EXTRA 300 Aircraft Service Manual

EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
Chapter 27
Flight Controls
PAGE DATE: 31. January 1995
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PAGE
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EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
TABLE OF CONTENTS
Chapter
Title
27-00-00
27-00-01
27-00-02
GENERAL
Free Play in the Control System
Control Rod Lengths
27-01-00
27-01-01
27-01-02
27-01-03
27-01-04
27-01-05
27-01-06
MAINTENANCE PRACTICES
Control Rod Removal/Installation
Bellcrank Removal/Installation
Front Control Stick Removal/Installation
Rear Control Stick Removal/Installation
Torque Tube Removal/Installation
Control Rod Length Adjustment
27-10-00
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AILERONS
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MAINTENANCE PRACTICES
Aileron Removal/Installation
Aileron Rigging
Spade Rigging
27-20-00
RUDDER
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27-21-00
27-21-01
27-21-02
27-21-03
27-21-04
27-21-04
27-21-05
27-21-06
MAINTENANCE PRACTICES
Rudder Removal/Installation
Bottom Hinge Bracket Removal/Installation
Bottom Hinge Bellcranks Removal/Installation
Control Cable Removal
Control Cable Installation
Fairlead Removal/Installation
Rudder Rigging
27-30-00
ELEVATOR AND TAB
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7
7
9
10
10
11
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27-11-00
27-11-01
27-11-02
27-11-03
27-31-00
27-31-01
27-31-02
27-31-03
27-31-04
3
3
5
12
14
14
15
16
18
20
20
20
20
20A
20A
21
21
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MAINTENANCE PRACTICES
Elevator Removal/Installation
Trim Tab Removal/Installation
Elevator Rigging
Trim Tab Rigging
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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 conventional control sticks and adjustable rudder pedals. The
control surfaces are operated by a direct mechanical linkage. The control surface deflections are shown in Figure 2.
From Ser. N° 64 there is a rubber plugged hole in the bottom
fuselage cover for rear torque tube bearing lubrication .
Controls
Figure 1
27-00-01
* measured at the trailing edge
and max. chord
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.
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SERVICE MANUAL EXTRA 300
GENERAL
Control Surface Deflections
Figure 2
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EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
27-00-02
GENERAL
Control Rod Lengths
The measurements given in this chapter refer to the distances between the centers of the rod end bearings (see
Figure 3).
Control Rod Measurement
Figure 3
Refer to the following Figure 4 for identification of the
control rods.
Control Rod Identification
Figure 4
PAGE DATE: 31. January 1995
Control rod
Measurements
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
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SERVICE MANUAL EXTRA 300
27-01-00
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.
Spacer Sleeve Displaced
Figure 5
NOTE
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.
Control Surface Mounting Aid
Figure 6
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SERVICE MANUAL EXTRA 300
27-01-01
MAINTENANCE PRACTICES
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 selflocking nuts. The control rods inside the wing are interconnected 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.
NOTE
In case of removal of the control rod connecting the control 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.
27-01-02
Bellcrank Removal/Installation
Refer to Figure 7
1 Remove the respective access panels.
2 Remove the adjacend control rods per Chapter 27-0101.
3 Remove the M5 attachment bolt (2).
4 Remove the bellcrank.
5 Reverse procedure to install the bellcrank using sufficient 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.
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SERVICE MANUAL EXTRA 300
MAINTENANCE PRACTICES
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).
Control Levers and Rods Removal/Installation
Figure 7
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SERVICE MANUAL EXTRA 300
27-01-03
MAINTENANCE PRACTICES
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 installation.
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EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
27-01-04
MAINTENANCE PRACTICES
Rear Control Stick Removal/Installation
1 Remove the leather protection cuff.
2 Disconnect the electrical wiring.
3 Bring the control stick in the foremost position and disconnect the control stick from the control rods per Chapter 27-10-01.
4 Remove the control stick attachment bolt.
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 installation.
27-01-05
Torque Tube Removal/Installation
1 Remove the respective access panels.
2 Remove the control sticks and rods per Chapters 27-0101 and 27-01-03/04.
3 Loosen the bolts of the front and rear bearing blocks.
4 Disassemble the bearing blocks and remove the torque
tube.
5 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).
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EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
27-01-06
MAINTENANCE PRACTICES
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.
NOTE
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.
IMPORTANT
Observe that the rod ends joined to the rocker type
bellcrank should be adjusted long enough not to obstruct
the travel.
IMPORTANT
Ensure that the threaded rod is visible in the check hole
(Figure 9) in any case.
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.
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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 to 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.
