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GUST LOCK — ADJUSTMENT / TEST
1. Gust Lock System — Rigging Procedure A. Preparation
SPECIAL TOOLS AND TEST EQUIPMENT Cable tensiometer, 10 - 200 pounds ..................................................... GSE2700321 or equivalent Flight controls rig pin kit ......................................................................... GSE2700924 or equivalent Cable block ............................................................................................ GSE2701039 or equivalent Cable block and chain ....................................................................................... 50082 or equivalent
(1) Reference(s)
• Supplemental Heating - Removal / Installation, 25-27-00, Removal / Installation or Code 252011
• Floorboard Clip Nut - Check, 53-00-00, Inspection / Check or Code 532016 CAUTION: FLIGHT CONTROL RIGGING IS PROHIBITED WHEN WIND SPEED IS GREATER THAN 10 MILES PER HOUR.
(2) Aircraft Preparation
(a) Prepare aircraft for safe ground maintenance.
(b) Place gust lock handle in unlocked (down) position.
WARNING: FAILURE TO ENSURE ALL PERSONNEL AND EQUIPMENT ARE
CLEAR OF FLIGHT CONTROL SURFACES BEFORE OPERATING FLIGHT CONTROLS MAY RESULT IN SERIOUS INJURY OR DEATH.
CAUTION: DO NOT RIG GUST LOCK SYSTEM WITH AIRCRAFT FLIGHT
CONTROL HYDRAULIC SYSTEMS PRESSURIZED OR WITH ANY RESIDUAL PRESSURE IN THE SYSTEM.
(c) Dissipate hydraulic system pressure by cycling flight controls and / or operating brake pedals several times.
(d) Remove interior furnishings and carpeting as required to gain access to floorboards being removed.
(e) Remove floor heater mats, if installed. See Supplemental Heating - Removal / Installation, 25-27-00, Removal / Installation or Code 252011 .
(f) Remove floorboards FLR-33 and FLR-37. See Figure 501.
(g) Gain access to tail compartment.
B. Bungee Rigging CAUTION: DO NOT RIG GUST LOCK SYSTEM WITH AIRCRAFT FLIGHT CONTROL
HYDRAULIC SYSTEMS PRESSURIZED OR WITH ANY RESIDUAL PRESSURE IN THE SYSTEM.
NOTE: If gust lock cable system has had maintenance accomplished, perform Step 1.B1.(1) prior to this task.
The following numbers in parenthese s()a r eu s e di nc o njunction with Figure 502.
(1) Place gust lock lever in locked (up) position.
(2) Lengthen aileron gust lock bungee assembly (9) so that gust lock latch hook fully engages aileron gust lock bushing without compressing bungee.
MAINTENANCE MANUAL 27-70-00 Page 501 April 29/16 TEMPORARY REVISION 27-3
NOTE: Do not overtorque bolts when installing bungee. Joints should be free to rotate.
(3) Lengthen bungee three turns and install between sector assembly and latch assembly.
(4) Tighten bungee jam nut and safety, as required.
(5) Lengthen elevator gust lock bungee assembly (11) so that elevator gust lock latch hook fully engages elevator gust lock bushing without compressing bungee.
(6) Tighten bungee jam nut and safety, as required.
(7) Lengthen bungee three turns.
(8) Install bungee between torque tube and latch assembly.
(9) Lengthen rudder gust lock bungee assembly (10) so that rudder gust lock latch hook fully engages rudder gust lock bushing without compressing bungee.
(10) Lengthen bungee three turns and install between torque tube assemblies.
(11) Tighten bungee jam nut and safety, as required.
(12) Go to Step 1.C.(1).
B1. Cable Tension Rigging NOTE: The following numbers in parenthese s()a r eu s e di nc onjunction with Figure 502.
(1) Place gust lock lever in locked (up) position.
(2) Insert rig pin No. 2 in sector at forward end of pedestal.
NOTE: For cable tensions at temperatures other than 70°F, see Table 501.
(3) Insert rig pins, 1/4 inch diameter at sector for aileron bungee assembly (9) and crank for elevator bungee (11).
(4) Tension gust lock 3/32 cable assembly 30 ±5 pounds at 70°F (forward inboard cable or right hand cable).
NOTE: Turnbuckle for forward outboard cable assembly is located under FLR-33 at FS 257.
(5) Tension gust lock 3/32 cable assembly 45 ±5 pounds at 70°F (aft inboard cable or right hand cable).
NOTE: Turnbuckle for aft outboard cable assembly is located at FS 750 in tail compartment.
(6) Tension gust lock 3/32 cable assembly 65 ±5 pounds at 70°F (outboard cable or left hand cable).
NOTE: Turnbuckle for inboard cable assembly is located at FS 740.
