Chapter 27 Flight Controls
Contents
1. PAGE DATE 1 July 1996 CHAPTER 27 PAGE 10 EXTRA FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 200 Control Rod Length Adjustment 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 1 July 1996 CHAPTER 27 PAGE 11 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 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 to the rear control stick 7 To reduce pilot s hand forces the hinge line of the ailerons is positi2. 26 Trim Tab Removal Installation 0a 26 Elevator Rigging 26 Trim Tab Rigging 28 PAGE DATE 1 July 1996 CHAPTER 27 PAGE 2 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 27 00 00 GENERAL Refer to Figure 1 The EXTRA 200 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 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 Trim tab 2 The rudder has a direct cable connection with retracting springs and is therefore always under tension PAGE DATE 1 July 1996 CHAPTER 27 PAGE 3 GENERAL EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 oQ0E U mop JOUBIO O 008 UMOP a OJAI 206 00 1 05 3485 5 SL 56 JOUBIO O oS I dn 4 27 Control Surface Deflections Figure 2 PAGE DATE 1 July 1996 EXTRA FLUGZEUGBAU Gm
3. CHAPTER 27 PAGE 7 EXTRA FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 200 Bellcrank Removal Installation Detail A Control Levers and Rods Removal nstallation Figure 7 27 01 03 Front Control Stick Removal Installation Refer to Figure 8 1 Remove front seat per Chapter 25 15 01 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 PAGE DATE 1 July 1996 CHAPTER 27 PAGE 8 EXTRA FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 200 Front Control Stick Removal Installation 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 27 01 04 Rear Control Stick Removal Installation 1 Remove rear seat per Chapter 25 15 02 Disconnect the electrical wiring Remove the control stick attachment bolt RW N Use the control stick to move the control rod attach ment bolt within the mounting hole area 2 Figure 8 and disconnect the stick from the control rods per Chap ter 27 01 01 5 Remove the control stick 6 Reverse procedu
4. longerons 3 Check if the elevator is in 0 position Trailing edge on chord line Fasten a lath to the tip rib of the hori zontal tail per Figure 15 using adhesive tape lath on chord line elevator 0 position adhesive tape Lath on Chord Line Figure 15 4 Ifnecessary adjust the length of the rearmost tail con trol rod per Chapter 27 01 06 5 Check if the elevator travel is within the given toler ances Use a conventional protractor Adjust the travel stops if necessary Check full travel of control sticks in each direction Check if the rear control stick travel is symmetrically So N If it is not contact the manufacturer PAGE DATE 1 July 1996 CHAPTER 27 PAGE 27 EXTRA FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 200 27 31 04 Trim Tab Rigging Refer to Figure 16 1 Secure the rear 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 16 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 within given tolerances If it is not check free travel of the trim levers fuselage bellcrank and bowden cables PAGE DATE 1 July 1996 CHAPTER 27 PAGE 28
5. sleeves 18 and a 771095 shrinking sleeve on the control cable Thread the free end of the control cable through the rear fairleads 11 and the hole in the fabric to the tail PAGE DATE 1 July 1996 CHAPTER 27 PAGE 20 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 MAINTENANCE PRACTICES Control Cable Installation IMPORTANT 10 Slip 600 mm teflon protective hose on the control cable end The protective hose should extend to the first fairlead inside the fuselage 11 Adjust rear pedals in middle position 12 Fix rear pedals in vertical position 90 relative to the footrest 13 Pre install the LN9355 06 20 bolt the DIN 125 M6 washers 2 washers outside 3 washers inside the spring clip the LN 9348 M6 stop nut and the thimble to the bottom hinge bellcrank also see item 9 on Fig 3 of Chapter 32 14 Slip the 771095 shrinking sleeve and a NICOPRESS 18 3 M sleeve on the cable end 15 Move the cable around the thimble and stretch the control cable with a force that is equivalent to the trac tive effort of the rear pedal retracting spring 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 16 Consider to let a distance of 1 mm between the thim ble and the sleeve and clamp the sleeve 17 Cut the free end of the cable 20 mm in front of the sleeve 18 Slip the shrinking sleeve on the cable end
6. 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 12 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 spade washer s Spade Rigging Figure 12 PAGE DATE 1 July 1996 CHAPTER 27 PAGE 16 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 27 20 00 IMPORTANT RUDDER Refer to Figure 13 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 keep the cables under tension when they are not operated Adjustment of the rear pedals is made via multihole rod 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 attachment bracket at the rudder by bonding leads A travel stop plate is located at the bottom hinge bracket A second safety stop is located at the 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 rudd
