Aviation Studies

Fly by knowledge

Steven Albertema Jurriaan Blom Siemaab Mahmood Stan van Mierlo Nehomar Nivillac Nick Poelstra

Appendices

Project ‘Flight Controls’

Groep: AJ

2011 - 2012

Appendixlist

Appendix 1 flight control systems of the Boeing 737NG..................... 3 Appendix 2: Hydraulic overview spoilers B737NG ............................... 6 Appendix 3: Airbus flight control systems................................................ 7 Appendix 4: Removal of the control wheel .............................................. 9 Appendix 5 section A Aileron removal ................................................... 12 Appendix 5 section B Aileron installation............................................. 13 Appendix 6: Aileron quadrant removal and installation.................. 16 Appendix 7: Side stick removal and installation ................................. 19 Appendix 8: Removal and installation of the Cable Quadrant ....... 25 Appendix 9: Glossary ..................................................................................... 28 Appendix 10: Proceeding report ............................................................... 30

Appendix 1 flight control systems of the Boeing 737NG

Appendix 1: Section A

Appendix 1: Section B

Appendix 1: Section C

Section D: Position Display

Appendix 2: Hydraulic overview spoilers B737NG

Appendix 3: Airbus flight control systems

In this appendix the hydraulics system of the Airbus A320 is shown, this can be seen in section A. The different hydraulic systems and the corresponding flight control surfaces are shown as well. The flight control computers and the corresponding transport of the digital signal can be seen in section B. In this schematic figure the hydraulic actuators can also be seen.

Section A

Section B

Appendix 4: Removal of the control wheel

The following steps have to be followed to remove the aileron control wheels correctly. These steps are owned by the Aircraft Maintenance Manuals of the Boeing 737: (An overview of the components can be found at Appendix 4)

Section A (1) Open the access panel: Forward Access Door. (2) Hydraulic systems A and B has to be depressurized. (PAGEBLOCK 27-11-00/201

of the AMM). (3) Set the aileron control wheels to the neutral positions. (4) Open the access door. (5) Install the rigging pins No. A/S-2 and A/S-1A (see table above) in the transfer

mechanism. (a) Make sure the rigging pins A/S-1 is fully in the transfer mechanism. (b) Make sure the rigging pin A/S-1 does not fall out by holding the pin (6) Install the rigging pin A/S-15 in the aileron trim mechanism. (7) Remove the aileron control wheel: (a) Remove the cotter pin, retaining nut and special washer. (b) Make a mark of the position of the control wheel and gear and sleeve

assembly. (c) Carefully remove the control wheel from the control column. (d) Do the following steps whole you hold the control wheel:

1) Make a mark of the wire bundle to identify the clamp location in the control wheel hub.

2) Remove the clamp. 3) Disconnect the four pairs of switch leads of stabilizer trim at the

terminal block. 4) Remove the retainer from the autopilot disengage switch. 5) Carefully pull the switch assembly from the control wheel. 6) Remove the two screws from the microphone switch and the

trigger assembly. 7) Carefully pull the assembly from the control wheel. NOTE: The interphone switch is part of the assembly. 8) Remove the two screws which hold the memory device (not all

types Boeing 737). 9) Pull the memory device from the control wheel. 10) Disconnect the wires from the memory device.

(8) Write down and make a mark of the configuration of the identified color wires. (9) Disconnect the wires from the terminals of the autopilot disengage, microphone and interphone switches. (10) Carefully disengage the wire bundle from the control wheel.

--------------------------- END OF TASK ---------------------------

Section B – Installation of the aileron/control wheel The following steps have to be followed to install the aileron control wheels correctly. These steps are owned by the Aircraft Maintenance Manuals of the Boeing 737NG:

(An overview of the components can be found at Appendix 4)

(1) Use a wire leader to put the electrical wires in the aileron control wheel. (a) Use a wire leader to put the electrical wires in the aileron control wheel. (b) Pull the wires away from the switch holes. (c) Install the Teflon sleeves on the wires. (d) Find and connect the correct color wires to the autopilot disengage,

microphone, interphone switches and memory devices.

1) Tape and put away the wires that you did not use.

(e) Install the microphone switch and the trigger assembly in the aileron control wheel with two screws. (f) Install the autopilot disengage switch in the aileron control wheel with the retainer and screw. (g) Install the memory device in the control wheel with two screws. (h) Apply the Dow Corning Compound No. 5 to the part you can get access to

on the wire bundle. (i) Put a clamp at the mark on the wire bundle. CAUTION: WIRE LENGT HAS TO BE THE CORRECT LENGT BETWEEN THE

COLUMN AND WHEEL, OTHERWISE THE CONTROL WHEEL CANNOT MOVE FREELY.

