Aerostar Maintenance Manual ATA-27-Flight Controls

FLIGHl CONTROLS
3F2
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHAPTER 27 - FLIGHT CONTROLS
T A B L E OF CONTENTS/EFFECTIVITY
PHAPTER
SECTION GRID
SUBJECT SUBJECT NO. EFFECTIVITY
27-00-00 GENERAL 3F5

27:01-00 Troubleshooting 3F5
27-02-00 Standard Practices 3F12
27-03-00 Control Column Assembly 3F12
27-03-01 Removal of Control Column Assembly 3F12
27-03-02 Installation of Control Column Assembly 3F13
27-03-03 Rigging Control Column Assembly 3F16
27-10-00 AILERON 3F16

27-11 -00 Removal/Installation of Ailerons 3F16
2'7-12-00 Aileron Controls 3F17
27-12-01 Removal of Aileron Control Linkage 3F17
27-12-02 Installation of Aileron Control Linkage 3F21
27-12-03 Rigging and Adjustment of Aileron Controls 3G4
27-20-00 RUDDER AND TAB 3G5

27 21-00 Rudder Pedal Assembly 3G5
27-21-01 Removal of Rudder Pedal Assembly 3G5
27-21-02 Installation of Rudder Pedal Assembly 3G5
27-22-00 Rudder Controls 3G7
27-22-01 Removal of Rudder Control Linkage 3G7
27-22-02 Installation of Rudder Control Linkage 3G10
27-22-03 Rigging and Adjustment of Rudder Controls 3G17
27-23-00 Rudder Trim Tab 3G13
27-23-01 Removal/Installation of Rudder Trim Tab 3G19
27-23-02 Rigging and Adjustment of Rudder Trim Tab 3G19
27-30-00 ELEVATOR AND TAB 3G21

27-31-00 Removal/Installation of Elevator 3G21
27-32-00 Elevator Controls 3G21
27-32-01 Removal of Elevator Control Linkage 3G21
27-32-02 Installation of Elevator Control Linkage 3H2
27-32-03 Rigging and Adjustment of Elevator Cont/ols 3H8
27-33-00 Elevator Trim Tab 3H10
27-33-01 Removai/lnstailation of Elevator Trim Tarjs 3H10
27-33-02 Rigging and Adjustment of Elevator Trim Tabs 3H10
27 - ContVEffftf:.
PHOJO -1
Issued: June 1,1995
3F3
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHAPTER 27- FLIGHT CONTROLS
T A B L E OF CONTENTS/EFFECTIVITY
CHAPTER
SECTION • GRID .
SUBJECT ' , SUBJECT , NO. • EFFECTIVITY
."I
27-50-00 FLAPS • 3H12

27-51-00 • Removal/installation of Flaps • 3H12 ,
27-52-00 • Flap Control Valve : * 3H12
27-52-01 Removal of Flap Control Valve : 3H12
27-52-02 - • Installation of Flap Control Valve 3H12
27-53-00 Flap Flow Control Valves ' " • - - 3H13
27-53-01 i Removal of Flap Flow Control Valves 3H13
27-53-02 Installation of Flap Flow Control Valves • 3H13
27-54-00 ' Flap Actuating Cylinder . . . ' 3H13
27-54-01 Removal of Flap Actuating Cylinder 3H13
27-54-02 Installation of Flap Actuating Cylinder SHU
27-55-00 Flap Position Transmitter •. 3H14
27-55-01 Removal of Flap Position Transmitter 3H14
27-55-02 Installation and Calibration of Flap Position Transmitter SHU
•27-56-00 ' Rigging and Adjustment of Flap Controls 3H15
27-60-00 FLIGHT CONTROL LINKAGE BOOTS

(fvlODELSeOIP. 602PAND700P).. ' SH19
27-61-00 Replacement of Pressure Balance Boots 3H19
27-90-00 STALL WARNING SH22

27-90-01 Lift Transducer 3H22
27-90-02 Removal of Lift Transducer 3H22
27-90-03 Installation of Lift Transducer 3H22
27-90-04 Rotary Switcfi 3H22
27-90-05 Removal of Rotary Switcti 3H22
27-90-06 Installation of Rotary Switcfi 3H22
27-90-07 Pre-Stall Waming System Cfiecl< Procedure 3H24
27 - Cont/Effec.
Page - 2
Issued:June 1,199?
3F4
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
GENERAL.
\
The flight control systems are operated by movement of dual pilot controls. A series of push-pull mechan-
ical linkages connect the pilot controls.to the control surfaces. Electrically actuated trim tabs are mounted on the
elevators and rudder. Trim tab position is electrically displayed on the instrument panel. A fixed position trim tab
is mounted on the right aileron. Coordination of rudder and aileron movement is provided by an interconnect
pushrod and spring assembly at fuselage station 146.80. . j
A ventral rudder has been attached to the rudder torque tube if Kit 764 969v has been installed.
On Model 60rP, 602P and 700P, pressure sealing boots are fitted to the flight control pushrods and bulk-
head, fuselage station 176.88. The cabin pressurization force acting on the pressure sealing boots is balanced
(compensated for) by two separate boots, pushrods, and bellcrank assemblies linked to the aileron and elevator
pushrods fonward of bulkhead fuselage station 176.88. These assemblies transmit equal and opposite pressuriza-
tion force on the control systems pushrods. ' .•«
The flaps are actuated by separate hydraulic cylinders which are connected to two flow control valves per
cylinder. The rate of hydraulic fluid flow through the valves provides synchronized movement of the flaps during
extension and retraction. The flap control lever is linked by cable to a flap control valve under the cabin floor,
which directs main hydraulic system fluid to the flow control valves.
All airframe models can be fitted with auto-pilot systems. These systems are linked to the aileron and ele-
vator pushrods under the fonward floor panel in the baggage compartment.
TROUBLESHOOTING.
Troubles which are peculiar to Flight Controls are listed in Chart 2701.
Abnormal operation of a flight control system, or ran out of rig condition is usually caused by damage,
excessive wear, or incorrect maintenance on affected system components.
The "clocked" positions referenced, for certain bellcranks and idler arms, in their "installation" procedures,
are of primary importance when troubleshooting a control problem, or when rigging a control system.
THIS SPACE INTENTIONALLY LEFT BLANK
27-01-00
Page 27-01
3F5 Issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
, MAINTENANCE MANUAL
' CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS)
-Trouble , , . -Cause „ . . . . . . Remedy
AILERON CONTROL SYSTEM •
Lost motion between pilot Tension too low on control Adjust chain tension.
control wheels. chain.
"/ >
Resistance when rotating.^ Tension tqo high on control Adjust chain tension.
control wheels. chains.
Frozen or tight'bearing in' Check bearings in bellcranks,

linkage system. idler arms, rod-ends, and ai-
leron hinges. Replace bearing.
Bent aileron or aileron Replace as required.