7. 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 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 adjacent control rods per Chapter 27 01 01 3 Remove the 5 attachment bolt 2 4 Remove the bellcrank 5 Reverse procedure to install the bellcrank using suffi cient washers min 2 at the nut side of the bolt to cover the shank except the rocker type bellcrank use only one washer on each side Replace the selflocking nuts Observe the first Note of Chapter 27 01 00 To ensure installation of the elevator rocker type bellcrank in cor rect direction this bellcrank is marked by which indicates the front side refer to Detail A of Figure 7 PAGE DATE 1 July 1996
8. EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Chapter 27 Flight Controls PAGE DATE 1 July 1996 CHAPTER 27 PAGE 1 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 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 05 27 21 06 27 21 07 27 30 00 27 31 00 27 31 01 27 31 02 27 31 03 27 31 04 TABLE OF CONTENTS Title GENERAL 3 Free Play in the Control System 0 3 Control Rod Lengths 0000 5 MAINTENANCE PRACTICES 6 Control Rod Removal Installation 7 Bellcrank Removal Installation 0000n 7 Front Control Stick Removal Installation 8 Rear Control Stick Removal Installation 9 Torque Tube Removal Installation 00 10 Control Rod Length Adjustment 10 AILERONS eee ee 12 MAINTENANCE PRACTICES o 14 Aileron 00an 14 Aileron Rigging 14 Spade Rigging 00000000000 16 RUDDER 00000 17 MAINTENANCE PRACTICES o 19 Rudder Removal Installation 19 Bottom Hinge Bracket Removal Installation 0 19 Bottom Hinge Bellcranks Removal Installation _____ 19 Control Cable Removal ___________________ 20 Control Cable Installation 000a 20 Fairlead Removal Installation 00a 22 Rudder Rigging 22 ELEVATOR AND TAB _ 24 MAINTENANCE PRACTICES o 26 Elevator Removal Installation 00a
9. ad retaining clip 2 Pull the fairlead halves out of the sleeve 3 Reverse procedure to install the fairlead 27 21 07 Rudder Rigging NOTE Inspect the control cables the pulleys the fairleads and the bottom hinge assembly with the travel stop plate for signs of wear or damage before beginning any ad justments 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 July 1996 CHAPTER 27 PAGE 22 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 MAINTENANCE PRACTICES Rudder Rigging Replace the control cables and adjust the length per Chapter 27 21 05 if necessary Check if the rudder travel is within the given toler ances If the rudder travel is out of limits contact the manu facturer for advice PAGE DATE 1 July 1996 CHAPTER 27 PAGE 23 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 27 30 00 ELEVATOR AND TAB Refer to Figure 14 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 bellcranks have two sealed ball bearings The elevator is mounted at five points in spherical bearings pressed into aluminium hinge arms For lightning protec
10. and heat up with a heat gun 19 Remove the pedal securing device 20 Mount the pre assembled shackle of the shorter con trol cable to the front pedal 2 Thread the free end of the control cable through the pulley the front fairleads and the pre installed NICO PRESS 18 3 M sleeves 22 Fix the front pedal in vertical position parallel to the firewall 23 Stretch the shorter control cable with a force that is equivalent to the tractive effort of the front pedal re tracting spring PAGE DATE 1 July 1996 CHAPTER 27 PAGE 21 EXTRA FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 200 Control Cable Installation 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 IMPORTANT To prevent twisting the cables clamp the sleeves in the same plane 24 Consider that the clamping area shall be 30 cm aft the rear pulley and clamp the sleeves 25 Cut the free end of the cable 20 mm behind the sleeve 26 Slip the shrinking sleeve on the rear sleeve and heat up with a heat gun The front sleeve can be left free for visual control of the cable to cable connection 27 Remove the front pedal securing device 28 Follow the steps 3 to 27 for the RH control cable 29 Remove rudder securing devices 30 Check free travel of rudder 27 21 06 Fairlead Removal Installation 1 Remove the fairle
11. bH SERVICE MANUAL EXTRA 200 GENERAL 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 resp of the clevis head see Figure 3 H 00 given measurements Control Rod Measurement Figure 3 Refer to the following Figure 4 for identification of the control rods Control Rod Identification Figure 4 clevis head at the rear control 0 801 mm stick 932 mm 1 2 520 mm 3 1884 mm PAGE DATE 1 July 1996 CHAPTER 27 PAGE 5 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 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 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 Ad Aileron Sik Control Surface Mounting Aid Figure 6 PAGE DATE 1 July 1996 CHAPTER 27 PAGE 6 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 MAINTENANCE PRACTICES 27 01 01 NOTE 27 01 02
12. ecessary replace parts and correct lengths per Chapter 27 01 06 1 2 Secure the control stick in the neutral position Check if the control rods connecting the torque tube and the inner wing bellcranks have the correct length 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 wing as shown in Figure 11 PAGE DATE 1 July 1996 CHAPTER 27 PAGE 14 EXTRA FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 200 Aileron Rigging Aileron Wing Trailing Edge Alignment Figure 11 5 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 6 Check if the left aileron travel is within the given tol erances Use a conventional protractor 7 Adjust the travel stops if necessary 8 Follow step 6 for the right aileron 9 If the travel of the right aileron exceeds the given tol erances contact the manufacturer 10 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 1 July 1996 CHAPTER 27 PAGE 15 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 MAINTENANCE PRACTICES Spade Rigging 27