(j) Engage the wire bundle in the control wheel hub with a clamp. (k) Apply the Dow Corning Compound No. 5 to the control wheel splines. (l) Wind the wire bundle four times around the control wheel hub. (m) Engage the splines on the aileron control wheel to the control column to

the marks that you made. (n) Install the special washer. (o) Tighten the retaining nut to 85-140 pound-inches. (p) Install the cotter pin.

(2) Do a check of the operation of the control wheel: (a) Make sure the captain’s and the first officer’s control wheels are in the

neutral position: 1) Put the straightedge across the top ends of the control wheels. 2) Make sure that one end of the first officer’s control wheel cannot be

farther than 0.20 inch from the straightedge. (b) Remove all the rigging pins (c) Make sure the control wheel can turn a minimum of 108 degrees in each

direction from the neutral position. (d) Make sure the control wheels moves smoothly and freely.

(3) Connect the switch leads to the terminal block: (a) Find the same wire colors. (b) Connect the four pairs of the stabilizer trim switches leads at the terminal block. (c) Install the washer, lockwasher and the nut.

(4) Do a test of the electrical circuits for continuity changed during the removal and installation procedures. (5) Use the insulation tester to do a test on the terminal block while you turn the control wheel from stop to stop. (a) Do a test on the terminal block resistance to the ground or wire to wire for a minimum insulation value of 100 megohms (6) Install the terminal cover with two screws. (7) Install the access panels (8) Do the task ‘Control Wheel Position Sensor-Adjustment/Test’ to check the aileron position sensor if it operates correctly after a replacement of the aileron control wheel. (8) Close the access panels: Forward Access Door.

Appendix 5 section A Aileron removal A. Safety Precautions (1) Put the safety barriers in position. (2) Put a WARNING NOTICE in position in the cockpit to tell persons not to operate the flight controls. B. Aircraft Maintenance Configuration W_A_R_N_I_N_G_ : MAKE SURE THAT THE TRAVEL RANGES OF THE FLIGHT CONTROLS ARE CLEAR. MOVEMENT OF FLIGHT CONTROLS CAN CAUSE INJURY TO PERSONS AND/OR DAMAGE. (1) Retract the flaps fully (Ref. TASK 27-50-00-866-009). (2) Make sure that the LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION is on the flap/slat control lever. (3) Depressurize the Green and the Blue hydraulic systems (Ref. TASK 29- 10-00-864-001), (Ref. TASK 29-10-00-864-003). (4) Depressurize the applicable hydraulic reservoir (Ref. TASK 29-14-00- 614-001). (5) Remove the safety collar from the circuit breakers 9CV and 11CV. C. Open, safety and tag this (these) circuit breaker(s):

D. Get Access (1) Put the ACCESS PLATFORM 4M (13 FT) in position below the applicable zone 575 or 675. (2) Remove the applicable access panels (Ref. TASK 57-51-37-000-007), (Ref. TASK 57-51-37-000-005): - for the left wing, remove 575AT, 575MB, 575KB, 575LB, 590AB, 590BB - for the right wing, remove 675AT, 675MB, 675KB, 675LB, 690AB. (3) Remove the static dischargers so that you do not cause damage to them (Ref. TASK 23-61-41-000-001). (4) Loosen the screws (1), (3) and (5) to let the upper and lower aileron seals (2), (4) and (6) move. (5) Manually move the aileron to get access to the actuators and the hinges. N_O_T_E_ : The internal flutter dampening system of the actuators will keep the aileron in position. (6) To prevent damage to the hydraulic pipes install the SUPPORT-AILERON ACTUATOR (98D27104002001) and attach it with the screw fasteners. (7) Install the LIFTING FRAME ASSEMBLY (AILERON) (98D27104001000): (a) Make sure that the side plates on the LIFTING FRAME ASSEMBLY (AILERON) are correctly installed. (b) Make sure that the adjuster assemblies on the LIFTING FRAME ASSEMBLY (AILERON) are as far apart as possible. (8) Lift the LIFTING FRAME ASSEMBLY (AILERON) with the crane. Put the LIFTING FRAME ASSEMBLY (AILERON) around the aileron, at the same distance from each end. N_O_T_E_ : The weight of the aileron and the brackets is 50 kg (110.2311 lb). (9) To lock the lifting frame assembly: C_A_U_T_I_O_N_ : DO NOT TIGHTEN THE ADJUSTER ASSEMBLIES ON THE LIFTING FRAME TOO MUCH OR YOU WILL DAMAGE THE AILERON. (a)Tighten the adjuster assemblies to lock the LIFTING FRAME ASSEMBLY (AILERON) in position. (10) Make sure that the aileron is supported by the crane and remove the hinge pins (19) and (42). Move the aileron aft and away from the wing and put it on the TRESTLE - PADDED.

