and under the bolt fastening the arm. Step 9. Next install the control sleeve assembly complete with the control yoke. See Figure Step 10. The control chain must now be fished over/around the chain sprocket contained in the sleeve. Furthermore, the pilot and co-pilot control yokes must be aligned with each other. Step 11. Next install the master link as indicated in Figure The clip link shall be installed on the forward face of the chain and sealed with a dab of witness mark. Step 12. Rotate the control wheel back and forth to ensure the lock wire securing the sprocket does not interfere with the master link. Adjust lock-wire as required. Step 13. Next install the control arm nut as shown in Figure Tighten the nut thus tensioning the control chain. Recheck the alignment of the pilot s and co-pilot s control yokes. Adjust the control chain if required. Step 14. Next tighten the pinch screws per Figure Step 15. Next install a new cotter pin as shown in Figure If necessary drill hole to provide alignment. Step 16. Install dust cap per Figure Step 17. Reinstall co-pilot P.T.T. as shown in figure and secure wires Page 6

15 27-03 CONTROL COLUMN (2C3 & 2C4) The aircraft is equipped with a dual control system. The control column provides inputs to both the elevator and aileron systems. For additional details see sections Aileron System and Elevator System. It is permissible to operate the aircraft without the Co-Pilot Control Column installed. Pilot's Control Wheel Control Column Figure Control Column Co-pilot's Control Wheel Control Column Removal: Reference Figure Step 1. Turn the Master Switch OFF. Step 2. Placard the aircraft as required to ensure that ailerons are not moved during removal. Step 3. Disconnect the circular electrical connector below center instrument panel. Step 4. Remove the co-pilot control arm, see "Co-pilot Control Arm Removal" in this section. Step 5. Remove the dust cap from the outboard end of the pilot's control arm. Step 6. Loosen the pinch screws on the control arm sleeve. Step 7. Loosen the chain in the pilot's control arm by turning the control arm nut using FAC tool TF1726 or equivalent. Step 8. Remove the lock-wire and using a 5/32 drift punch drive out the roll pin from the forward sprocket in the center hub. Discard the hardware Page 1 July 7, 2011

16 Step 9. Remove the bolt securing the control arm to the control arm mounting flange. Retain hardware. Step 10. Simultaneously pull the control arm off the center shaft while inserting a 3/4 pin into the center hub. This will keep the sprockets and the spacers inside the center hub in exactly the same configuration eliminating a need for reassembly. The control arm is now free. Control Column Installation: Reference Figure Step 1. Turn the Master Switch OFF. Step 2. Placard the aircraft as required to ensure that ailerons are not moved during installation. Step 3. Simultaneously install the control arm onto the center shaft while removing a 3/4 pin from the center hub. Step 4. Install the bolt through the control arm into the control arm mounting flange and secure with the nut. Step 5. Install the roll pin through the forward sprocket in the center hub. Step 6. Tighten the chain in the control arm by tuning the control arm nut using FAC tool TF1726 or equivalent. Step 7. Tighten the pinch screws on the control arm sleeve. Step 8. Temporarily secure the ailerons in the neutral position and check whether the pilot's control wheel is in correct orientation. If not, remove the roll pin and adjust. Step 9. Double lock wire the roll pin in the forward sprocket with.032 S.S. wire. Step 10. Install the dust cap into the outboard end of the control arm. Step 11. Install the co-pilot's control arm, see "Co-pilot Control Arm Installation" in this section. Step 12. Connect the circular electrical connector below center instrument panel. Step 13. Remove any temporary placards. Step 14. Perform a function check Page 2

17 Control arm mounting flange Master link (access thru cutout in the bottom of the control arm) Control arm mounting bolt Center shaft Roll pin Copilot chain sprocket CONTROL ARM NOT SHOWN Ø3/4 Shaft Figure Control Column Removal Page 3 July 7, 2011

18 Co-Pilot's Control Arm Removal: Reference Figure Step 1. Turn the Master Switch OFF. Step 2. Placard the aircraft as required to ensure that ailerons are not moved during installation. Step 3. Remove the dust cap from the end of the control arm. Step 4. Loosen the pinch screws from the control arm sleeve. Step 5. Loosen the chain in the control arm by turning the control arm nut using FAC tool TF1726 or equivalent. Step 6. Disconnect the chain master link. Step 7. Remove the bolt securing the control arm to the center hub. Note: If the intention of removing the co-pilot's control arm is to remove the entire control column follow Step 8ep 8 through Step 10. Otherwise go to Step Step 8. Pull out the control arm from the center hub. Do not pull away too far as the control arm is connected to the electrical wiring. Step 9. Remove the lock-wire and using a 5/32 drift punch drive out the roll pin from the AFT sprocket in the center hub. Discard the hardware. Step 10. Proceed to Control Column Removal Step 5. Step 11. Cut the electrical wires at the junction with the pilot's control arm wires. Step 12. Pull out the control arm from the center hub. The co-pilot's control arm is now free. Step 13. Remove the lock-wire and using a 5/32 drift punch drive out the roll pin from the AFT sprocket in the center hub. Discard the hardware. Step 14. Remove and retain the chain. Step 15. Replace the roll pin in the AFT sprocket and lock wire with S.S. lock wire. Step 16. Install the dust cap into the center hub. Step 17. Remove any temporary placards. Step 18. The aircraft is ready to fly without the co-pilot's control arm Page 4

19 Co-Pilot's Control Arm Installation: Reference Figure Note: If the installation of the co-pilot's control arm is part of the installation of the entire control column follow Step 8ep 1 through Step 10. Otherwise go to Step Step 1. Temporarily insert the control arm into the center hub and ensure the chain could be connected approximately in the center of the access cutout on the bottom of the control arm. If not adjust as required. Step 2. Connect the chain master link. Step 3. Temporarily secure the ailerons in the neutral position and check control wheel alignment. Step 4. Remove the arm from the center hub. Step 5. Replace the roll pin in the AFT sprocket in the center hub and double lock wire with S.S. lock wire. Step 6. Install the control arm into the center hub and secure with a bolt. Step 7. Tighten the chain in the control arm by turning the control arm nut using FAC tool TF1726 or equivalent. Step 8. Tighten the pinch screws in the control arm sleeve. Step 9. Install the dust cap at the outboard end of the control arm. Step 10. Proceed to the Control Column Installation Step 12. Step 11. Turn the Master Switch OFF. Step 12. Placard the aircraft as required to ensure that ailerons are not moved during installation. Step 13. Remove dust cap from center section of control column. Step 14. Remove the safety wire from the roll pin of the AFT sprocket in the center hub. Step 15. Using a 5/32 drift punch, drive out the roll pin. Step 16. Fish the co-pilot control chain over the aft sprocket. Step 17. Feed the chain through the control arm and over the control wheel sprocket. Step 18. Temporarily insert the control arm into the center hub and level/align the control wheel with the pilot's control wheel. Step 19. Connect the chain master link. Step 20. Remove the control arm from the center hub, install the roll pin into the AFT sprocket and lock wire with.032" S.S. wire. Step 21. Install the control arm into center hub and secure with a bolt. Step 22. Tighten the chain in the control arm by turning the control arm nut using FAC tool TF1726 or equivalent. Step 23. Tighten the pinch screws in the control arm sleeve. Step 24. Install the dust cap at the outboard end of the control arm. Step 25. Perform a function check Page 5 July 7, 2011