13. equence 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 July 1996 CHAPTER 27 PAGE 19 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 27 21 04 27 21 05 Control Cable Removal 1 2 3 4 Remove the respective access panels Remove the cable to fuselage attachment bolts Remove the cable to rudder bellcrank attachment bolts Cut the control cables behind the front shrinking sleeves and behind the cable to cable connection Remove the control cable parts by pulling out to the back Control Cable Installation Use only control cables manufactured by EXTRA FLUGZEUGBAU GmbH Those cables are prepared for simply installation 1 2 Remove the respective access panels per Chapter 51 Secure the rudder 3 Figure 13 in 0 position Mount the pre assembled shackle of the longer control cable to the LH cable fastening 20 Slip 800 mm teflon protective hose on the control ca ble Thread the cable through the S shaped tube at the pedal and the pulley 19 Adjust rear rudder pedals 4 in rearmost position Let the front end of the protective hose extend to 10 mm in front of the pedal S tube and cut the rear end 10 mm in front of the pulley Slip 2 NICOPRESS National Telephone Supply Co Cleveland Ohio 18 3 M
14. er cabels will result in misuse of this second stop and a subsequent overload of the rudder bearing A subsequent inflight failure of the footrest could occur To prevent flutter the rudder is mass balanced The mass balance weight of the rudder is installed in the rudder horn PAGE DATE 1 July 1996 CHAPTER 27 PAGE 17 EXTRA FLUGZEUGBAU GmbH RUDDER SERVICE MANUAL EXTRA 200 55 8 Pa na oO io g 55565 so tose ee HET 85 5 PRESSPASS Re Markings only one side 4 Z LD Rudder Control Figure 13 PAGE DATE 1 July 1996 CHAPTER 27 PAGE 18 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 27 21 00 MAINTENANCE PRACTICES IMPORTANT Perform checks 10 11 of Flight Controls presented in Chapter 05 20 04 after each maintenance work affect ing 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 s
15. ical stabilizer has to be disassembled 1 2 3 4 Remove the respective access panels Remove the rudder per Chapter 27 21 01 Remove the vertical stabilizer per Chapter 55 21 01 Loosen the bowden cables from the trim tab If a re placement is necessary order new cable Disconnect the elevator actuator arm from the push pull rod Loosen the hinge bolts and the ground bonding leads and remove the bolts Install in reverse sequence of removal Observe the sec ond Note of Chapter 27 01 00 Trim Tab Removal Installation 1 2 3 Loosen bowden cables If a replacement is necessary order new cable Disconnect the safety cotter pin and remove the hinge pin Install in reverse sequence of removal and use a new cotter pin Elevator Rigging 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 15 December 1999 CHAPTER 27 PAGE 26 EXTRA FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 200 Elevator Rigging 1 Remove the canopy and the main fuselage cover per Chapter 51 and the seats per Chapter 25 2 Secure the rear control stick in the neutral position Control stick parallel to the vertical steel tube carriing the trim tab control lever resp perpendicular to the upper
16. oned at 20 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 1 July 1996 CHAPTER 27 PAGE 12 AILERONS EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 sdojs TZ 8 07 SULI 6 spor g reo JOYS P S WA JONS 1295 110 9 uoe 8 7 13 27 Aileron Control Figure 10 PAGE DATE 1 July 1996 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 27 11 00 27 11 01 27 11 02 MAINTENANCE PRACTICES Aileron Removal Installation 1 Disconnect the actuator rod from the aileron center link age Disassemble the spade if necessary observing the quan tity and location of washers Loosen the hinge bolts and the ground bonding leads and remove the bolts Install in reverse sequence of removal Ensure that the spade is installed with the same quantity and location of washers refer to Figure 12 Observe the second Note of Chapter 27 01 00 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 n
17. re 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 1 July 1996 CHAPTER 27 PAGE 9 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 MAINTENANCE PRACTICES 27 01 05 27 01 06 NOTE IMPORTANT IMPORTANT Torque Tube Removal Installation 1 Remove the respective access panels 2 Remove the control sticks and rods from the torque tube per Chapters 27 01 01 and 27 01 03 04 3 Remove the bolt of the rear torque tube bearing 4 Push torque tube some centimeters to the rear to remove pin from the front bearing and remove the torque tube 5 Reverse procedure to install the torque tube Consider to secure the castle nut of the rear torque tube bearing Lubricate the bearings with Aeroshell grease 22C or equivalent MIL G 81322D 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 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
18. tion 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 a piano hinge The trim tab is not mass balanced PAGE DATE 15 December 1999 CHAPTER 27 PAGE 24 SC 9661 0 1 ADVd 1 UWHLdVHO pI 212 9 QUE 9 12 14 15 16 21 22 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 006 45 NVEONAZON TA ANV YOLVAYTA EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 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 vert
Download Pdf Manuals
Related Search