Appendix 5 section B Aileron installation Installation of the aileron A. Safety Precautions (1) Make sure that the SAFETY BARRIERS are in position. (2) Make sure that the WARNING NOTICE to tell persons not to operate the flight controls are in position. B. Preparation for Installation (Ref. Fig. 402/TASK 27-14-41-991-002) If the aileron is safe tied with STA-LOK nuts, do the steps that follow: (1) Use a MISCELLANEOUS (Material No. 19-003) made moist with CLEANING AGENTS (Material No. 11-026) to clean: - the heads of the bolts (30), (45) and (47) - the nuts (23), (53) and (55) - The ends of the bonding straps (25), (40) and (49). (2) Clean the component interfaces and/or the adjacent areas with a MISCELLANEOUS (Material No. 19-003) made moist with CLEANING AGENTS (Material No. 11-026). (3) Make sure that the parts retained from clean and in the correct condition. C. Aircraft Maintenance Configuration W_A_R_N_I_N_G_ : MAKE SURE THAT THE TRAVEL RANGES OF THE FLIGHT CONTROLS ARE CLEAR. MOVEMENT OF FLIGHT CONTROLS CAN CAUSE INJURY TO PERSONS AND/OR DAMAGE. (1) Make sure that the flaps are retracted fully (Ref. TASK 27-50-00-866- 009). (2) Make sure that the LOCKING TOOL-FLAP SLAT LEVER, INT. POSITION is on the flap/slat control lever. (3) Make sure that the Green and the Blue Hydraulic systems are depressurized (Ref. TASK 29-10-00-864-001) (Ref. TASK 29-10-00-864- 003). (4) Make sure that the applicable hydraulic reservoir is depressurized (Ref. TASK 29-14-00-614-001). (5) Make sure that the safety collars on the circuit breakers 9CV and 11CV are removed. (6) Make sure that the ACCESS PLATFORM 4M (13 FT) is in position below the applicable zone 575(675). (7) Make sure that the applicable access panels are removed (Ref. TASK 57-51-37-000-007), (Ref. TASK 57-51-37-000-005): - for the left wing, panels 575AT, 575MB, 575KB, 575LB, 590AB, 590BB - for the right wing, panels 675AT, 675MB, 675KB, 675LB, 690AB, 690BB. D. Make sure that this (these) circuit breaker(s) is (are) open, safe tied and tagged.

(22) Use For the crane to put the aileron in position. (23) hinge No.s 1, 2 and 3, do the steps that follow: (24) For hinge No.s 4 and 5, do the steps that follow: (a) Install the GUIDE CONE - AILERON (98D27104000001) on the hinge pin (71). Install the hinge pin (71) with the head outboard. Remove the GUIDE CONE - AILERON.