20 Pilot's Control Arm Center Hub Center Shaft Aft Sprocket Pinch Screws in Control Arm Sleeve Master Link (access thru cutout in the bottom of the control arm) Control Wheel Shaft. Control wheel not shown. Control Arm CONTROL ARM NOT SHOWN Figure Co-pilot's Control Arm Removal Page 6 July 6, 2011

21 27-05 CONTROL WHEEL (2C3 & 2C4) The 2C3 and 2C4 are equipped with a dual control system. The ailerons and elevators are operated via the control wheels. Pilot's Control Wheel Center Harness Co-pilot's Control Wheel Figure Control Wheel Control Wheel Removal Reference Figure Step 1. Turn the Master Switch OFF Step 2. Remove the face plate (2 screws) from the control wheel. Retain hardware. Step 3. Remove the control wheel switches, see Chapter 22. Step 4. Remove the bolt securing the wire harness and pull out the wires. Retain hardware. Step 5. Remove the remaining 2 bolts. The control wheel is now free Page 1 July 7, 2011

22 Control Wheel Installation Reference Figure Step 1. Turn the Master Switch OFF. Step 2. Placard the aircraft as required to ensure that ailerons are not moved during installation. Step 3. Secure the ailerons in the neutral position. Step 4. Place the control wheel onto the mount and install 2 bolts, snug only. Install the bolts that do not support the electrical wires. Step 5. Ensure the wheel is straight and level, adjust position if necessary, and torque the bolts (2). Step 6. Feed the wires and install the 3rd bolt with the clamp. Snug the bolt only. Step 7. Install the switches, see Chapter 22. Step 8. Ensure proper wire routing inside the control wheel and torque the last bolt. Step 9. Install the control wheel face plate. Step 10. Remove any temporary placards. Step 11. Perform a function check Page 2 July 6, 2011

23 WASHER (3 PLACES) BOLT. (3 PLACES) WASHER (3 PLACES) CONTROL COLUMN MOUNT CYGNET CONTROL WHEEL NUT (3 PLACES) CLAMP SECURING WIRES Figure Control Wheel Installation Page 3 July 7, 2011

24 INTENTIONALLY LEFT BLANK Page 4 July 7, 2011

25 27-10 AILERON SYSTEM The aileron system starts at the control wheel, which is rotated left or right as desired. This input rotates a sprocket over which a chain is positioned. Each end of the chain is attached to a cable which runs uninterrupted out to bellcranks located at Station 115 in each wing. Each bellcrank is connected to each other with an aileron balance cable. The bellcrank in each wing translates the cable input to a pushrod which is attached to the aileron, thus causing it to move up or down. See Figure and Aileron Removal & Installation One or both ailerons may be removed or installed at the same time. Step 1. Placard aircraft as required to ensure that ailerons are not moved during removal or installation as personnel injury can occur if hands are caught in moving parts. The aileron pushrod may also become caught on the lightning hole in the rear spar and damage the rear spar if the control wheel is moved while either aileron is removed. Step 2. Disconnect the aft end of the aileron pushrod from the aileron. Step 3. Ensure that the aileron is supported in such a manner that further disconnection will not cause damage to the aileron. Step 4. Remove the hinge pin locking screws at the four hinge locations and withdraw the hinge pins. The aileron is now free. Step 5. Place aileron on a flat surface of sufficient size to ensure its safety. Never place ailerons on end in the vertical position unless the lower surface is padded and a tie off is used to prevent the aileron from falling. Installation of the aileron is accomplished by reversing the above steps, with the addition of carrying out aileron operational and function check Aileron Rigging The following steps are shown in the order in which they should be carried out. If a step can not be achieved it may be necessary to make an adjustment to bring the system to a point where the next step can be carried out. See Figure Step 1. Level the control wheel by placing a level across both of the uprights (top or the bottom). Care must be taken to ensure that the level does not interfere with any switches or other accessories which may be on the control wheel. When the wheel is level, both ends of the chain on the sprocket at the forward end of the control torque tube should be within 1/4 of level to each other. See Figure Page 1

26 Step 2. Place a rigging pin through the bellcrank support brackets and the bellcrank in each wing. Access through panels WP12 and WS12 (Ref. Figure or ). Step 3. Level the aircraft. (Ref : Chapter 8) Step 4. See Figure for aileron neutral. Adjust the aft end of the aileron push rod to gain the correct inclinometer measurement. Step 5. To adjust the deflection of the ailerons there are stops on the bellcrank support brackets in each wing. The stops are a threaded type with a jamb nut. Adjust the stops to achieve the correct deflection. See Table , for aileron deflection. Step 6. Ensure that all cable tensions are correct (Ref : TABLE ) and all safety devices are installed or tightened Page 2

27 27-20 RUDDER SYSTEM The rudder system starts at rudder pedals installed in the flight compartment. There is a set of pedals on the Port side, and an optional set which may be installed on the Starboard side, which are suspended from a layshaft. Control arms on the layshaft and the rudder pedals are connected to pushrods which in turn attach to bellcranks mounted in the center console. See Figure The center console bellcranks are connected to cables which run to a bellcrank which has a pushrod connected from it to the rudder control arm. See Figure Rudder Removal & Installation Step 1. Placard aircraft as required to ensure that rudder is not moved during removal or installation as personnel injury can occur if hands are caught in moving parts. Step 2. Ensure that the rudder is supported in such a manner that further disconnection will not cause damage to the rudder. Step 3. For aircraft equipped with electric rudder trim, remove access panel and disconnect trim servo connector. Feed forward portion of the harness through the lightening hole in rudder spar such that the wires don t get caught when the rudder is removed. Step 4. Disconnect bonding wire. Step 5. Remove the bolt from the rudder actuator arm at the bottom starboard side of the rudder. Step 6. The rudder has three hinge positions. Remove the hinge bolts at each location. The rudder is now free. See Figure Step 7. Place rudder on a flat surface of sufficient size to ensure its safety. Never place rudder on end in the vertical position unless the lower surface is padded and a tie off is used to prevent the rudder from falling. Installation of the rudder is accomplished by reversing the above steps, with the addition of carrying out a rudder function check Rudder Rigging The following steps are shown in the order in which they should be carried out. If a step cannot be achieved it may be required to make an adjustment to bring the system to a point where the next step can be carried out. Jack the tail of the aircraft (Ref: Chapter 7). Weight on the tail wheel may adversely affect the rigging of the rudder Page 1