hinge.
..... Linkage interference. Check/repair linkage system as

required. ,
Cannot obtain aileron Long pushrods in wing not Adjust length of puslirods.
neutral droop position set to proper nominal
and/or aileron travel lengths.
limits. - ;
—NOTE— Bellcrank idler arms Check/adjust all bellcrariks and

not set at designated idler arms, per procedures given.
Failure to obtain "clocked" positions with
correct aileron neutral controls in neutral.
droop position and full
up and down travel per Damage to structure or Check/repair damage, as re-
rigging procedures are linkage system effecting quired.
due to the same causes. the linkage geometry.
Control columns install- Rig control column installation,

ation out of rig with perprocedures given.
bellcrank sprocket
assembly.
Rigging template not Fabricate template, per Chapter 91.

fabricated to dimensions
given.
27-01-00
Page 27-02
Issued: June 1,1995
3F6
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (cont)
Trouble Cause Re'niedy
. AILERON CONTROL SYSTEM '

(cont.)
Control wheels riot in, , , Control column chain Rig chain assembly, per pro-
same position. assembly out of rig. ^ cedures given. '
Control wheels do not. Control column chain Rig chain assembly, per pro-
turn fully. assembly out of rig. cedures given.
Stops put of adjustrnent. Adjust stops.
Bellcrank reversed.' Install correctly.
Pushrod(s) connected to Install pushrod(s) per Figure

wrong throw on idler arm. illustration.
Damage to control system. Check/repair, as required.
.Low wing attitude at Aileron_trim tab out of Adjust trim tab.

all .times, in level "rig. "
flight.
Excessive rudder pedal Rudder to aileron inter- Check spring connection

movement required for connect not connected, F.S. 146.80. Adjust interconnect
banking airplane in or out of rig with con- pushrod to position spring verti-
flight. trol linkages in neutral. cal when rudder and aileron
linkage in neutral.
RUDDER CONTROL SYSTEM
Lost motion between Linkage loose or worn. Check linkage. Tightener

rudder pedals. replace.
Loose or worn rudder Repair/replace hinges.

hinges. ' '
Resistance to rudder Frozen or tight bell- Chock bearings and replace as

pedal movement. crank, idler arm. or required.
rod-end bearings.
Brake cylinder inter- Lengthen pushrods between

ference with pedals. F.S. 61.00 and F.S. 77.60 as
required.
Linkage interference Check system and repair as

with adjacent objects, required.
or reverse bellcrank or
idler arm connected with
push rods.
27-01-00
Page 27-03
A^.'-
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (cont)
' ' ' Trouble Cause Remedy
RUDDER C O N T R O f S Y S T E M
(cont.)
Rudder pedals not aligned System linkage out of Refer to linkage installation/
with rudder in neuti-al rig. ^ • rigging procedures.
position.
>
Incorrect rudder travel. Rudder bellcrank stops Adjust stops.
incorrectly adjuste.d.
to • .
Cannot obtain correct System pushrod'linkage Ensure all pushrods are adjusted
rudder travel by ad- not siet to nominal lengths to nominal lengths per di-
justing stops. given, prior to installa- mensions given
tions.
Rigging template not fab- Fabricate template per Chapter

ricated to correct dimen- 91.
sions. .
Lost motion in rudder Excessively worn universal Replace torque tube assembly.
movement. joint on torque tube.
Rudder trim does not Faulty actuator. Replace actuator.

operate.
Fault in electrical Repair circuit.
circuit..
Not enough trim tab Faulty actuator. Replace actuator.

travel.
Out of rig. Rig trim tab per instmctions
given.
Position indicator does Faulty indicator, Replace indicator.

not agree with rudder
trim tab position. Faulty circuit in trim Replace actuator.
actuator. ^
27-01-00
Page 27-04
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (cont.)
Trouble . . . .Cause ., _ Remedy . ,
ELEVATOR CONTROL SYSTEfil
Resistance to contror [ Interference in linkage Cfieck/iêpair, as required.,

column movenient system witfi adjacent
objects.
Frozen or tiigfit'bearings Cfieck and replace b'earing(s).

. . .- , . . . . in bellcrank, idler arms,
fonward torque tube sup-
port plates, or aft torqUe
tube pillow blocks.
Pusfirod connections on Cfieck connections and correct

idler arm reversed. as required per illustrations
given.
Control column binding Lubricate guides witfi silicone.

— • -- -.
on guide in instrument
panel."
Incorrect elevator travel. Control stops not .adjusted Adjust stops.

correctly.
Cannot adjust correct Linkage pusfirods not set Ensure all pusfirods are adjusted
elevator travel at stops. . to nominal lengtfis.giyen to nominal lengtfis prior to
prior to installation. installing..
Incorrect bellcrank Install bellcranks per installa-

installation. tion procedures.
Reverse pusfirod connec- Cfieck idler arm connections,

tions on idler ariTn(s). per illustrations, and correct as
required.
Rigging template not Fabricate template per di-

•
fabricated to correct mensions in Chapter 91.
dimensions.
Excessive free-play VJorn universal joints Replace torque tube assembly.

on elevators. in torque tube. t.
Loose or wom linkage Connections/replace bearings

connections or worn as required.
bearings in linkage.
f
27-01-00
Page 27-05
3F9 Isisued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL ,
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS)(cont)
Trouble" •.' • Cause Remedy
TRIM TAB CONTROLS '
Trim tab 8des not ' Faulty actuator. Replace actuator.'

operate.
Faulty electrical circuit. Repair circuit
Not enough trim tab Faulty actuator. Replace actuator.

travel.
Out of rig." Rig trim tab per instructions '}'
given.
Position indicator does ^ Faulty indicator.- Replace indicator.

not agree with' trim tab
position. Faulty circuit in Replace actuator.
actuator. " '» r
FLAP CONTROLS '
Flap skin wrinkles in Rod end adjustment on - Adjust rod-end.