(b) Make sure that the hinge pin (71) is correctly aligned, so that the locking plate (72) can be installed. (c) Install the washer (79) and the nut (80) on the hinge pin (71). (d) TORQUE the nut (80) to between 4.7 and 5.2 m.daN (34.66 and 38.34 lbf.ft). (e) Install the locking cap (81) on the nut (80). (f) Safety the locking cap (81) with the new cotter pin (82). (g) Install the locking plate (72), the bolt (73) and the nut (74). (h) Install the bonding strap (77), the washers (76) and (83), the bolt (84) and the nut (75) (Ref. TASK 20-28-00-912-004). (16) Remove the SUPPORT-AILERON ACTUATOR. (17) Move the aileron through its travel range and examine for: - free movement - the correct installation of the applicable bonding straps (25), (40) and (49). E. Close Access (1) Make sure that the work area is clean and clear of tool(s) and other items. (2) Install the applicable access panels (Ref. TASK 57-51-37-400-007), (Ref. TASK 57-51-37-400-005): - for the left wing, install 575AT, 575MB, 575KB, 575LB, 590AB, 590BB - for the right wing, install 675AT, 675MB, 675KB, 675LB, 690AB, 690BB. F. Adjustment of the Aileron Upper and Lower Seals (Ref. Fig. 401/TASK 27-14-41-991-001, 403/TASK 27-14-41-991-004) (1) Manually align the aileron with the trailing edge structure (to its neutral position). (2) Make sure that the dimensions W and Z are between 0.0 mm (0.0000 in.) and 0.5 mm (0.0196 in.). If necessary, adjust the seals (2), (4) and (6) then tighten the screws (1) and (5). (3) Loosen the screws (3) on the applicable panels 575AT(675AT), 575KB(675KB), 575LB(675LB) or 575MB(675MB) to let you move the seals (4). (4) Position the seals (4) so that the dimension Y is 18 mm (0.7086 in.) + 0 mm (0.0000 in.) - 2 mm (0.0787 in.). Make sure that the dimension X is between 0.0 mm (0.0000 in.) and 0.5 mm (0.0196 in.). If necessary, adjust the seals (4) to get the two dimensions, then TORQUE tighten the screws (3) to between 0.11 and 0.13 m.daN (9.73 and 11.50 lbf.in). N_O_T_E_ : Make sure that the seals are not above a level between the upper surface of the access panels and the aileron. (5) Manually push the aileron up as far as possible. Make sure that the lower panel seals do not go below the leading edge of the aileron hinge/actuator points. (6) Slowly move the aileron to its neutral position and monitor the seals. Make sure that they do not catch the leading edge of the aileron hinge/actuator points. (7) Manually push the aileron down as far as possible. Make sure that the upper panel seal 575AT(675AT) and the fixed panel seal do not catch the aileron upper surface. (8) Move the aileron to its neutral position and monitor the upper seals. Make sure that they do not catch the aileron hinge/actuator points. (9) If the seals catch the aileron, loosen the applicable screws (3). Adjust the seal(s) at the point where they catch and TORQUE tighten the screws (3) to between 0.11 and 0.13 m.daN (9.73 and 11.50 lbf.in). (10) Do the steps (3) thru (8) again. G. Pressurize the Hydraulic Systems W_A_R_N_I_N_G_ : MAKE SURE THAT THE CONTROLS AGREE WITH THE POSITION OF THE ITEMS THEY OPERATE BEFORE YOU PRESSURIZE A HYDRAULIC SYSTEM. (1) Pressurize the Green hydraulic system (Ref. TASK 29-10-00-863-001). (2) Pressurize the Blue hydraulic system (Ref. TASK 29-10-00-863-003).

Subtask 27-14-41-865-052 H. Remove the safety clip(s) and the tag(s) and close this(these) circuit breaker(s): 15CE1, 15CE2, 16CE1, 16CE2. Subtask 27-14-41-710-050 J. Operational Test W_A__R_NI__NG_ : MAKE SURE THAT THE TRAVEL RANGES OF THE FLIGHT CONTROLS ARE CLEAR. MOVEMENT OF FLIGHT CONTROLS CAN CAUSE INJURY TO PERSONS AND/OR DAMAGE. (1) Do an operational test on the ailerons (Ref. TASK 27-14-00-710-001). During the operational test, make sure that the ailerons move correctly. (2) Install the safety collar on the circuit breakers 9CV and 11CV. 5. C_l_o_s_e_-_u_p_ Subtask 27-14-41-942-050 A. Removal of Equipment (1) Remove the SAFETY BARRIERS. (2) Remove the warning notice(s). (3) Remove the access platform(s). (4) Remove the ground support and maintenance equipment, the special and standard tools and all other items.

Appendix 6: Aileron quadrant removal and installation In this appendix the maintenance task of the removal and installation of the aileron quadrant will be further explained in detail be use of figures and abstracts of the AMM. The abstract of the removal with the precise proceedings can be found in section A. In section B the rig pin figure is displayed and section C the detailed figure of the quadrant can be seen with all the bolts, washers and nuts. Section D provides the abstract of the installation and in section E the table of the tension of the cables versus the ambient temperature is given. Finally in section F, the final check of the correctness of the job is checked by turning the Captain's wheel via specific

instructions.