28 Step 1. Ensure that both of the rudder pedals on the pilots side are even. If necessary secure a straight edge to both pedals to ensure they are even and will not move. Step 2. Check the rudder pedals on the Starboard side (if installed) to ensure that they are also even. Adjust as required. Step 3. Check that the rudder is positioned on the centerline of the aircraft. If it is not on the centerline, adjust the pushrod from the bellcrank to the rudder control arm until the correct position is attained. See Figures Sheet 2 for plain flap equipped aircraft and Figure Sheet 2 for Fowler flap equipped aircraft. Step 4. To adjust the deflection of the rudder there are adjusters located near the bottom of the rudder. The stops are a threaded type which stop against the lower hinge on the vertical stabilizer. Adjust the stops to achieve the correct deflection. See Figures Sheet 2 for plain flap equipped aircraft and Figure Sheet 2 for Fowler flap equipped aircraft for correct deflections Ensure that the control stops are met before the rudder pedals reach the end of their travel. Step 5. Ensure that all cable tensions (Ref: TABLE ) are correct and all safety devices are installed or tightened Page 2

29 27-25 ELECTRIC RUDDER TRIM SYSTEM The electric rudder trim system consists of a trim tab, located on the trailing edge of the rudder, controlled by an electric actuator via a push rod. A damper rod is installed in parallel to the push rod as a fail safe feature to prevent the tab from inducing flutter into the rudder system should the push rod become disconnected. The actuator is in turn controlled by the pilot with a rocker switch located at the top of the flight panel. This switch is oriented horizontally as is the associated LED position indicator. The actuator is mounted on the starboard side of the rudder using four fasteners. The friction device uses the spring tension of the associated Belleville washers to create friction between the stainless steel damper rod and the bracketing nylon washers. The actuator is designed to operate from a 12 volt dc source. This voltage is derived from a converter which is supplied via a 1 amp circuit breaker from the main bus. In addition to the electric trim tab, a ground adjustable tab is located directly above the electric trim tab. It is used to assist the performance of the electric trim tab Removal and Installation A. Servo: Removal, Refer to Figure Step 1. Disconnect rudder trim circuit breaker located on the circuit breaker panel. Step 2. Remove access panel from rudder. Step 3. Disconnect electrical connector. Step 4. Remove cotter pin from push rod yoke and disengage the push rod from the servo by removing the clevis pin. Removed cotter pin is scrap and must be replaced at installation. Step 5. Remove 4 screws securing the servo to structure. Step 6. The rudder trim servo is now free. Installation can be accomplished by reversing the above steps. Ensure replacement of cotter pin. Perform system function check after completion. B. Push Rod: Removal, Refer to Figure Step 1. Disconnect rudder trim circuit breaker located on the circuit breaker panel. Step 2. Remove access panel from rudder. Step 3. Remove cotter pins at both ends of the push rod. Removed cotter pins are scrap and must be replaced at installation. Step 4. Remove clevis pins at each end. Step 5. Loosen one of the lock nuts securing the yoke to push rod Page 1 July 7, 2011

30 Step 6. Remove the yoke by turning it counter-clock wise. Step 7. The push rod is now free. Installation can be accomplished by reversing the above steps. Ensure replacement of cotter pins. Minimum thread engagement between rod and yoke is 3/16 inch. Perform system function check after completion. C. Damper Rod: Removal, Refer to Figure Step 1. Disconnect rudder trim circuit breaker located on the circuit breaker panel. Step 2. Remove access panel from rudder. Step 3. Loosen the lock nut securing the damper bolt. Step 4. Remove cotter pin at the trim tab end. Removed cotter pin is scrap and must be replaced at installation. Step 5. Remove the clevis pin securing the push rod to trim tab. Step 6. The damper rod is now free. Installation Step 1. Insert damper rod into position. Step 2. Tighten the lock nut to secure the rod in damper bolt. Step 3. Using a spring scale adjust the lock nut on the damper bolt to provide 3-6 lbs resistance to the damper rod motion. Step 4. Attach the yoke end to the trim tab using clevis pin. Use a new cotter pin. Step 5. If the nut securing the yoke to the damper rod was loosened, hand tight the nut ensuring minimum thread engagement between the rod and yoke is 3/16 inch. Step 6. Perform function check. D. Trim Tab: Removal, Refer to Figure Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Disconnect rudder trim circuit breaker located on the circuit breaker panel. Remove cotter pins securing push and damper rods to the trim tab. Removed cotter pins are scrap and must be replaced at installation. Remove the clevis pins securing the push and damper rods to the trim tab. Cut the lock wire securing the hinge pin to the trim tab. The hinge pin is lock wired at the top of the trim tab. Remove cut lock wire. Remove the hinge pin by pulling it upwards. The trim tab is now free. Installation can be accomplished by reversing the above steps. Ensure replacement of lock wire and cotter pins. Perform system function check after completion Page 2 July 6, 2011

31 E. Indicator and Switch: Removal, Refer to Figure Step 1. Step 2. Disconnect rudder trim circuit breaker located on the circuit breaker panel. Remove face decal. Removed decal is scrap and it must be replaced on installation. Step 3. Remove screws, x2. Step 4. Indicator/Switch is now free. Installation can be accomplished by reversing the above steps. Ensure replacement of face decals. They can be purchased from Aircraft Spruce & Speciality Co, p/n (Switch) and (Indicator). Perform system function check after completion Trim Tab Travel Limits Refer to Figure The trim tab is limited to 26 o ± 4 o to the right and 26 o ± 4 o to the left from rudder center line. At this point the servo must be at its maximum travel limit in that direction. The trim tab runs through the servo s full range of motion. A. Adjustment: Refer to Figure and Step 1. Turn master ON. Step 2. Press toggle switch to move the trim tab all the way to the right. The servo must be at its maximum travel in that direction. Step 3. Turn master OFF Step 4. Disconnect rudder trim circuit breaker located on right hand instrument panel. Step 5. Remove access panel from rudder. Step 6. Loosen lock nut securing damper bolt. Step 7. Loosen lock nuts securing the yokes on the push rod. Step 8. Turn the push rod so that the trim tab forms an 8 o angle with the center line of the rudder. Minimum thread engagement between rod and yoke is 3/16 inch. Step 9. Tighten lock nuts securing the yokes on the push rod. Step 10. Tighten damper lock nut to provide 3 to 6 lbs resistance to the damper rod motion. Step 11. Perform system function check Step 12. If required, repeat Step 4 through 11 Step 13. Install access panel. Step 14. Carry out function check Page 3 July 7, 2011