full retract position. actuating cylinder too
short.
Flap skin wrinkles in Rod-end adjustment on Adjust rod-end.

full down position. actuating cylinder too
long.
Flap track rollers loose Flaps out of rig. Rig flaps.

in slots with flaps fully
retracted
Rate of flap travel move- Flow control valves not Match flow control valves rate
ment not within limits of matched for rate of fluid of flow.
opposite flap. flow.
Flow control valve ori- Clean valve, check fluid system

fice restricted. for contamination.
"Down" travel flow con- < Do not mix "Down" valves with
trol valve and "Up" "Up" valves.
travel valve intermixed.
One flap retracts, oppo- Hydraulic lines are Install lines correctly. •
site flap extends. crossed.
if
27-01-00
Page 27-06
Issued: June 1,1995
3F10
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
, MAINTENANCE MANUAL
'f . CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (cont.)
Trouble Cause Remedy
FLAP CONTROLS (cont.)
Flap moverrient is'"jerky" - Flap track hardvyare im- Install hardware correctly.-
properly installed.
Damaged-track and/or flap. Check and repair/replace as

required.
Restriction in hydraulic Check, clean, and repair as

system. required.
Flap position indicator. • Transmitter out of adjust- Adjust transmitter. . . .

not in agreement witti ment.
actual flap-position.
Faulty transmitter. Replace transmitter.
Faulty indicator. Replace indicator.

tt
i
Faulty electricar circuit Repair circuit.
27-01-00
Page 27-07

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
STANDARD PRACTICES.
—NOTE—
Prior to performing maintenance on fligfit control systems familiarization
witfi all standard procedures is recommended.
1. The removal and installation steps, for control system components, require careful note of loca-
tion, access, position, hardware stacl<-up, pushrod nominal lengths, and the adjustment/opera-
tional effect on other (downstream) related components. . •
2. All, or only a part of the access, removal, installation, or i-igging steps given may be required to
accomplish repairs, adjustments, or rigging the control systems.
3. To adjust the length of an installed pushrod, the rod-end must be disconnected due to right hand
threads on all rod-ends. >
4. The rod-end shank must be threaded past its relative witness and with maximum thread
exposure from outboard locknut Gam-nut) not to exceed .380 inch.
5. Thread exposure on shank of rod-end fittings can be controlled by one jamnut, double jam
nut, or one spacer (P/N 600063-1) with one jam-nut. -
6. The ailerons, elevators, mdder, and flaps are rigged using a special tooling template. A propeller
protractor is used in conjunction with template when rigging flaps.
7. Minor rigging adjustments, for installed pushrods, should be made at the locations recommended
in the rigging procedures.
8. The bottom skin between fuselage station 204.00 and fuselage station 224.00 must be opened,
to remove the long pushrods from under cabin floor.
9. Short pushrods, bellcranks, and idler arms under cabin floor can be removed by removing related
floor panels/access covers as applicable.
10. The long pushrods in aft fuselage are removed through the frame opening, fuselage station
378.50.
11. For bellcrank and/or idler arm installation, use thick and thin washers, as required, to shim for '
axial play (end play) on mounting bolt.
CONTROL COLUMN ASSEMBLY.
REMOVAL OF CONTROL COLUMN ASSEMBLY. (Refer to Figure 27-1.)
—CAUTION—
When left control column is removed/installed the airplane should be
placed on jacks as precaution against accidental main landing gear retraction.
1. Remove snap-on trim cover from control wheel and remove wheel retaining nuts. Note neutral
position on the control column.
•2. Disconnect control wheel electrical wires, as required, from instmment panel, and remove wheel.
27-03-01
Page 27-08
Issued: June 1,1995 3F12
'AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
V 3. Disconnect spring (12) and pushrod (7) from control column sleeve assembly (9).>
—NOTE—
Spring (12) is not used on pilot's side of 700P
4. Disconnect and remove support assembly (31) from behind instrument panel. Remove
V - rivets/machine screws as applicable. .,
5. Note and mark position of each control chain assembly on affected sprockets, disconnect lower
turnbuckles to remove chain assemblies
• : , 6. . Remove mounting bolts from column base support assembly (Detail B).
7. Disconnect cable linkage from main landing gear control lever/flap control lever behind instru-
ment panel. • :
8. Remove mounting screws from the affected lower instrument panel.
9. : Remove 'Ty-raps;', as required, from behind instrument panel, and pull panel back as far as the
slack in the electrical hamess provides. , • ' . .
-.10.. Collapse control column tube assembly far enough to push through the instrument panel.
11. Replace base support assembly on control column if bearing has loose fit in support plate or
roughness in bearing when rotated.
12. Check chain assembly for general condition and cracked links. Clean chain and lubricate per
Chapter 12. , •
INSTALLATION O F CONTROL COLUMN ASSEMBLY. (Refer to Figure 27-1.)
1. Refer to "CAUTION" information under Control Column Removal.

2. Install control column base support assembly (Detail B) on column tube.
3. . Collapse control column tube assembly (6), and place in position behind instrument panel to
insert tube back through column guide in instrument panel.
. 4. Install instrument panel mounting screws.
5. Connect base support assembly by bolting to mount bracket (30) aft side of bulkhead fuselage
station 54.25.
6 Connect cable linkage to control lever for main landing gear, or flaps, as applicable.
7. Install chain assemblies on affected sprockets from control column to bellcrank assembly (23) in
same position as previously noted. If not noted, install chain, per "Rigging Control Column
Assembly."
8. Adjust turnbuckles to obtain 1/4 inch +1/4 inch -0 inch chain deflection midway between sprock-
ets. Tumbuckles must not contact sprockets when controls are operated through full range of
travel.
9. Install instrument panel support assembly (31) with guide on sleeve assembly (9) engaged in slot
on support assembly.,
10. Secure electrical leads behind instrument panel.
11. Connect elevator control pushrod (7) and spring (12) to sleeve assembly, per illustration (Detail C).
—NOTE—
Spring (12) is not used on pilot's side of 700P.
12. Install control wheel and snapron trim cover.