Section A (1)Remove the wing quadrant: (a) Remove the cotter pin, nut, washer, and bolt that hold the aileron control rod to the wing quadrant clevis. (b) Disconnect the cables ABSA and ABSB at the turnbuckles (Figure 402). (c) Safety the disconnected cables. (d) Remove the nuts, washers, and screws to remove the retaining plates from the wing quadrant. (e) Disengage the cables ABSA and ABSB from the wing quadrant. (f) Remove the cotter pin, nut, washer, bushing and bolt that hold the wing quadrant to the aileron hinge (structure). (g) Remove the wing quadrant. (h) Isolate the bushing from the aileron hinge (structure), if it is necessary. SUBTASK 27-11-24-034-006 (2) Disassemble the wing quadrant if it is necessary: (a) Remove the bushings from the attachment point (wing quadrant clevis) of the aileron control rod. (b) Remove the bearings (swaged), bushing, and spacer from the quadrant attachment

point, if it is necessary. ------------------------- END OF TASK ---------------------------

Section B: Rig pin

Section C:

Section D: Abstract of installation 1) Install the aileron quadrant: (a) If it is necessary, assemble the wing quadrant with the steps that follow: 1) Install the bearings (swaged), bushing, and spacer with bolt, washer, and self locking nut in the attach point of the wing quadrant, if they are not installed. 2) Tighten the self locking nut to 160-200 pound-inches. (b) Put the aileron control rod in position to be connected to the aileron hinge (structure) and to the wing quadrant clevis with the steps that follow: 1) Install the bushing in the aileron control rod attach point, if it is not installed. 2) Put the bushing in the aileron hinge (structure), if it is necessary. 3) Put the wing quadrant in its position. 4) Install the bolt, washer, and nut at the aileron rod end/aileron hinge joint. 5) Tighten the nut to 60-85 pound-inches. 6) Install the cotter pin. (c) Put the cables ABSA (for the left wing) and ABSB (for the right wing) in the bottom groove of the wing quadrant. (d) Put the cables ABSB (for the left wing) and ABSA (for the right wing) in the top groove of the wing quadrant. (e) Install the cable retaining plates with screws, washers, and nuts. (f) Install the cable guard on the structure at the forward edge of the wing quadrant. (g) Adjust the cable guard clearance to 0.03 +0.05/-0.03 inch. (h) Attach the aileron control rod to the wing quadrant clevis with the steps that follow: 1) Connect the aileron control rod to the wing quadrant with bolt, washer, and nut. 2) Tighten the nut to 60-85 pound-inches. 3) Install the cotter pin. (i) Connect the cables ABSA and ABSB to the turnbuckles, but keep the cable tension at zero. (j) Make sure that the rig pin A/S-4 is installed (k) Tighten the turnbuckles for each cable (ABSA and ABSB) to put the ailerons at the correct position NOTE: The index point B on the inboard end of each aileron must align with the index

point A on the adjacent wing structure (use a tolerance of ±0.03 inch). (l) Continue to tighten cables in equal increments until you get the correct tension (Figure 404). (m) Install the turnbuckle clip locks. (3) Install the access panels. (4) Install the protractor mount and the protractor on the captain’s aileron control wheel. (5) Compare the movement of the aileron control wheel with the movement of the aileron surface: (a) Turn the captain’s aileron control wheel more than 87 degrees counterclockwise from the neutral position. (b) Make sure that the left aileron moves up and the right aileron moves down in the specified limits. (c) Turn the captain’s aileron control wheel more than 87 degrees clockwise from the neutral position. (d) Make sure that the left aileron moves down and the right aileron moves up in the specified limits. (6) Remove the protractor and protractor mount from the captain’s aileron control wheel. (7) Close these access panels: Number Name/Location 7218 Wing Rear Spar Access Panel (WS 512.78) 7418 Wing Rear Spar Access Panel (WS 512.78) 8108 T.E. Upper Access Door (WS 517.76) 8808 T.E. Upper Access Door (WS 517.76)

Appendix 7: Side stick removal and installation

In this appendix the maintenance task of the removal and installation of side stick of the Airbus A320 will be further explained in detail by use of figures and abstracts of the AMM. The abstract of the removal with the precise proceedings can be found in section A. The installation of the side stick assembly is described in section B. In section C the location of the side stick can be found as well as the cover panel.

Section A The steps needed to remove the side stick assembly are as follows. These steps have been looked up in the aircraft maintenance manual for the Airbus A320.

(1) The ground service network needs to be energized. This is subtask 27-92-41-861-052.

(2) Accessing the side stick assembly is done by performing the following steps, this is

subtask 27-92-41-010-065:

(a) The access platform needs to be put in position at the access door 822.

(b) The access door 822 needs to be opened.