32 System Function Check The system function check must be performed after removal of any parts of the system as well as after any adjustments. The system must be operational throughout the full range of travel without any interference of the actuation system. Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Turn master ON. Press the toggle switch to move trim tab all the way to the right. The indicator should show full right position. It is acceptable for 9 of the 10 indicator bars to light up during the full travel check. The one unlit bar may be on either end of the indicator. Verify trim tab position to be in Full Right, 26 o ± 4 o from rudder center line. Press the toggle switch to move the trim tab all the way to the left. The indicator should show full left position. It is acceptable for 9 o ft e10 indicator bars to light up during the full travel check. The one unlit bar may be on either end of the indicator. Verify the position of the trim tab. Press toggle switch to move the trim tab to desired position. Turn master OFF Page 4 July 7, 2011

33 RUDDER FWD. GROUND ADJUSTABLE TRIM TAB ELECTRIC TRIM TAB SERVO ACCESS PANEL DAMPER ROD PUSH ROD Figure Rudder with Electric Rudder Trim Tab Page 5 July 7, 2011

34 LOCK NUT Torque to provide 3 to 6 lbs resistance to damper rod motion. STEEL WASHER BELLVILLE WASHER (x7) CLEVIS PIN YOKE WASHER DAMPER ROD NYLON WASHER STEEL WASHER DAMPER BOLT LOCK NUT COTTER PIN SERVO DAMPER ROD FWD. WIRE CONDUIT PUSH ROD SERVO CONNECTOR #4 SCREW (x4) WASHER (x4) HINGE PIN Figure Electric Rudder Trim Installation Page 6

35 #2 NUT (x4) #2 WASHER (x4) FLIGHT PANEL SWTICH DETAIL 'A' #2 SCREW (x4) INDICATOR DECAL FLIGHT PANEL A RUDDER TRIM SWITCH RUDDER TRIM INDICATOR Figure Electric Rudder Trim Switch & Indicator Installation Page 7

36 P R M A R Y WC-5 5 Conductor Cable Teflon Sheath B U S S L F23 1 Rudder Trim 0425A-22 RS2 Rudder Trim (Rocker Switch) (Skt 2 Plc) (Pin 2 Plc) 0431B B A-24 White+ 0432A-24 White- Red 0428C B A-22 Red 0427A-24 Y PDIG22-1 SOLDER SLEEVE X PN18-10R Y PN18-8R I Black A RP3 Rudder Trim Indicator (LED Indicator) 0427B-22 Black 0426A-24 X 0426B-22 REG-1 24 To 12Vdc White 0425B-24 AS or MS or 2TC2-1 Or Equivalent (CPC) (Skt-5 Plc) 0433B B B A-24 Blue 0434A-24 Green 0435A-24 Orange Black White CPC - Series 1 Pins And Sockets Chart III+ Pin III+ Skt III+ Pin III+ Skt III+ Pin III+ Skt WC-5 5 Conductor Cable Teflon Sheath Flight Panel To Rudder Red X (CPC) (Pin-5Plc) A A 1/2 Trim Master SW26 Bright Dim 0421B A (Pin 1 Plc) (Skt 1 Plc) 0446B x REF: See L2025 Electric Cowl Flap x T2-7A 0435C-24 Orange 0434C-24 Green 0433C-24 Blue 0432C-24 White- 0431C-24 White+ 0435D-24 Orange 0434D-24 Green 0433D-24 Blue 0432D-24 White- 0431D-24 White+ Figure Electric Rudder Trim Schematic Page 8 July 7, 2011

37 26 ±4 26 ±4 PORT SIDE STBD SIDE C L Figure Electric Rudder Trim Travel Limits Page 9 July 7, 2011

38 INTENTIONALLY LEFT BLANK Page 10 July 7, 2011

39 27-30 ELEVATOR SYSTEM The elevator system starts at the control column, where forward and aft movement is transferred via cables to a rocking beam at Arm 194 (Ref: Chapter 6, Figure ). A push rod on the rocking beam is connected to the elevator control arm on the elevator torque tube located between the two elevators. In addition, the 2C3 & 2C4 elevator system utilizes an elevator down spring to enhance the elevator stick force at low airspeeds. The spring is attached to brackets welded to the elevator push rod and the horizontal stabilizer trim arm. The landplane configuration also utilizes an extension link at the forward end of the spring. Both ends of the spring are connected directly to the welded brackets for the floatplane configuration see Figure Sheet 2 of 2. Elevator Removal & Installation Reference Figure , and Note: The elevators may be removed one at a time and either elevator may be removed with the torque tube attached or the torque tube may be removed separately, but under NO circumstances shall the torque tube be removed with both elevators attached. To remove one elevator only: Step 1. Placard aircraft as required to ensure that elevators are not moved during removal or installation as personnel injury can occur if hands are caught in moving parts. Step 2. Remove the three bolts which attach the elevator torque tube to the elevator which is to be removed. Step 3. Ensure that the elevator is supported in such a manner that further disconnection will not cause damage to the elevator. Step 4. Remove the centre and outboard hinge bolts. See Figure The elevator is now free. Step 5. Place elevator on a flat surface of sufficient size to ensure its safety. Never place elevator on end in the vertical position unless the lower surface is padded and a tie off is used to prevent the elevator from falling. To install the elevator reverse the above steps and carry out function check. To remove one elevator and the torque tube: Step 1. Placard aircraft as required to ensure that elevators are not moved during removal or installation as personnel injury can occur if hands are caught in moving parts Page 1