(7) Rig pins installed in Step 1.B1.(3) should be easily removed after cables are tensioned.
(8) Remove all rigging pins and check system for freedom of motion.
(9) Double check for locking action of latches versus gust lock handle motion (i.e., handle aft and locked - latches locked).
NOTE: With gust lock system engaged, control surfaces should have the following approximate positions:
• Elevators: 13 ±1° down
• Rudder: Preset ±3°
• Ailerons: 0 ±1.5°
MAINTENANCE MANUAL 27-70-00 Page 502 April 29/16 TEMPORARY REVISION 27-3
(10) With gust lock system engaged, a small amount of movement can be made by hand at all control surfaces. Also, controls in cockpit can be moved a small amount with a spongy feeling in lateral control wheel.
C. Follow On
(1) Inspect for presence of any fluid accumulations.
(2) Aircraft with floorboard clip nuts installed, perform Floorboard Clip Nut - Check, 53-00-00, Inspection / Check or Code 532016 .
(3) Inspect for presence of foreign objects.
(4) Install floorboards removed in Step 1.A.(2)(f).
(5) Install floor heater mats removed in Step 1.A.(2)(e).S e eSupplemental Heating - Removal / Installation, 25-27-00, Removal / Installation or Code 252011 .
(6) Install carpeting and interior furnishings removed in Step 1.A.(2)(d).
(7) Record all maintenance actions in accordance with current governing authority.
Table 501: Secondary Control System Cable Tensions
CABLE TENSION VS AIRCRAFT STEADY STATE TEMPERATURE - 3/32 INCH DIAMETER CABLE Temperature(1) Pretension 30 Pounds at 70°F Pretension 45 Pounds at 70°F Pretension 65 Pounds at 70°F 30°F 22 35 54 35°F 23 36 55 40°F 24 37 57 45°F 25 39 59 50°F 26 40 60 55°F 27 42 62 60°F 28 43 63 65°F 29 44 64 70°F 30 45 65 75°F 31 47 67 80°F 32 48 69 85°F 34 49 70 90°F 35 50 71 95°F 36 52 72 100°F 37 53 73 105°F 38 54 74 110°F 40 55 76
MAINTENANCE MANUAL 27-70-00 Page 503 April 29/16 TEMPORARY REVISION 27-3
CABLE TENSION VS AIRCRAFT STEADY STATE TEMPERATURE - 3/32 INCH DIAMETER CABLE Temperature(1) Pretension 30 Pounds at 70°F Pretension 45 Pounds at 70°F Pretension 65 Pounds at 70°F 115°F 41 57 78 120°F 42 58 79 125°F 43 60 80 130°F 44 61 81
(1) The aircraft structural temperature may be assumed to be the same as the local ambient air temperature, provided that the aircraft has been in that ambient air environment for at least 1 hour and provided that the direct solar effects are minimal (i.e., aircraft not parked in direct sunlight).
MAINTENANCE MANUAL 27-70-00 Page 504 April 29/16 TEMPORARY REVISION 27-3
80324C00 FLR-17 FLR-20 FLR-22 FLR-26 FLR-30 FLR-25 FLR-24 FLR-15 FLR-21 FLR-23 FLR-27 FLR-28 FLR-29 FLR-34 FLR-33 FLR-32 FLR-31 FLR-38 FLR-37 FLR-36 FLR-35 FLR-16 FLR-18 FS 133 FS 169 FS 181 FS 193 FS 193B FS 193E FS 235.5 FS 257 FS 287 FLR-19 AIRCRAFT 1000 THRU AIRCRAFT 1447 Cockpit / Forward Cabin Access Figure 501 (Sheet 1 of 2)
MAINTENANCE MANUAL 27-70-00 Page 505 April 29/16 TEMPORARY REVISION 27-3
80314C00 FLR-17 FLR-20 FLR-22 FLR-26 FLR-30 FLR-25 FLR-24 FLR-15 FLR-21 FLR-23 FLR-27 FLR-28 FLR-29 FLR-34 FLR-33 FLR-32 FLR-31 FLR-38 FLR-37 FLR-36 FLR-35 FLR-16 FLR-18 FS 133 FS 169 FS 181 FS 193 FS 193B FS 193E FS 235.5 FS 257 FS 287 AIRCRAFT 1448 AND SUBSEQUENT FLR-15A FLR-19FLR-16A FLR-19BFLR-19A Cockpit / Forward Cabin Access Figure 501 (Sheet 2 of 2)
MAINTENANCE MANUAL 27-70-00 Page 506 April 29/16 TEMPORARY REVISION 27-3
TIL-026969C
DETAIL C SEE
DETAIL B SEE
DETAIL A SEE
DETAIL A
DETAIL B
DETAIL C
REVERSE THRUST LEVERS
POWER LEVERS
FUEL COCK LEVERS
COCKPIT FLOOR RIG POINT NO. 2 RIG POINT NO. 3 RODS
CONTROL RIG POINT NO. 1
LOWER SECTORS 133 FS
DETAIL D SEE
LH SIDE
VIEW LOOKING FWD UNLOCK
779.700 FS 13.00 LBL CL APL 10 WL 106.875 WL 101.734 12 11
1.625 RBL HOLE
RIG PIN
SEE DETAIL E