13. Connect electrical leads from control wheel to instrument panel.
14. Perform control column operational check for freedom of travel, synchronization between
columns, and center position when control surfaces are neutralized.
15. Perform landing gear/flaps operational check.
16. Down jack airplane per Chapter 7.
17. Perform aileron control rigging check.
27-03-02
Page 27-09
3F13
l!3sued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2914
NOTE
THERE SHOULD B ENO MORE THAN

.010 IN CLEARANCE (TOTAL) B E -
TWEEN THECONTROL COLUMN AND.
T H E T E F L O N B U S H I N G . IF R E Q U I R E D ,
SHIM T H E I.D. O F T H E C O N T R O L
C O L U M N H O L E IN T H E C O N S O L E W I T H
# 4 2 5 A L U M I N U M F O I L T A P E (3 M CO.)
TRIM T H E EXCESS TAPE FROM THE
AFT SURFACE OF THE PANEL TO
MATCH T H E O.D. O F THE T E F L O N
BUSHING. ;
.010 MAX'
CLEARANCE
(TOTAL)
SEE
NOTE
Figure 27-1. Control Column Assembly
27-03-02
Page 27-10
Issued: June 1,1995
3F14
• AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE^MANUAL
1. C O V E R . 16. BOLT
2. CLIP 17. W A S H E R
3. C O N T R O L W H E E L A S S E M B L Y 18. NUT
4. NUT 19. W A S H E R
5. W A S H E R 20. W A S H E R
6. C O N T R O L C O L U M N A S S E M B L Y 21. BOLT
7. ELEVATOR P U S H R O D 22. S P R O C K E T C O N T R O L C O L U M N
8. BUSHING S P A C E R S 23. B E L L C R A N K S P R O C K E T A S S E M B L Y
'9. S L E E V E A S S E M B L Y 24. CHAIN S E C T I O N
10. S P A C E R 25, CHAIN LINK
11. W A S H E R 26. T U R N B U C K L E
12. S P R I N G (Not used on pilot's side of 700P) 27. CHAIN S E C T I O N
13. S P A C E R 28. CHAIN S E C T i O N
14. BOLT 29. CHAIN S E C T I O N
15. S U P P O R T PLATE A S S E M B L Y 30. M O U N T B R A C K E T
31. PANEL SUPfÔRT A S S E M B L Y
Figure 27-1. Control Column Assembly (cont.)
27-03-02
Page 27-11
3F15 Issued: June 1,199£)

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
; . , MAINTENANCE MANUAL
RIGGING CONTROL COLUMN ASSEMBLY. (Refer to Figure 27-1 ) ' i
1. . Position and secure bellcrank assembly (23) witti arm at 3 o'clock positibn,:as viewed from
pilot's seat.
V .V —NOTE—
Both control chain assemblies consist of two chain sections. Left assembly
sections have 26 and 42 links each. Right assembly sections have 34 and
46 links each. Chain assemblies must be installed with short chain section
around the control column sprocket
2. Connect chain sections together at one tumbuckle. and place chain assembly over top of related f
sprockets per illustration. Chain must be placed on sprockets with control column wheel in hori-
zontal position, and with chain turnbuckles in vertical alignment when bottom tumbuckle is con- •.:
nected. '
3. Adjust turnbuckies, as required, to obtain 1/4 inch H-1/4 inch - 0 inch chain deflection midway
between sprockets. Check tumbuckle witness holes for thread engagement. Tumbuckles must
not contact sprockets at limits of control surface travel.
4. Unlock controls and perform control system operational check, for freedom of travel, synchro-
nization between columns, and center wheel position when control surfaces are neutralized.
—NOTE—
Control wheel position can be adjusted by equally loosening and tightening
affected turnbuckles.
AILERON.
Rigging adjustments on the control linkage system can be accomplished by removing affected access
covers, and/or panels.
Removal and installation, of pushrods and related bellcranks/idler arms under cabin floor, center fuse-
lage section, and in the wing, requires additional prior access be performed as called out in their removal proce-
dures.
REMOVAL/INSTALLATION OF AILERONS.
1. Remove and install ailerons per Chapter 57.
27-11-00
Page 27-12
Issued: June 1,1995
3F16
• i'
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
A
MAINTENANCE MANUAL
1 AILERON CONTROLS.
REMOVAL OF AILERON CONTROL LINKAGE. (Refer to Figure 27-2.)
—NOTE—
Additional requirements for Model 601P, 602P and 700P are indicated by an
asterisk (*).
. 1. Pushrods (3) and (5) removal.

A. Remove first and second seats from left row.
*B. Remove third seat from left row.
C. Remove trim panel(s) from console structure.,
V D. ' Remove center aisle carpet.
: E. Remove second access cover, aft of console, from center aisle floor panel.
*F. Remove third access cover, aft of console, from center aisle floor panel.
I G. Defuel airplane (all tanks) per Chapter 12 and jack airplane per Chapter 7.
H. Open main landing gear wheel-well doors per Chapter 32.
\, I. Remove "kidney" panel from aft bulkhead in left wheel-well, and disconnect fuel sump
^ ' drain and vent lines from inside of bottom skin panel between fuselage station 204.80
and fuselage station 224.00.
J. Remove rivets from left and right bottom skin panels between fuselage station 204.00
and fuselage station 224.00. Rivets should be removed from bottom centerline outward
• to half-way around skin's bottom radius attachment.
K. Remove access cover from inboard panel in right wheel-well.
*L. Remove access cover from bottom skin aft of fuselage station 176.88.
'• *M. Disconnect both outboard forward pushrods from outboard idler arms at fuselage station 202.90.
f^; • N. Disconnect pushrods (5) and (7) from bellcrank (6). Disconnect auto-pilot pushrod (20)
from bellcrank," if installed. Bellcrank can now be rotated for pushrod (5) removal.
*0. Remove clamp from front of boot (17) and loosen boot from duct flange.
*P. Disconnect arm (19) from pushrod (5).
Q. Disconnect pushrod (5) from idler arm (4) and remove pushrod rearward through bottom
skin opening.
R. Disconnect pushrod (3) from idler arm (4) and bellcrank (2) and remove rearward
through bottom skin opening.
/ 2. Pushrod (7) removal.
A. Remove access cover from hat-shelf.
B. Jack airplane per Chapter 7.
C. Open right main landing gear wheel-well door per Chapter 32.
D. Remove access cover from inner panel inside right v/l-,eel well,
f E. Disconnect pushrod (7) from bellcrank (6).
F. Disconnect pushrods (9) and (10) from bellcrank (8) and remove mounting bolt from bell-
crank.
27-12-01
Page 27-13
2ip-|y Issued: June 1,1995
w AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
LEFT WING
W.S. 153.00 .
F.S. 176.8S
1. PUSHROD 8. BELLCIUNK 1 5 . CLE\aS