40 Step 2. Ensure that the elevator is supported in such a manner that further disconnection will not cause damage to the elevator. Step 3. Disconnect elevator down spring from elevator push rod. The 2C3 & 2C4 aircraft only. Step 4. Remove the tail cone. Step 5. Remove the three bolts which attach the elevator torque tube to the elevator opposite the one which is to be removed. Step 6. Remove the bolt from the push rod to the elevator torque tube control arm. Step 7. Remove the bolt from the centre hinge position. Step 8. Remove the centre and outboard hinge bolts. The elevator and torque tube are now free. Step 9. Place elevator on a flat surface of sufficient size to ensure its safety. Never place elevator on end in the vertical position unless the lower surface is padded and a tie off is used to prevent the elevator from falling. Never place the elevator in a vertical position with the torque tube in the down position. To install one elevator and torque tube reverses the above steps and carry out function check. To remove torque tube only: Step 1. Placard aircraft as required to ensure that elevators are not moved during removal or installation as personnel injury can occur if hands are caught in moving parts. Step 2. Ensure that the elevators are supported in such a manner that further disconnection will not cause damage to the elevators. Step 3. Disconnect elevator down spring from elevator push rod. The 2C3 & 2C4 aircraft only. Step 4. Remove the tail cone. Step 5. Remove the three bolts which attach the elevator torque tube to each elevator. Step 6. Remove the bolt from the push rod to the elevator torque tube control arm. Step 7. Remove the bolt from the centre hinge position. The torque tube is now free. To install the torque tube reverse the above steps and carry out function check Page 2

41 Elevator Rigging The following steps are shown in the order in which they should be carried out. If a step cannot be achieved it may be required to make an adjustment to bring the system to a point where the next step can be carried out. Note: Place Horizontal Tail Plane Trim In Neutral. If it is not correct the elevators can not be rigged correctly. See Chapter for stabilizer trim rigging. Step 1. Level the aircraft. (Ref : Chapter 8). Step 2. Ensure that all cable tensions are correct. (Ref: TABLE ). Step 3. Disconnect the elevator down spring from elevator push rod. The 2C3 & 2C4 aircraft only. Step 4. Place stabilizer trim in neutral position. Step 5. Refer to Figure for establishing elevator neutral, position by placing an inclinometer on top of the horizontal stabilizer at he location shown in Figure and then on top of the elevator as shown in Figure Adjust the aft rod end on the elevator push rod to gain the correct inclinometer measurement. The elevator is now set to the neutral position. Step 6. The maximum elevator defection is set via stop screws located on the elevator torque tube as shown in Figure and disconnect the control rod at the elevator torque tube and using the inclinometer as above, adjust he stop screws till the travels in Table (for Plain Flap aircraft) or Table (for Fowler Flap aircraft) are reached. Step 7. Connect the control rod at the elevator torque tube and with the horizontal stabilizer in the neutral position verify the elevator contacts the stops on the elevator torque tube simultaneously or just before the control column comes up against its stops. This is done by pulling the control column out to.125 from the stop in the center console. Adjust the pushrod to obtain the elevator to contact the stop just before the control column contacts its stops. Push the control column in and confirm bounce back on stop on column. Note: with the horizontal stabilizer set to either of its maximum travel positions it is acceptable for the control column to come up against its stops before the elevator contacts its stops as long as the elevator deflections meet the limits. CAUTION: All cable tension measurements shall be accomplished with the elevator down spring disconnected from the system. 2C3 & 2C4 ONLY Page 3 July 7, 2011

42 Step 8. Ensure that all cable tensions (Ref: TABLE ) are correct and all safety devices are installed or tightened. Step 9. Connect elevator down spring. The 2C3 & 2C4 only. H-STAB DATUM 6.6 ± ± ±0.5 AIRCRAFT DATUM AND FLOOR LEVEL Figure Elevator and Horizontal Stabilizer Neutral Positions Page 4

43 Figure Photo of Inclinometer Location on Elevator Figure Photo of Elevator Torque Tube and Stop Screws Page 5 July 7, 2011

44 Horizontal Stabilizer Rear Spar Jam Stop Screw Elevator Torque Tube Elevator Torque Tube Stop TOP VIEW END VIEW Figure Elevator Stop Bolts Figure Photo of Inclinometer Location on Horizontal Stabilizer Page 6

45 27-40 HORIZONTAL STABILIZER The horizontal stabilizer is a one piece assembly which is also the means of attitude trim. The control wheel for trimming the stabilizer is located on the center console in the flight compartment. The control wheel is attached to a drum assembly with two cables which run back to the trim actuator located at Arm 190. The trim actuator converts rotary motion into linear motion and is attached to the arm on the horizontal stabilizer thus causing the stabilizer to move up and down. See Removal and Installation Reference Figure , and Note: The stabilizer may be removed with the elevators installed or removed. For elevator removal see Chapter Step 1. Placard aircraft as required to ensure that elevators or stabilizer is not moved during removal or installation as personnel injury can occur if hands are caught in moving parts. Step 2. Remove tail cone. Disconnect wire from navigation light. Step 3. Remove the elevator down spring, Ref. Figure Sheet 2 of 2. The 2C3 & 2C4 aircraft only. Step 4. Remove both aft fuselage access panels. See Chapter 6, Figure or Step 5. Remove the bolt which attaches the stabilizer trim actuator to the stabilizer control arm. Step 6. Disconnect the stabilizer balance spring from the trim arm, see Figure The 2C2 S/N 106 and onwards, all 2C3 and 2C4 aircraft. Step 7. If elevators are still installed remove bolt which attaches either the elevator push rod to the elevator torque tube or the rocking beam to the elevator push rod.. Step 8. Remove the Stabilizer fail safe link bolt on each side of the fuselage. The stabilizer trim must be in the full AIRCRAFT NOSE DOWN position to have access to the bolts (2C1 & 2C2 only). Step 9. Remove the stabilizer fail safe rod, (2C3 & 2C4), see Figure Step 10. Ensure that the stabilizer is supported in such a manner that further disconnection will not cause damage to the stabilizer Page 1 July 7, 2011

46 Step 11. Remove the two hinge bolts which are attached at the forward end of the stabilizer. The stabilizer is now free, but care should be taken to move the stabilizer straight aft until the elevator push rod and the stabilizer control arm are clear. Take care that the push rod and the stabilizer control arm do not catch on any structure. Step 12. Place stabilizer on a flat surface of sufficient size to ensure its safety. Never place stabilizer on end in the vertical position unless the lower surface is padded and a tie off is used to prevent the stabilizer from falling. To install the stabilizer reverse the above steps and carry out function check Stabilizer Trim Actuator System The control wheel for trimming the stabilizer is located on the centre console below instrument panel. The control wheel is attached to a drum assembly with two cables which run back to the trim actuator. The trim actuator converts rotary motion into linear motion and is attached to the arm on the horizontal stabilizer thus causing the stabilizer to move up and down Trim Control Wheel The control wheel is located on the centre console in the flight compartment. The wheel is mounted in a vertical position. Turning the top of the wheel aft will cause the nose of the aircraft to raise while in flight. There is a trim indicator mounted horizontally beside the control wheel which moves a needle indicator to the left (nose up) or right (nose down) of a marked neutral position. The control wheel is connected to a dual cable drum assembly, which spools or unspools as the wheel is turned. The cables then run aft to the trim actuator Trim Indicator The stabilizer trim indicator gives a visual reference for the position of the stabilizer trim. The indicator may be adjusted by removing the two screws on the indicator cover and repositioning the indicator needle one groove on the trim drum to the left or right as required. Replace the indicator cover and rig the stabilizer to neutral and confirm that the pointer indicates neutral Trim Actuator The rotary to linear type actuator is located at Arm 190 (Ref: Chapter 6, Figure ). Input from the trim control wheel is transmitted via two cables to the actuator Page 2