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Legend:
1 aileron
5 torque tube
6 front seat stick
7 rear seat stick
8 push-pull rods
9 bellcranks
10 aileron center linkage
22 travel stops
EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
PAGE DATE: 31. January 1995
AILERONS
Aileron Control
Figure 10
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SERVICE MANUAL EXTRA 300
27-11-00
MAINTENANCE PRACTICES
27-11-01
Aileron Removal/Installation
1 Disconnect the actuator rod from the aileron center linkage.
2 Disassemble the spade if necessary observing the quantity 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 (refer to Figure 11) and spade to mounting plate connection (refer to Figure 14). From Serial No. 41 the washers of the aileron to linkage connection have been omitted. Also observe the second Note of Chapter 27-0100.
Aileron to Linkage Connection
Figure 11
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SERVICE MANUAL EXTRA 300
27-11-02
MAINTENANCE PRACTICES
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 Secure the control stick in the neutral position.
2 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.
Central Bellcrank Middle Position
Figure 12
3 If necessary adjust the control rod connecting the torque
tube and the central bellcrank per Chapter 27-01-05.
4 Reinstall the front seat back rest.
5 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).
6 Adjust length if necessary per Chapter 27-01-06.
7 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
13).
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MAINTENANCE PRACTICES
Aileron Rigging
Trailing Edge Alignment
Figure 13
8 If necessary adjust the length of the control rods connecting the aileron center linkage to the outer wing
bellcrank per Chapter 27-01-06.
9 Check if the left aileron travel is within the given tolerances (up/down 30°, ±2°). Use a conventional protractor.
10 Adjust the travel stops if necessary.
11 Follow step 8 for the right aileron.
12 If the travel of the right aileron exceeds the given tolerances, contact the manufacturer.
13 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.
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SERVICE MANUAL EXTRA 300
27-11-03
MAINTENANCE PRACTICES
Spade Rigging
For roll trim the spade rigging angle of incidence has to be
changed. Insert washer(s) between the spade and the mounting plate (refer to Figure 14). For example: When the
aircraft rolls to the left, insert washer(s) at the front attachment bolt of the right spade.
Spade Rigging
Figure 14
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SERVICE MANUAL EXTRA 300
27-20-00
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. Adjustment (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 attachment 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 at the rudder pedal bearing having the only purpose
of protecting the lower brake system fitting in case of
rudder cable failure.
IMPORTANT
This second stop must not be reached under normal
operation conditions. Missallignment or exessive elongation 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 of the rudder is installed in the rudder horn.
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PAGE DATE: 31. January 1995
Rudder Control
Figure 15
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rudder
rudder pedals
fairleads
bottom hinge bellcrank
rudder control cable
pedal adjustment
pedal link rod
retracting springs
RUDDER
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13
17
18
19
20
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SERVICE MANUAL EXTRA 300
27-21-00
IMPORTANT
27-21-01
MAINTENANCE PRACTICES
If airplane is factory equipped or retrofitted with electric actuated rudder pedal adjustment perform checks
10-11 of "Flight Controls" presented in Chapter 05-2004 after each maintenance work affecting the rudder
control cables.
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 second 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.
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SERVICE MANUAL EXTRA 300
MAINTENANCE PRACTICES
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 of the 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
NOTE
Rudder Rigging
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 leading edge in alignment with the leading edge of the vertical stabilizer.)
1. June
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MAINTENANCE PRACTICES
Rudder Rigging
3 Replace the control cables and adjust the length per
Chapter 27-21-04 if necessary.
4 Check if the rudder travel is within the given tolerances (left/right 30°, ±2°).
5 If the rudder travel is out of limits, contact the manufacturer for advice.
PAGE
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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 control 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 corresponding 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 two piano hinges.
The trim tab is not mass balanced.
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PAGE DATE: 31. January 1995
Elevator and Trim Tab Control
Figure 16
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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
ELEVATOR AND TAB
CHAPTER
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5
6
7
8
9
9a
12
14
15
16
21
22
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SERVICE MANUAL EXTRA 300
27-31-00
MAINTENANCE PRACTICES
27-31-01
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 replacement 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 second Note of Chapter 27-01-00.
27-31-02
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 Install in reverse sequence of removal.
27-31-03
Elevator Rigging
1 Remove the respective access panels.
IMPORTANT
PAGE DATE: 31. January 1995
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.
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MAINTENANCE PRACTICES
Elevator Rigging
2 Remove the control stick leather protection cuff.
3 Secure the control stick in the neutral position. (Vertical back edge of the torque tube parallel to the control
stick like shown in Figure 17).
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
Figure 18
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MAINTENANCE PRACTICES
Elevator Rigging
5 If necessary adjust the length of the middle tail control
rod per Chapter 27-01-06.
6 Check if the elevator travel is within the given tolerances (up/down 25°, ±2°). Use a conventional protractor.
7 Adjust the travel stops if necessary.
8 Check if the rear control stick travel is symmetrically.
9 If it is 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.
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27-21-04
MAINTENANCE PRACTICES
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 rear) 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 of the 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 cable 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 thimble to the bottom hinge bellcrank.
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