(c) The two screws on the battery power center 105VU need to be loosened in order to

remove the protective cover.

(3) The following circuit breakers need to be opened and tagged, this is subtask 27-92-41-

865-050:

Panel Designation Ident Location

49vu Flight controls/elac1/norm/sply 15CE1 B11

49vu Flight controls/sec1/norm/sply 21CE1 B08

49vu Com/audio/acp/f/o 5RN G07

49vu Com/audio/acp/capt 4RN G06

105vu Flight controls/elac2/stby sply 16CE2 A02

105vu Flight controls/elac1/stby sply 16CE1 A01

105vu Flight controls/sec1/stby sply 22CE B01

121vu Auto flight/stick/lock 13CA N16

121vu Flight controls/sec3/sply 21CE3 Q19

121vu Flight controls/sec2/sply 21CE2 Q18

121vu Flight controls/elac2/norm/sply 15CE2 R20

(4) The cover panel needs to be removed, to do this the following steps need to be

conducted. This is subtask 27-92-41-010-050. A figure showing the different screws,

washers and catches can be found in section C.

(a) The handle (1) needs to be removed after releasing the lock (8).

(b) The following screws need to be removed: 4 and 6. The following washers need to be

removed: 5 and 7.

(c) Release the catches (2) and the cover (3).

(5) The needed tools need to be installed next, this is subtask 27-92-41-480-050. A figure

displaying this procedure is also shown in section D.

(a) The pin-side stick locking needs to be put in the central universal joint.

(b) A warning notice needs to be put in place such that no one operates the side stick.

(6) The actual removal of the side stick assembly, this corresponds with subtask 27-92-41-

020-050. A reference figure can be seen in section D.

(a) Remove screws (26) and washers (25). This is followed by disengaging the side stick

assembly (11) from the support (12).

(b) Following electrical connectors need to be disconnected: 13, 14, 15, 22, 23 and 24.

Mark these connectors.

(c) Remove the side stick assembly (11).

(d) Blanking caps need to be put on the electrical connectors: 13, 14, 15, 16, 17, 18, 19,

20, 21, 22, 23 and 24.

(7) Removal of the casing, this is subtask 27-92-41-010-060.

(a) Remove the screws (28) and the washers (29).

(b) This is followed by removing the casing assembly (27) and (30).

Section B The steps needed to install the side stick assembly are as follows. These steps have been looked up in the aircraft maintenance manual of the Airbus A320.

(1) This is subtask 27-92-41-861-053.

(2) This is also the same task as stated above. This is subtask 27-92-41-010-066.

(3) Same goes for this task. This is subtask 27-92-41-865-054.

(4) Aircraft maintenance configuration, this is subtask 27-92-41-860-050. A reference figure is

shown in section E.

(a) The cover panel needs to be removed.

(b) The pin-side stick locking needs to be installed.

(c) The warning notice needs to tell personnel not to operate the side stick.

(5) Installation of the casing, this is subtask 27-92-41-410-060. The clips need to be in position

and installed correctly on the side stick assembly. A reference figure is shown in section D.

(a) The casing assembly (27) and (30) needs to be installed on the side stick assembly (12).

(b) The washers (29) and screws (28) need to be installed.

(6) Installing the side stick, this is task 27-92-41-420-050-A.

(a) The blanking caps need to be removed from the electrical connectors (16), (17), (18),

(19), (20) and (21).

(b) The connectors need to be clean and in the right condition.

(c) The connectors need to be connected: 13, 14, 15, 22, 23 and 24.

(d) Carefully put the side stick assembly (11) in position on its support (12).

(e) The next step is to install the washers (25) and the screws (26).

(f) The screws (26) need to be torqued between 33.62 and 37.16 lbf.in.

(7) The pin-side stick locking (10) and the warning sign needs to be removed. This is subtask 27-

92-41-410-050.

(8) Installing the cover panel is subtask 27-92-41-410-050. This is shown in section C.

(a) The cover (3) needs to be put in position.

(b) Install the following things: washers (5) and (7) and screws (4) and (6). Lock the catches

(2).

(c) The lock (8) needs to be released and the handle (1) needs to be installed.

(9) The side stick movement needs to be checked, this is subtask 27-92-41-210-050.

(a) The side stick must be free to move.

(b) It must not have a friction point along its full range of operation.

(c) The side stick must go correctly to its stops in all directions.

(d) It has to go back to its neutral position when released.