47 Trim Actuator Removal and Installation Step 1. Placard aircraft as required to ensure that stabilizer and actuator are not moved during removal or installation as personnel injury can occur if hands are caught in moving parts. Step 2. Remove both aft fuselage access panels. See Figure or Step 3. Ensure that the stabilizer is supported in such a manner that further disconnection will not cause damage to the stabilizer. Step 4. Gain access to aft fuselage interior and disconnect stabilizer trim cables at the turn barrels. Step 5. If aircraft is equipped with auto pilot trim servo, loosen trim servo mounting bolts and slide the servo inboard and remove the trim chain from the sprocket, ref Chapter 22. Step 6. Remove the bolt from the actuator to stabilizer control arm. Step 7. Remove the bolt from the bottom of the trim actuator. There are several spacers at this location, take care to retrieve them when the bolt is withdrawn. Step 8. Remove the two bolts from the keeper ring. Actuator is now free. Pull actuator from structure taking care that attached cables do not catch on any structure. To install trim actuator, reverse above steps and carry out rigging and operational check. If aircraft is equipped with auto pilot trim servo, ensure sprocket alignment between the servo sprocket and actuator sprocket, Ref Chapter Stabilizer Rigging The following steps are shown in the order in which they should be carried out. If a step cannot be achieved it may be required to make an adjustment to bring the system to a point where the next step can be carried out. Step 1. Level the aircraft. (Ref: Chapter8). Step 2. Ensure that plastic cable stops in the aft fuselage are tight, (Ref. Figure ). Step 3. 2C3 and 2C4 aircraft only. Disconnect the stabilizer trim arm from the trim jack to set the fail safe rod. Step 4. 2C3 and 2C4 aircraft only. Place the stabilizer in the 4 o ± 0.5 o nose up position and set the bottom nut on the fail safe rod, (Ref Figure ) Page 3 July 7, 2011

48 Step 5. 2C3 and 2C4 aircraft only. Tighten the top nut to secure the spacer on the fail safe rod. The fail safe rod is now set. Secure the top nut with the jam nut, (Ref Figure ). Step 6. 2C3 and 2C4 aircraft only. Verify the full range of travel allowed by the fail safe system, 4 o ± 0.5 o leading edge up and 6 o ± 0.5 o leading edge down. Step 7. With the trim jack disconnected from the stabilizer trim arm, ensure that the trim jack is in the mid travel position. The trim jack may be adjusted manually via the control wheel in the flight compartment. With the trim jack in the mid travel point there should be equal turns (+/- 1 turn) of cable on each side of the trim jack drum. Step 8. Connect the horizontal stabilizer trim arm to the trim jack and place stabilizer trim in neutral position. Refer to Figure for establishing neutral position by placing an inclinometer on top of the horizontal stabilizer at the location shown in Figure Step 9. Check to ensure that the needle indicator is in the middle of its range of travel (Ref : ). Step 10. The turnbuckles for the trim system should be aligned +/- 1/4. Step 11. If necessary, adjust the fitting on the top of the trim jack so that the bolt through the stabilizer trim arm and the fitting on the top of the trim jack can be installed with no interference. Step 12. It is permissible to turn the cable drum on the trim actuator up to two full turns in either direction to align the stabilizer trim arm and the fitting on the top of the trim jack, or the trim actuator rod may be turned 1/2 turn in either direction. Step 13. Ensure that the trim jack does not bottom out in either direction when the trim wheel is turned so that the needle indicator shows full up and down travel. Step 14. 2C3 and 2C4 aircraft only. Place the stabilizer in the full nose up position per Table If the swaged cable stop contacts the plastic stop shown in Figure , go to Step 18. Otherwise, remove the swaged cable stop and go to the next Step. Step 15. 2C3 and 2C4 aircraft only. Mark the cable the AFT side of the stop and move the cable aft to make room for swaging. Step 16. 2C3 and 2C4 aircraft only. Swage the stop onto the cable. Forward end of the stop shall be on the mark line Page 4

49 Step 17. 2C3 and 2C4 aircraft only. Repeat Step for the stabilizer leading edge down position. Step 18. Check cable tension (Ref: TABLE ) and ensure all safety devices are installed. Step 19. Carry out operational check. Figure 101 Horizontal Stabilizer Trim Cable Stops (2C3 &2C4) Page 5 July 7, 2011

50 Stabilizer Arm Fail Safe Rod A ISOMETRIC VIEW Tail Boom Bracket (2C4) Tail Skid (2C) SIDE VIEW Fail Safe Rod Jam Upper Lower DETAIL 'A' Figure 202 Fail Safe Rod Installation (2C3 &2C4) Page 6

51 27-50 PLAIN FLAPS The flaps are manually operated by a lever located above and between the forward seats. Including the fully up position there are five flap positions, 0 (fully up), 8, 15, 22 & 32. To move the flaps from any position depress the thumb button on the bottom of the flap lever and move the lever to the desired position and release the thumb button. Depressing the thumb button disengages a lock mechanism which allows the handle to move. Releasing the thumb button engages a lock mechanism in a five position cam. The lever is connected to a torque tube located aft of the main wing spar which has pushrods at each end thus moving the flaps. See Figure Flap Removal & Installation Step 1. Placard aircraft as required to ensure that flaps are not moved during removal or installation as personnel injury can occur if hands are caught in moving parts. Step 2. Lower the flaps to the full down position. Step 3. Ensure that the flaps are supported in such a manner that further disconnection will not cause damage to the flaps. Step 4. Gain access to the outboard end of the torque tube and disconnect the forward end of the pushrod from the torque tube. Step 5. Remove the flap hinge pin locking wire at the hinge and withdraw the hinge pin. The flap is now free. Pull flap straight aft until pushrod clears rear spar. To install the flap, reverse the above steps and carry out a function check Flap Rigging Due to the design of the flap system the only rigging is for the fully up position. There are no adjustments for any of the four flap down positions. Step 1. Place flap lever in the fully up position. Carry out Step 2 on either flap. Step 2. Refer to Figure If flap is not at correct angle, adjust flap pushrod until correct angle is obtained. Step 3. Carry out Step 2 on the opposite flap Page 1