(NOM. LEMGTH 21.40"3 9. PUSHROD 16. BOOT
2. BELLCRAiS'K (NQM. LENGfH,:156.6S") 17. PRESSURE BOOT *
5. PUSHROD 10. PUSHROD 18. SPRING
(NONL LENGTH 82.00") (NOM. LENGTH 156.00") 19. ARM LI.NK
4. IDLER ARM 1 1 . BELLCRANK 20. PUSHROD - '
5 . PUSHROD 12. PUSHROD AUTOPILOT INST.
(NO^L LENGTH 56.12") (NCM. LFJNGTH 4.43") 21. BELLCRANK
6. BELLCRANK 13. CLEVIS SPROCKET ASSY.
7. PUSHROD 14. C L E V I S .v>-MODEL 601P, 602P
(NQM. LENGTH 14.82") AND 700?
Figure 27-2. Aileron Control Linkage Schematic
27-12-01
Page 27-14
Issued: June 1,1995
3F18
/ AEROStAR AIRCRAFT
, 600/601/601P/602P/700P
MAINTENANCE MANUAL
-< -^:] ' [

29192
AILERON TRAVI^L QiV.CX
if^- UP FROM NEUTFiU DROOJ'
-2" + Nemi^L DROOP
15° - 1° DOIVN FROM NH^TÂ1- DlÔOP
NOTE
REFER TO CHAPTER 91 FOR FABRI-
CATION OF TOOL.
Figure 27-2. Aileron Control Linitage Sciiematic (cont.)
27-12-01
Page 27-15
3F19 issued: June 1,1995

AEROSTAR'AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
G. Remove clamp from boot (16). Support boot to prevent tearing, and remove bellcrank (8)
witti pustirod (7) attactied up ttirougti hat-stielf access. ' - '
—NOTE—
I.,Airplanes having plenum assembly mounted above hat-shelf require Steps H
' through K be performed to remove bellcranl< and pushrod.
H. Raise bellcrank higfi enough to disconnect upper clevis (15).

Support pushrod (7), and remove upper and lower clevises from pushrod (7).
J. Disconnect strobe-light power supply, if installed, and remove "kidney" panel from aft
bulkhead.
K. " Support boot (16% and slide pushrod (7) down and out, as required, through bottom
frame opening and "kidney" panel access hole.
3. , Pushrods (9) or (10) removal.
A. Drain fuel from applicable wing tarik per Chapter 12, and purge fuel tank in accordance
with AC 43.13-1 A.
B. Remove access cover from hat-shelf.
C. Counting from inboard, remove second, fifth, sixth, and seventh access covers from wing
trailing edge.
J D. Remove wing tip per Chapter 57.
E. Remove pressure relief valve and mounting flange assembly from aft outboard side of
wing rib wing station 195.00 per Chapter 28.
F. Remove fuel tank access cover from aft inboard side on wing rib wing station 156.00
(inside wing bellcrank compartment).
G. Remove bellcrank (11) from wing.
H. Disconnect pushrod (9 or 10) from bellcrank (8).
I. Guide pushrod (9 or 10) outboard through the rib holes provided, and pull pushrod from
wing.
4. Pushrod (12) removal.
A. Remove access cover from bottom of wing below bellcrank (11) wing station 153.00.
B. Disconnect pushrod (12) from bellcrank and aileron bracket and remove.
5. Idler arm (4) removal.
A. . Perform Steps A, D, and E, under Paragraph 1 for pushrods (3) and (5) removal.
B. Disconnect pushrods and spring (18) from idler arm.
C. Remove mounting bolt and hardware from idler arm, noting hardware locations.
6. Bellcranks (2),(6),(8) and (11) removal.
A. For bellcrank (2), remove trim panel(s) from console, disconnect bellcrank from
pushrods, remove mounting bolt hardware, and remove bellcrank.
B. For bellcrank (6), gain access to bellcrank through right wheel-well per Steps G. H, and
K under Paragraph 1, Pushrods (3) and (5) removal. Disconnect bellcrank from
pushrods, remove mounting bolt hardware to remove bellcrank. Note hardware locations
for adjacent idler arm installations.
C. For bellcrank (8); refer to Paragraph 2, pushrod (7) removal, and perform Steps A,
through F, and as applicable, G and H to remove bellcrank.
D. For bellcrank (11), remove access cover from bottom of wing below bellcrank wing sta-
tion 153.00 Disconnect bellcrank from pushrods, and remove mounting bolt hardware,
noting hardware locations. •
27-12-01
Page 27-16
Issued: June 1,1995
3F20
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF AILERON CONTROL LINKAGES. (Refer to Figure 27-2.)
—NOTE—
Familiarization with standard procedures is recommended prior to linkage
installation. Additional requirements for Model 601P, 602Pand 700P are
indicated by asterisk(*).
Pusfirods (3) and (5) installation.

A. Secure bellcrank sprocket assembly (21) with arm at 3 o'clock as viewed looking for-
ward.
B. . Ensure control wheels are centered per Rigging Control Column Assembly.
C. Connect/adjust pushrod (1) to set bellcrank (2) arms at 6 o'clock and 9 o'clock as viewed
from left side.
D. Insert pushrod (3) into bottom skin opening, between fuselage station 204.00 and fuse-
lage station 224.00, and slide fonward to connect with bellcrank (2).
E. Connect/adjust pushrod (3) to set idler ami (4) at 12 o'clock vertical position.
F. . Install/connect spring (18) to idler arm (4) and rudder interconnect pushrod. Spring
should be in vertical position.
G. Insert pushrod (5) through bottom skin opening, between fuselage station 204.00 and
fuselage station 224.00, and slide fonward to connect with idler ami (4) and arm link (19).
*H. Insert boot (17) over aft end of pushrod (5) and slide fonward on pushrod to mate with
bulkhead fuselage station 176.88. Secure boot to bulkhead mating duct with 1.50 inch
overlap on duct. With controls in neutral, position aft end of boot on pushrod six inches
from bulkhead, and secure with clamp.
I. Connect/adjust pushrod (5) to set bellcrank (6) arms at 3 o'clock and 6 o'clock positions
as viewed from right side.
Pushrod (7) installation.
A. On work bench, connect pushrod (7) to bellcrank (8). Insert pushrod with bellcrank down
through access in hat-shelf. Support boot (16) from below, and guide pushrod through
boot.
—NOTE—
Airplanes having plenum assembly mounted above h^t shelf require
Steps B through F to install pushrod and bellcrank.
B. Remove both clevises from pushrod (7).