RH SIDE
VIEW LOOKING DOWN
285.437 FS
21.937 BL
4.00 BL 9 HOLE
RIG PIN Gust Lock System - Rigging Figure 502 (Sheet 1 of 2)
MAINTENANCE MANUAL 27-70-00 Page 507 April 29/16 TEMPORARY REVISION 27-3
UNLOCK
DETAIL E
775.025 FS
790.812 FS
793.750 FS
RH SIDE
LOOKING FWD
113.339 WL
101.734 WL
8.560 RBL
1.625 RBL REF 10 FWD TIL-30671CB
DETAIL D
187.203 FS Gust Lock System - Rigging Figure 502 (Sheet 2 of 2)
MAINTENANCE MANUAL 27-70-00 Page 508 April 29/16 TEMPORARY REVISION 27-3
2. Gust Lock System — Operational Test A. Procedure WARNING: FAILURE TO ENSURE ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF
FLIGHT CONTROL SURFACES BEFORE OPERATING FLIGHT CONTROLS MAY RESULT IN SERIOUS INJURY OR DEATH.
CAUTION: DO NOT TEST GUST LOCK WITH AIRCRAFT FLIGHT CONTROL HYDRAULIC
SYSTEMS PRESSURIZED OR WITH ANY RESIDUAL PRESSURE IN THE SYSTEM.
(1) Ensure all power levers are aft and all controls are in neutral.
(2) Verify that gust lock lever will return from locked position to unlocked position smoothly.
(3) Advance throttles to maximum power.
(4) Move gust lock lever aft to engage gust lock and verify both throttles move toward idle.
(5) Verify that all control surfaces are locked by manually attempting to move the rudder surface right and left, aileron surfaces up and down and elevator surfaces upward.
NOTE: The aileron surfaces will have approximately ±0.75 inches of spongy freeplay with the gust lock engaged. This is because the gust lock latch is upstream of the aileron actuators. Although the rudder surface gust lock may be engaged and holding the rudder surface fixed, it will still be possible to move the rudder pedals several inches under force against the rudder arti ficial-feel bungee. This is normal behavior and is due to the clearance between the input and output sectors at the rudder actuator.
(6) Move gust lock lever forward to disengage gust lock.
(7) Operate aileron, rudder and elevators. They should move freely through their full range.
B. Follow On
(1) Inspect for presence of foreign objects.
(2) Record all maintenance actions in accordance with current governing authority.
3. Rudder Gust Lock Hook — Adjustment / Test A. Preparation
SPECIAL TOOLS AND TEST EQUIPMENT
Shim stock1159CM20556
Flight controls rig pin kit ......................................................................... GSE2700924 or equivalent
WashersAN960-516L
Torque wrench, 20 - 1000 inch-pounds (22.60 - 112.98 Nm) ............... GSE5100722 or equivalent Safety wire ................................................................................................................... MS 20995C32
CONSUMABLES Cotter pin .................................................................................................................... MS 24665-151 Shim stock ............................................................................................................. 1159CM205 56-11
(1) Aircraft Preparation
(a) Prepare aircraft for safe ground maintenance.
MAINTENANCE MANUAL 27-70-00 Page 509 April 29/16 TEMPORARY REVISION 27-3
B. Procedure WARNING: FAILURE TO ENSURE ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF
FLIGHT CONTROL SURFACES BEFORE OPERATING FLIGHT CONTROLS MAY RESULT IN SERIOUS INJURY OR DEATH.
CAUTION: FLIGHT CONTROL RIGGING IS PROHIBITED WHEN WIND SPEED IS GREATER THAN 10 MILES PER HOUR.
DO NOT RIG GUST LOCK SYSTEM WITH AIRCRAFT FLIGHT CONTROL
HYDRAULIC SYSTEMS PRESSURIZED OR WITH ANY RESIDUAL PRESSURE IN THE SYSTEM.
NOTE: The following numbers in parenthese s()a r eu s e di nc onjunction with Figure 503.
(1) Position rudder pedals in midrange by use of adjustment handle.
NOTE: Midrange should be fifth slot from either end of adjustment handle.