(10) The safety clips and tags need to be removed and the the following circuit breakers need to

be closed: 15CE1, 15CE2, 16CE1, 16CE2, 21CE1, 21CE2, 21CE3, 22CE, 13CA, 4RN, 5RN. This is

subtask 27-92-41-865-063.

(11) The side stick needs to be tested, this is subtask 27-92-41-710-050. The operational test of

the side stick assembly must be conducted.

(12) Subtask 27-92-41-942-050: Make sure that the work area is clean and that all the tools have

been stored.

(13) De-energize the ground service network, this is subtask 27-92-41-862-052.

(14) Subtask 27-92-41-410-065: closing access.

(a) The protective cover on the battery power center 105vu needs to be installed.

(b) The two screws need to be tightened.

(c) The access door 822 needs to be closed.

(d) The access platform needs to be removed.

Section C

Section D

Section E

Appendix 8: Removal and installation of the Cable Quadrant

Section A

Tools

Fixtures, Tools, Test and Support Equipment No specific circuit breaker(s) safety clip(s) No specific warning notices No specific access platform 2.06 m (6 ft. 9 in.) No specific access platform 5.50 m (18 ft. 1 in.) R 98A27901002000 1 PIN,RIGGING-RUDDER CONTROL 98D27207547000 1 PIN - RIGGING 98D27207548000 1 PIN - RIGGING

Consumable Materials No specific lockwire 0.6 mm (0.024 in.)

(1) Disconnect the cables (10) from the cable quadrant (1). WARNING : WEAR GLOVES WHEN YOU TOUCH THE CABLES. (a) Open the locking clips (30) and turn the turnbuckles (31) until you can remove the ends of the cables (10) from the levers (3). (b) Remove the cables (10) from the cable quadrant (1). (c) Keep the cables (10) clear of the cable quadrant (1). (2) Disconnect the control rod (2) from the cable quadrant (1). (a) Remove and discard the cotter pin (15). (b) Remove the nut (16) and the washer (17) from the screw (19). (c) Remove the screw (19). (d) Move the control rod (2) clear of the lever arm (4). (e) Safety the bush (18) in the lever arm (4) with lock wire 0.6 mm (0.024 in.) (3) Disconnect the cable quadrant (1) from the aircraft structure. (a) Remove and discard the cotter pins (5). (b) Remove the nuts (6) and the washers (7) from the screws (8),(9). (c) Hold the cable quadrant (1) in position. (d) Remove the screws (8) from the top connection positions. (e) Remove the screws (9) from the bottom connection positions. (f) Remove the cable quadrant (1). NOTE : Identify the screws (8) and the screws (9) for installation in the same positions.

Appendix 8: Installation of the Cable Quadrant

Section B (1) Connect the cable quadrant (1) to the aircraft structure. (a) Put the cable quadrant (1) in position at the aircraft structure. (b) Hold the cable quadrant (1) in position. (c) Install the screws (8) at the top connection positions. (d) Install the screws (9) at the bottom connection positions. (e) Install the washers (7) and the nuts (6) on the screws (8),(9). (f) Tighten the nuts (6). (g) Safety the nuts (6) with the cotter pins (5). (2) Connect the control rod (2) to the cable quadrant (1). (a) Install the bush (18) in the lever arm (4).

(b) Put the control rod (2) in position in the lever arm (4). (c) Align the hole in the eye-end bearing of the control rod (2) with the hole in the lever arm (4). (d) Install the screw (19). (e) Install the washer (17) and the nut (16) to the screw (19). (f) TORQUE the nut (16) to 0.7 m.daN (61.94 lbf.in) and then loosen it, if necessary, to the next cotter pin hole. (g) Safety the nut (16) with the cotter pin (15). (3) Connect the cables (10) to the cable quadrant (1). (a) Release the cables (10). (b) Put the cables (10) in position on the cable quadrant (1). (c) Put the ends of the cables (10) in position in the levers (3). (d) Make sure that the adjustment of the screws (11) is correct (Ref. TASK 27-21-00-820-002). (e) Turn the turnbuckles (31) to apply some tension to the cables

Appendix 9: Glossary

Actuator Hydraulic mechanism that causes the flight control surface to move

Angel of Attack The angle between a reference line on a chord line

Anti-servo tabs Works in the opposite way to a servo tab

Ailerons Flight control surfaces attached to the trailing edge of the wing

Airfoil A two-dimensional perspective of a wing profile

Balance tabs An anti-servo tab acts as a trimming device

Bell cranks A type of crank that changes motion through an angle

Centre pedestal Control panel between the pilots

Chord line Refers to the imaginary straight line joining the trailing edge and. the center of curvature of the leading edge of the cross-section of an airfoil