C. Insert pushrod (7) through bottom skin opening, if existing, or through the "kidney" panel
access inrightwheel-well, and then forward through pushrod carry-through opening,
fuselage station 204.00.
D. Guide aft end of pushrod up through boot (16) high enough to install upper clevis (15),
then lower the pushrod to install bottom clevis (14), but do not connect with bellcrank.
E. Connect pushrod (7) to bellcrank (8) by supporting the components high enough in hat
shelf access to make the connection, and slide pushrod (7) down through the boot in
order to connect lower clevis with bellcrank (6).
F. Center boot (16) on pushrod, with controls in neutral and secure with clamp.
G. Install mounting bolt in bellcrank (8). Check/adjust.pushrod (7) to set bellcrank (8) at
12 o'clock vertical position.
27-12-02
Page 27-17
Issued:June 1,1995
3F21
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B448
*NOTE: AN 960-416/416L AS REQUIRED TO ELIMINATE IDLER

ARM END-PLAY AND TO CENTER ARMS FOR STOP-BOLT CONTACT.
Figure 27-3. Aiieron idler Arm F.S, 146.80
27-12-02
Page 27-18
Issued: June 1,1995
3F22
i AEROSTAR AIRCRAFT
600/601/601P/602P/700P
. MAINTENANCE MANUAL
Figure 27-4. Aiieron BelicranIt F.S. 64.78
27-12-02
Page 27-19

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
b450
7
*NCfrE-. AN 960-416/416L AS REQUIRED TO
ELIMINATE BELLCRANK END-PLAY.
Figure 27-5. Aiieron Lower Bellcranit F.S. 202.90
27-12-02
Page 27-20
Issued: June 1,1995
3F24
. AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B451
1. BELLCRANK
2. BOLT
Q (TTP 3 PLCS) 3. VVASi-iER
4. NUTPLATE
5. BOLT
6. BUSHINGS-SPACER
7. VV/^HER
8. NUT
9 . PUSHROD
10. C L W
11. BOOT
Figure 27-6. Aileron Upper Bellcrank F.S. 202.90
27-12-02
Page 27-21
3G1 issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
~v£^ *NOTE: AN 960-416/416L AS REQUIRED <^

TO ELIMINATE BELLCRANK AND ROD END W^^^5
BEARING END-PLAY.
Figure 27-7. Aileron Bellcrank W.S. 153.00
27-12-02
Page 27-22
Issued: June 1,1995
3G2
AEROSTAR AIRCRAFT
600/601/601 P/602P/7bOP
MAINTEiNIANCE MANUAL
3. Pushrods (9) or (10) installation. . .
—NOTE—
Neutral position for bellcrank (11) is determined only by the lengths of
pushrods (9) or (10) which are not the same.
A. Insert pushrod in outboard wing rib access hole and carefully guide pushrod through the
wing to connect with bellcrank (8).
—NOTE— -
Steps B through D involve sealing access covers on wing ribs and the
bottom skin in the fuel tank structure area. Refer to Sealant Procedures,
per Chapter 20.
B. Install access cover on aft inboard side of wing rib wing station.156.00 (inside bellcrank
connpartment).
C. Install pressure relief valve and mounting flange assembly on aft outboard side of wing
rib wing station 195.00.
D. Install fuel tank access covers on bottom of wing per Chapter 28. Cfieck for fuel leaks
after servicing tank.
E. Install wing tip per Chapter 57.
F. Install bellcrank (11) per paragraph 6.
4. Pushrod (12) installation.
A. Install pushrod with clevis end to bellcrank (11) and rod-end bearing to aileron bracket.
5. Idler arm (4), fuselage station 146.80 installation.
A. Install idler arm per Figure 27-3. Shim as required to center both idler arms with their
stop bolts and to reduce end play on mounting bolt.
6. Bellcranks(2). (6), (8) and (11) installation.
A. Install bellcrank (2), with short arm down, per Figure 27-4. Shim as required to reduce
end-play on its mounting bolt.
B. Install bellcrank (6), with long arm down, per Figure 27-5. Shim as required to reduce
-, end-play on its mounting bolt.
C. Install bellcrank (8) per Figure 27-6 and per aileron pushrod (7) installation.
D. Install bellcrank (11) per Figure 27-7. Refer to "NOTE" under paragraph 3, Pushrods (?)
or (10) installation.
27-12-02
Page 27-23
Issued: June 1,1995
AEROSTARÂIRCRAFT
600/601/601R/602P/700P -V
, . MAINTENANCE MANUAL
RIGGING AND ADJUSTMENT OF AILERON CONTROLS. (Refer to Figure 27-2.) . .v j
Thte ailerons' neutral position and ttieir up and down travel limits are ctiecked witti a rigging template. See
Chapter 91 for rigging tool fabrication. Both aileron control surfaces are designed to droop down when the con-
trols are in neutral position. When control-system linkage has been installed in accordance with installation proce-
dures, both ailerons can be rigged by adjusting the pushrods connected to the control surfaces, and adjusting the
travel stops under cabin floor, fuselage station 146.80. Correct aileron droop position must be established prior to
checking/rigging control surfaces travel limits.
- 1. ' Checking/adjusting aileron neutral (droop) position.
A. Secure control wheels in center (neutral) position.
B. Place rigging template on top of left wing, wing station 156.00, over rivet row from wing
' . leading edge to aileron center hinge poinL
C. • Note and record droop angle degrees on template opposite aileron trailing edge. For rig-
ging purposes, aileron droop angle is -2° ± 1° down from 0°. Adjust pushrod (12) as
required.
D. Repeat Step C for right aileron.
2. Checking/adjusting aileron travel limits.
A. Accomplish steps under paragraph 1 above. - . . . v ..
B. Release control wheels and roll left aileron full down. For rigging purposes, down travel is
15° ± 1° down from droop setting. Adjust travel stop under cabin floor on aft side of idler
arm, fuselage station 146.80.
C. Roll right aileron full down. For rigging purposes, down travel is 15° ± 1 ° from droop set-
ting. Adjust travel stop under cabin floor on front side of idler arm fuselage station
146.80.
D: Check each control surface for freedom of movement as follows. Roll control surface full
down with control wheels. Apply upward hand force on aileron trailing edge and push
aileron to neutral position. Controls should move smoothly without binding or roughness.
E. Aileron up travel is controlled by the geometry of linkage bellcranks, provided their neu-
tral clocked positions are in accordance with installation procedures. For rigging check
purposes, aileron up travel is 25° ± 1 ° up from neutral droop position.
—NOTE—
If aileron up travel is not within limits, all system bellcranks must be
checked for their neutral (clocked) positions per tiellcrank installation.
3. Checking/adjusting aileron trim tab.