(2) Position arrow indicator on RUDDER TRIM wheel to zero.
NOTE: For the purpose of this procedure, there are 20 units on the RUDDER TRIM wheel dial. Turning the wheel full left from zero to 10 is 10 equal units. Turning the wheel full right from zero to 10 is 10 equal units.
(3) Dissipate hydraulic system pressure by cycling flight controls and / or operating brake pedals several times.
(4) Insert rig pin in neutral pin hole in rudder sector. See Figure 504.
(5) Apply hydraulic power to aircraft.
(6) Place gust lock lever in locked (up) position.
(7) Remove rig pin inserted in Step 3.B.(4).
CAUTION: DO NOT MOVE RUDDER PEDALS TO SET RUDDER GUST LOCK HOOK.
(8) Visually inspect / adjust relationship of rudder gust lock hook to roller as follows:
(a) If rudder gust lock bushing fully engages rudder gust lock hook, go to Step 3.B.(14).
(b) If rudder gust lock bushing is below rudder gust lock hook engagement slot, rotate RUDDER TRIM wheel clockwise slowly until bushing is fully engaged.
(c) If rudder gust lock bushing is above rudder gust lock hook engagement slot, rotate RUDDER TRIM wheel counterclockwise slowly until bushing is fully engaged.
NOTE: Rudder trim wheel position arrow indicator tolerance is ±0.25 units from zero with gust lock lever in locked (up) position.
(d) Using RUDDER TRIM wheel units, determine amount of rudder trim required to have rudder gust lock hook fully engage rudder gust lock bushing.
(e) Record measurement from Step 3.B.(8)(d) _________________. If rudder trim wheel arrow indication is greater than ±0.25 units adjust rudder gust lock hook shim stack as required.
(9) Place gust lock lever in unlocked (down) position.
(10) Position arrow indicator on RUDDER TRIM wheel to zero.
(11) Remove hydraulic power from aircraft.
MAINTENANCE MANUAL 27-70-00 Page 510 April 29/16 TEMPORARY REVISION 27-3
(12) Adjust shim stock to gust lock hook pedestal assembly (1) as follows:
(a) Using measurement recorded in Step 3.B.(8)(e), determine how much shim stock (9) to add or remove for rudder gust lock hook (2) to freely engage bushings at bellcrank.
NOTE: One unit of RUDDER TRIM wheel is equal to approximately 0.060 inches of shim.
(b) Remove cotter pin (3), washer (4) and pin (5). Discard cotter pin (3).
(c) Remove safety wire from bolt (6) and discard.
(d) Remove bolt (6) and beveled washer (7) under bolt head. Retain stack of washers (8) under beveled washer (7) for installation.
(e) Add or remove shim stock (9) determined in Step 3.B.(12)(a).
(f) Adjust washers (8), under bolt (6) head and beveled washer (7) to achieve 0.60 ±0.03 inches from underside of bolt (6) head to top of rudder gust lock hook pedestal assembly (1).
(g) Install shim stock (9) between gust lock hook pedestal assembly (1) and gust lock hook
(2).
(h) Install bolt (6) and beveled washer (7) under bolt (6) head and stack of washers (8).
(i) Tighten bolt (6) and verify measurement as follows:
1 If measurement is not 0.60 ±0.03 inches from underside of bolt (6) head to top of rudder gust lock hook pedestal assembly (1), adjust as required with washers (8) and repeat Step 3.B.(4) thru Step 3.B.(11) and verify RUDDER TRIM wheel indication is within limits.
2 If measurement is 0.60 ±0.03 inches from underside of bolt (6) head to top of rudder gust lock hook pedestal assembly (1), go to Step 3.B.(12)(j).
(j) Torque bolt (6) to 240 - 280 inch-pounds (27.12 - 31.64 Nm).
(13) Safety wire bolt (6) to rudder hook pedestal.
(14) Remove rig pin installed in Step 3.B.(4).
(15) Check for locking action of rudder gust lock hook versus gust lock handle motion.
NOTE: With gust lock system engaged, control surfaces should have the following approximate positions:
• Elevators: 13 ±1° down
• Rudder: 0 ±3.0°
• Ailerons: 0 ±1.5° C. Follow On
(1) Inspect for presence of foreign objects.
(2) Record all maintenance actions in accordance with current governing authority.
MAINTENANCE MANUAL 27-70-00 Page 511 April 29/16 TEMPORARY REVISION 27-3
TIL-027468K
SEE DETAIL A
DETAIL A 6 7 5 3 4 2 8 9 1 Gust Lock Rudder Hook Figure 503
MAINTENANCE MANUAL 27-70-00 Page 512 April 29/16 TEMPORARY REVISION 27-3