Drag Aerodynamic term for resistance

Elevators Flight control surfaces, usually at the rear of an aircraft

Flaps Part of a wing that is extendable to increase lift

Flight control primary and secondary flight controls

Flight levels Altitude an aircraft is flying

Hydraulics Worked by the pressure of water or some other liquid

Ideal gas , A theoretical gas composed of a set of randomly-moving non- interacting point particles

Indicated Airspeed is the airspeed read directly from the airspeed indicator

Leading edge Front of an airfoil

Leading Edge devices Devices on the front of the wing such as flaps.

Lift Aerodynamic lift

Master caution Master switches

Mean camber line The shape of the airfoil is defined by the mean camber line

Primary Flight Controls Ailerons, elevator and rudder

PSI An indication for the pressure on a object

Pulleys A wheel on an axle that is designed to support movement of a cable or belt

along its circumference

Relative wind the direction of movement of the atmosphere relative to an aircraft or an airfoil

Rudder Directional control surface attached to horizontal tail structure

Ruddervators A combine of two, rudder and elevators

Slats Secondary flight control that increases lift

Secondary Flight Controls Slats ,flaps, spoilers, air brakes

Servo tabs A small device installed on an aircraft control surface to assist the ovement of the control surface

Servo valves Valve which controls in which directions the fluid can flow

Skid An outward side-slip in an aircraft turn

Skydroll Kind of hydraulic fluid

Stagnation point The point in a flow field where the local velocity of the fluid is zero

Speed brake lever Control to reduce speed

Spoilers Part of the wing that increases drag

Teflon (PTFE) Polytetrafluoroethylene

Trailing edge Back of an airfoil

Trailing Edge devices Devices on the end of the wing such as ailerons

Trim tabs A trailing edge tab that is used to trim that control surface.

wing profiles Is the shape of a wing or blade

Appendix 10: Proceeding report

At the beginning of project ‘Flight Controls’ we started with nine project members. However, at the first day of meeting, one member stated to quit with the study immediately. He left us at the first day so we started with a total of eight man, but only one week later, two project members also decided to quit with the education. It was a pleasure that one of them announced it on time so the project group could take care with the planning and workload. Unfortunately, the other member did not say ‘goodbye’ nor announcing his leaving plans. A big disappointment for the project group by abandoning them. In the second week we were with only six men left. However one member even did not turn up yet in the past week. It was an unknown person and hard to contact him, so for the feeling the project group only existed of five man. Fortunately, during the second week this member did turn up and the project supervisor, Daan Nederlof, announced the project group with great news: A new member will join the group. A big acquisition because this member already got three years’ experience at an aviation related university. Finally after a week of appearing and disappearing of members, the project group was able to start with the Plan of Approach. The Plan of Approach comes with an introduction of the project group with a picture and contact list but also with concerning contents such as an introduction about the project itself, a problem description and the corresponding objectives. During writing the Plan of Approach, a brainstorm session was needed to decide how we classify the ‘problem’ into parts for the chapters. Each new project week there is a new chairman and a new secretary. There is a project meeting with the project leader once a week, each Monday. The project leader leads us through the right ways to the right goal by correcting our way of thinking, way or working and communicating. But also concerning thinks such as: what is the best way to handle this? Our experience with our project leader, Daan Nederlof, went very well. He managed us greatly during hard times. During the whole process from first week till last week, the project group noticed a lot of resistance regards workload, managing, planning, communicating and especially dealing with deadlines. Some members took the project too easy. Thought it would an easy job: just explain the axis of movements of the airplane with their aerodynamic laws and theory, explain the working mechanics of the flight controls, explain a few maintenance task and we are done. By this way you get an imaginary break line through the group. One half understood the project problem very well and the other half insufficient. By this way a few members of the group distrusted the members who did insufficient work. In the final week the workload went to a higher level. Especially because chapter three about the maintenance tasks took the project group more time than estimated. It was a hard job to understand the Aircraft Maintenance Manuals and Maintenance Planning Documents of Boeing and Airbus, and especially to see relations between these two documents. The workload also increased because two days before the final deadline we got a call that again a member is going to quit with his study. With two days remaining, undone and insufficient work, there was creating some tension in the group. At this moment we took as group a deep breathe, and finally reached our goal with a positive and hardworking mindset.