A. Rigging adjustments are made on right aileron "fixed position" trim tab by bending tab.
Tab adjustment will provide minor changes to control surface neutral position in flight.
—NOTE—
Control wheels may have to tie re-rigged, for inflight center position, after
adjusting aileron trim tab.
27-12-03
Page 27-24
Issued: J u n e l , 1995
3G4
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
RUDDER AND TAB. '
RUDDER PEDAL ASSEMBLY. *
REMOVAL OF RUDDER PEDAL ASSEMBLY. (Refer to Figure 27-8.) .
1. Remove pilot and copilot seats as required. ' .

2. Remove scuff-plates and carpet from floor panel. -
3. Disconnect rudder pedal (2) from arm (8), note different hardware stack-up for pilot and copilot "
locations.
4. Rotate pedal upward and disconnect pedal from brake cylinder.
5. Remove extended seat tracks, if installed, from affected floor panel, noting hardware stack-up.
6. Remove floor attach screws from arm assembly brackets (1). Note hardware stack-up.
7. Remove floor panel.
8. Disconnect arm (8) from pushrod, and remove arm and bracket assembly from floor
9. Disconnect arm from brackets.
INSTALLATION OF RUDDER PEDAL ASSEMBLY. (Refer to Figure 27-8.)
1 On work bench, connect arm (8) to brackets (1).

2. Place arm and bracket assembly in its respective floor location and connect pushrod to arm.
3. Slide floor panel under arm mounting brackets (1) and install panel with brackets as applicable.
Ensure floor hardware does not interfere with objects under floor.
4. Connect pedal (2) to brake cylinder.
5. Install pedal on arm (8). Pilot pedals utilize longer mounting bolts with spacer under bolt head.
6. Perform pedal assembly operational check. Ensure rudder controls can be fully deflected when
toe braking is fully applied.
""T. Install seat tracks as applicable, ensuring attach screws do not interfere with objects under floor
8. Install carpet and scuff-plates.
9. Check pedal rigging per "Rigging and Adjustment of Rudder Controls".
27-21-02
Page 27-25
3G5 Issued: June 1,1995

AEROSTAR AIRCRAFT
.600/601/601P/602P/700P
MAINTENANCE MANUAL
B453
1. MOUNT BRACKET
2. PEDAL
3. WASHER
4. NUT '
*5. SPACER (PILOT PEDALS.ONLY)
*6. BOLT (PILOT PEDALS ONLY)
7. BOLT (COPILOT PEDALS ONLY)
8. ARM • . .
• 9. WASHER '
10. NUT '• "
11. BOLT
12. BOLT
13. BUSHING -SPACER.
14. WASHER
15. NUT , : ,;,
*NOTE:
REQUIRED FOR CONTROL-LOCK INSTALLATION.
Figure 27-8. Rudder Pedal Assembly
27-21-02
Page 27-26
Issued: June 1,1995
3G5
A E R O S T A R AIRCRAFT
600/601/601P/602P/700P
; . MAINTENANCE M A N U A L
RUDDER CONTROLS. , , , . , ,.
REMOVAL OF RUDDER CONTROL LINKAGE, (Refer to Figure 27-9.)
—NOTE-^ \
Additional requirements for model 601P, 602P and 700P are indicted by
an asterisk (*).
1. Pushrod (4) and/or (7) removal.