52 INTENTIONALLY LEFT BLANK Page 2

53 27-60 FOWLER FLAP General The Fowler type flap installation on the FBA-2C1/FBA-2C2 employs a toggle switch and an indicator on the centre instrument panel, an electric motor/actuator connected to torque tubes which transfer motion to pushrods. Each flap is actuated by one pushrod and travels on two flap tracks. See Figure for general layout of the flap system Maintenance Requirements It is the responsibility of the operator to ensure that adequate safety measures are taken while inspecting, adjusting or when other work is being conducted on the flap system. The Fowler Type flap system has an electric motor and actuator, flap tracks and rollers, torque tubes and levers that can all cause serious personal injury. Ensure that the power is off and that circuit breakers are pulled any time the flap system is being worked on. Placard the cockpit to ensure power is not accidentally applied. Electrical wiring diagrams see Figures and Flap Limit Switches Both the upper and lower flap limit switches are the same, switch mounting, means of adjustment, and removal or replacement is identical. Instructions are given for one switch, but are also applicable for the opposite switch. Flap Limit Switch Removal Step 1. Gain access to the flap actuator assembly through panel WP16 (Reference Figure ). Step 2. Remove the two screws that secure the switch to the slide block. Step 3. Identify the three wires on the switch. Remove the three wires from the switch. Switch is now free. Flap Limit Switch Installation Reverse the above steps to install the switch. Carry out a function check Page 1

54 Adjustment See Fowler Flap Rigging section for correct flap settings. Gain access to the flap actuator assembly through panel WP16 (Reference Figure ). Before moving the switch, ensure that a starting reference is made. Loosen the allen screw just enough to move the slide block up or down until the required setting is achieved. Tighten allen screw Flap Motor and Actuator General The flap motor and actuator can be removed without disturbing the limit switches. Flap Motor and Actuator Removal Step 1. Gain access to the flap actuator assembly through panel WP16 (Reference Figure ). Step 2. Both limit switches must be disconnected. See removal instructions above. Step 3. Carry out the removal instructions on Figure Flap Motor and Actuator Installation Step 1. Reverse the removal instructions on Figure Step 2. With one person viewing the actuator assembly, and one person operating the flaps, cycle the flaps through (at least) 2 full cycles, looking for interference with wing structure. Step 3. Check flap rigging. Carry out adjustments to flap system as required. See Flap Limit Switch Adjustment and Fowler Flap Rigging sections for instructions. Functional Test Step 1. Gain access to the flap actuator assembly through panel WP16 (Reference Figure ). Step 2. Turn on the master switch. Step 3. Momentarily depress the flap switch down and release it. The flaps should be observed to begin to extend then stop immediately Page 2

55 Step 4. Momentarily depress the flap switch up and release it. The flaps should be observed to begin to retract then stop immediately. Step 5. Depress the flap switch down and hold it. The flaps should be observed to deploy and stop. Check that the down limit switch is engaged, and the rollers do not contact the end of the flap track slot. Step 6. Depress the flap switch up and hold it. The flaps should be observed to retract and stop. Check that the up limit switch is engaged, and the rollers do not contact the end of the flap track slot Flap Indicator Flap Indicator Removal Step 1. While sitting in the pilot seat, remove the four AN525 screws that secure the center instrument panel and withdraw the panel sufficiently to allow access to the flap indicator. Step 2. Remove the electrical connector from the back of the instrument. Step 3. Remove the four screws that secure the indicator to the instrument panel. Flap Indicator Installation Step 1. Reverse the removal instructions. Step 2. Carry out an operational check. Indication Adjustment Step 1. This procedure will require two persons to perform it efficiently. Step 2. Remove the interior panel over the Port wing section, aft of the main spar. The flap position transducer is mounted on the inboard side of the first rib. Step 3. While sitting in the pilot seat, remove the four AN525 screws that secure the center instrument panel and withdraw the panel sufficiently to allow access to the flap indicator adjustment control located at the top, aft of the flap position indicator. This adjustment is accessed thru a hole in the indicator which is sealed and will require resealing Page 3

56 Step 4. With the flaps up, turn on the master switch, adjust the transducer to give a zero reading on the indicator. That is, rotate the transducer shaft. Note; the adjustment in the region of zero indication is very sensitive. Tighten the set screw. Step 5. Use the flap switch to extend the flaps to maximum deflection and adjust the gain of the indicator until the indicator reads 30 degrees. This is done by turning the small potentiometer with a non-conductive screwdriver accessed thru the hole referenced in step 3). Step 6. Once maximum flaps are set on the indicator, return the flaps to zero and make sure indicator reads zero. If necessary, repeat steps 4 and 5). Step 7. Cycle flaps two or three times to confirm consistent readings. Step 8. Turn off master switch. Reseal indicator adjustment hole with seal tape removed in step 3). Reinstall centre instrument panel. Use Loctite type P/N to fix the set screws on the transducer and reinstall the access cover on the wing Fowler Flap Rigging Step 1. The angles referenced in this document are between the cabin floor (zero degree reference) and the inboard upper flap skin between the first two corrugation ridges. Reference Figure Step 2. Open the access panels below the flap tracks on both wings. Step 3. Synchronize the flaps by setting the port flap push rod ends to their nominal adjustment (i.e. insure the rod end threads are inserted past the witness hole), and measure the flap deflection, set the starboard flap push rod ends so as to match this angle of defection. (Insure the rod end threads are inserted past the witness hole.) WARNING THE FLAPS MUST BE RIGGED TO WITHIN 0.8 OF EACH OTHER IN THE FULL DOWN POSITION. A DIFFERENCE OF GREATER THAN 0.8 MAY ADVERSELY AFFECT THE STALL CHARACTERISTICS OF THE AIRCRAFT. Step 4. Adjust the port flap fully retracted position to 14.9 o +/- 0.5 o. Note: Make this adjustment slowly by making small incremental changes to the upper limit micro- switch position. Confirm that none of the flap roller bearings have contacted the end of the flap rails. Confirm that the starboard flap is within tolerances Page 4

57 Step 5. Adjust the port flap fully extended position to 44.9 o +1 o /- 2 o. Note: Make this adjustment slowly by making small incremental changes to the lower limit micro- switch position. Confirm that none of the flap roller bearings have contacted the end of the flap rails. Confirm that the starboard flap is within 0.8 of the port flap. Step 6. Apply Loctite type 222MS to each of the micro switch set screws. Replace all access panels Continuity Tests Step 1. Step 2. Perform all continuity tests with external and internal aircraft power disconnected. Using a suitable ohm meter verify that continuity exists on all lines relevant to the appliance being tested in this procedure. Confirm that no shorts to ground exist on each lead and that no shorts between individual leads exist excluding those lines that are electrically common, or are shown as connected to ground Page 5

58 INTENTIONALLY LEFT BLANK Page 6

59 27-65 FLIGHT CONTROL STATIC BALANCING Control surface balance must be checked when control surfaces are repaired, modified, or repainted. The control surface balance limits are shown in Figure They apply to complete painted control surfaces only. The flight control must have counter weights installed to carry out the balance, but no pushrods may be attached. Control Surface Hinge Moment (in-lbs)* 2C1 and 2C2 2C3 and 2C4 Aileron (Left) 0 to to Aileron (Right) 0 to to Elevator 0 to to -8.0 Rudder 0 to to * Positive hinge moment for leading edge heavy Figure Control Surface Hinge Moments Required Equipment Two knife-edges Small bubble level FAC balance tool TF1734 or fabricate equivalent balance tool Aileron Balance Procedure Step 1 Set up the knife-edge hinge supports so that they are level and perpendicular to the aileron hinge axis. Space the knife edges far enough apart so that they may support the aileron at the inboard and outboard hinge locations as shown in Figure Step 2 Install a section of MS20001P5 piano hinge (2-3 inches) at the inboard and outboard aileron hinges. Insert the two sections of piano hinge in the knife-edges. Step 3 Check and verify the aileron has free and unrestricted movement after placement on the knife-edges. Step 4 FAC balance tool has a threaded rod and weight at the front of the tool, which is used to counterbalance the tool. Ensure that the tool is balanced about the hinge point before each use. Step 5 Install the balance tool on the top surface of the aileron at the inboard end as shown in Figure The hinge section may require repositioning to ensure the upper slot in the balance tool sits directly on the hinge pin Page 1

60 Step 6 Note: Place a small bubble level on top of the tool centered over the aileron hinge axis. Move the sliding weight until the tool is level. If the sliding weight is aft of the hingeline then the balance is positive (i.e. leading edge heavy). If the sliding weight is forward of the hingeline then the balance is negative (i.e. trailing edge heavy). Measure the distance from the hinge line to the centre of the weight as shown in Figure The balance tool may be equipped with either a 0.5 lbs or 1.0 lbs sliding weight. The sliding weight should be marked with its weight. The hinge moment equals the weight (lbs.) of the slider times the distance (in.). If the balance weight is too heavy to achieve the correct balance then weight can be removed by drilling a hole in the inboard face of the weight. If the aileron is trailing edge heavy then a heavier weight must be installed, contact FAC for replacement weights. Figure Aileron Installed on Knife Edges Page 2

61 Figure Aileron Balance Tool Diagram Elevator Balance Procedure The elevators are balanced separately. Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Set up the knife-edge hinge supports so that they are level and perpendicular to the elevator hinge axis. Space the knife-edges apart as required to support the elevator at its two hinge locations. Insert a bolt through each elevator hinge and position the elevator on the knifeedges. The inboard bolt should be long enough to support the balance tool. Check and verify the elevator has free and unrestricted movement after placement on the knife-edges. FAC balance tool has a threaded rod and weight at the front of the tool, which is used to counterbalance the tool. Ensure that the tool is balanced about the hinge point before each use. Install the balance tool on the top surface of the elevator at the inboard hinge location as shown in Figure and -05. Place a small bubble level on top of the tool centered over the aileron hinge axis. Move the sliding weight until the tool is level. If the sliding weight is aft of the hingeline then the balance is positive (i.e. leading edge heavy). If the sliding weight is forward of the hingeline then the balance is negative (i.e. trailing edge heavy). Measure the distance from the hinge line to the centre of the weight as shown in Figure Page 3 July 7, 2011

62 Note: The balance tool may be equipped with either a 0.5 lbs or 1.0 lbs sliding weight. The sliding weight should be marked with its weight. The hinge moment equals the weight (lbs.) of the slider times the distance (in.). If the balance weight is too heavy to achieve the correct balance then weight can be removed by boring holes in the back of the weight. If the elevator is trailing edge heavy and more weight is needed, there are cavities on the aft face of each mass balance weight, which can be filled with molten lead. Do not place loose pieces of lead in the cavities as they will vibrate and may cause damage to the structure. Alternatively the weight may be moved forward on the structure by adding a steel or aluminium shim up to thick behind the weight. Be sure to use the correct length bolts for proper attachment. Figure Balance Tool Installed on Elevator Page 4

63 Figure Elevator & Rudder Balance Tool Diagram Rudder Balance Procedure Step 1 Step 2 Step 3 Step 4 Step 5 Set up the knife-edge hinge supports so that they are level and perpendicular to the rudder hinge axis. Space the knife-edges apart as required to support the inboard and outboard hinges as shown in Figure Insert a bolt through the lower and upper rudder hinges and position the rudder on the knife-edges. Check and verify the rudder has free and unrestricted movement after placement on the knife-edges. FAC balance tool has a threaded rod and weight at the front of the tool, which is used to counterbalance the tool. Ensure that the tool is balanced about the hinge point before each use. Install a bolt in the center hinge and install the balance tool on the top surface of the rudder at the middle hinge location as shown in Figure 5. If the rudder trim tab interferes with this location for the balance tool, install at 4 long ¼ bolt in the lower hinge (Figure ) and place the balance tool a the root of the rudder as shown in Figure The root rib of the rudder should rest on the top edge of the plastic guide as shown in Figure Secure the balance tool to the root rib with a small strip of masking tape to ensure the tool does not fall off the rib Page 5 July 7, 2011

64 Step 6 Note: Place a small bubble level on top of the tool centered over the aileron hinge axis. Move the sliding weight until the tool is level. If the sliding weight is aft of the hingeline then the balance is positive (i.e. leading edge heavy). If the sliding weight is forward of the hingeline then the balance is negative (i.e. trailing edge heavy). Measure the distance from the hinge line to the centre of the weight. The balance tool may be equipped with either a 0.5 lbs or 1.0 lbs sliding weight. The sliding weight should be marked with its weight. The hinge moment equals the weight (lbs.) of the slider times the distance (in.). If the balance weight is too heavy to achieve the correct balance then weight can be removed by boring holes in the back of the weight. If the rudder is trailing edge heavy the weight may be moved forward on the structure by adding a steel or aluminium shim behind the weight. Be sure to use the correct length bolts and check for interference between the balance weight and vertical stabilizer. Figure Rudder Balance Setup Page 6

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