A; . Remove first four seats per Chapter 25.
B. Remove scuff-plates and floor carpet .
C. Remove first four sections of aft tracks, noting hardware positions.
D. Remove floor panel from pilot's location and^ remove first floor panel aft of console. Note
hardware positions.
E. Disconnect pushrod(s) and remove clevises, if required, to remove pushrod(s) from floor
structure. Note clevis position and thread exposure to jam-nut.
2 Pushrod (13) removal :
A. Remove pilot's seat.
B. Remove center aisle carpet from over first access cover aft of console and remove
cover.
C. Disconnect pushrod (13) from bellcrank (9).
D. Remove rivets from right bottom skin panel between fu.selage station 204.00 and fuse-
lage station 224.00. Rivets should be removed from b o l t o r n center line outward to half-
way around the panel's bottom radius attachment.
E. Disconnect pushrod (13) from idler arm (14).
F. Remove all seats, floor carpets, and "Royalite" trim panel on front of bulkhead fuselage
station 176.88.
*G. Remove all seat tracks and aft floor panel.
*H. Remove fonward clamp fro.m boot (19). Support boot by hand to slide pushrod through
boot.
I. Slide pushrod (13) aft and out through bottom skin opening between fuselage station 204.00
*J. Remove boot (19) from bulkhead fuselage station 176.88.
A. Install airplane tail stand per Chapter 7
B. Remove tailcone from fuselage per Chapter 53.
. C. Remove batteries per Chapter 24.
D. Remove fonward "Royalite" barrier panel from battery compartment.
E. Remove screws from relay assembly mounting plate on aft side of frame fuselage station 378.50,
and remove screws from "Royalite" barrier panel.
F. Disconnect electrical leads between relay and A.P.U. (Auxiliary Power Unit) receptacle,
as required, to move aside the relay and barrier to provide opening for pushrod (13)
removal.
G. Remove aft curtain panel cover from baggage compartment.
H. Jack airplane per Chapter 7. Open right wheel well door per Chapter 32, and remove
access cover from inner pane! in wheel well.
i. Disconnect pushrod (15) from idler arms (14) and (16). Slide pushrod aft and out through
frame opening, fuselage station 378.50.
27-22-01
Page 27-27
3Q7
' Issued: June 1,1995
A E R O S T A R AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2916
F.S.61.0
1. PEDAL
^ 2. ARM ASSBO^LY
5: BRACKI:T
4. PUS}[ROD mi. LENGTH 16.61"
5. CLFv'IS
6. BELLCRANK
7. PUSHROD NOM. LFi^GTH 19.44" 350.9 349.6
8. cmas
9. BELLCimK
10. CLEVIS
11. INTERCONNECr PUSHROD
12. SPRING/ CLEVIS BOLT
13. PUSI-IROD NCM. LENGTH 106.40"
14. IDLER ARM
15. PUSHROD NOM, LENGTH 131.15"
16. IDI^R ARM
17. PUSHROD NOM. LENGTH 19.00"
18. TORQUE TUBE
*19. BOOT (MODEL 6 0 1 P , 6 0 2 P MD 700P)
20. STOPS, CONTROL TRAVEL
21. RUDDER
Figure 27-9. Rudder Control Linkage Schematic
27-22-01
Page 27-28
issued: June 1,1995
3G8
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2916
16.7" ± 0.5" FROM BOTTQM RUDDER HINGE
R E F E R T O C H A P T E R 91 F O R
TOOL FABRICATION DATA.
Figure 27-9. Rudder Control Linkage Schematic (cont)
27-22-01
Page 27-29
3G9
issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
.4. - Pushrod (17) removal.
A. Install airplane tail stand per Chapter 7. , * :
B. Remove aft trim panel cover from baggage compartment. ' ;
C. Disconnect pushrod (17) from idler arm, fuselage station 330.90, and from mdder torque
tube (18). Remove pushrod out through baggage compartment.
5. Rudder torque tube (18) removal ;
A. Install airplane tail stand per Chapter 7.
B. Remove aft curtain from baggage compartment.
C. Disconnect pushrod (9) from torque tube (1) per Figure 27-10.
D. Disconnect rudder trim tab actuator leads from terminal strip fuselage station 332.50.
Remove 'Ty-raps" securing leads to torque tube. ^
E. Remove rudder per Chapter 55 .r^ •
F. Remove adapter plate (2) from torque tube by drilling out rivets. - ' ;
G. Remove lock bolts from base support assembly (5) and pillow block (4). Remove torque
tube out through baggage compartment. •>
6. Bellcranks (6) and (9) removal.
A. For bellcrank (6), remove fonward seats, two seat track sections, scuff-plates, carpet, and
floor panel from above left or right bellcrank (6). Disconnect bellcrank from pushrods (4)
and (7) and remove mounting bolt hardware from bellcrank. Note hardware locations.
B. For bellcrank (9), remove first .four seats, fonward four seat track sections, carpet, and
first floor panel aft of console. Disconnect pushrods (7), (13) and (11), and remove
mounting bolt hardware from bellcrank noting hardware locations.
7. Idler arms (14) and (16) removal.
.. A. For idler arm (14), jack airplane per Chapter 7; open right main landing gear-wheel well
door per Chapter 32; remove access cover from inner panel in wheel well; disconnect
. pushrod from idler arm (14), and remove mounting bolt hardware from idler arm. Note
hardware locations.
B. For idler arm (16), install airplane tail stand per Chapter 7; remove aft curtain from bag-
gage compartment; disconnect pushrods (15) and (17), and remove mounting bolt hard-
ware from idler arm. Note hardware locations
INSTALLATION OF RUDDER CONTROL LINKAGE. (Refer to Figure 27-9.) .
—NOTE—
Additional requirements for Model 601P, 602P and 700P are indicated by
an asterisk (*). Familiarization with standard procedures is recommended prior
to linkage installation.
1. Pushrod (4) and (7) installation.
—NOTE—
If clevis(es) must lye removed to insert pushrod In sub-structure of floor,
note position and thread exposure to maintain pushrod nominal length
during re-installation of clevis.
27-22-02
Page 27-30
Issued: June
3G10
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
! MAINTENANCE MANUAL
B454
NOTE: * REPLACE "HIJCKS"; WITH AN173 BOLTS, AN WASHERS,

AND MS NUTS.
NOTE ** FOR REPLACEMFJiT, RIVETS ONE DIAMETER LARGER

ARE APPROVED. SPOri'F.ACE HOLES, AS REQUIRED,
TO SEAT RIVETS.
Figure 27-10. Rudder Torque Tube
27-22-02
Pafie 27-31

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
A. Remove mounting bolts.from all rudder pedals (1). Note hardware locations.
B. Fabricate two six inch pins from 1/4 inch rod stocl<. Insert pins into left and right pedal
arms (2), in order to center (neutralize) rudder arm assemblies to each other.
C. Install pushrod(s) (4), and adjust pushrod(s), as required, to obtain 90° angle between
pushrods (4) and bellcrank (6) at each of four points. Do not shorten pushrods more than
one full turn on clevis from the nominal length called put in Figui-e 27-9
D. Install pushrod(s) (7), and adjust pushrod(s), as required, to obtain 90° angle between
pushrods (7) and bellcrank (9).
2. Pushrod (13) installation. , . * -
*A. Install boot (19) with 1.25 inch-overlap on carry-through duct at bulkhead, fuselage sta-
tion 176.88. Set head of clamp at 9 o'clock. Boot should be supported by hand when
inserting pushrod.
B. Adjust pushrod (13) to nominal length called out in Figure'27-9. Insert pushrod in bottom
skin opening and slide fonward to bellcrank (9) position. Connect pushrod to bellcrank (9)
and idler arm (14).
*C. Wjth control linkage in neutral, secure boot (19) to pUshrod (13) with front edge of boot
six inches fonward of fuselage station '176.88 bulkhead.
D. Close up bottom skin opening. Install floor panels, access covers, seat tracks, cabin fur-
nishings and seats.
3. Pushrod (15) installation. ' .
A. Adjust pushrod (15) to nominal length called out in Figure 27-9. Insert pushrod in frame
opening fuselage station 378.50, and slide forward to idler arm (14). Connect pushrod to
idler arms (14) and (16).
B. Close up frame opening, fuselage station 378.50, and install tailcone. Install fonvard bar-
rier panel in battery compartment and install batteries.
4. Pushrod (17) iristallation.
A. Secure rudder controls in neutral position, as required per Steps A, B, and C under
Paragraph 1, "Pushrod (4) and (7) installation".
B. Secure rudder in neutral (trail) position with vertical stabilizer.
C. Measure distance between idler arm (16) and horn throw on torque tube (18). Adjust
pushrod (17) to required length, and install pushrod.
D. Install aft trim panel in baggage compartment, and remove neutral attachments from con-
trols.
E. Perform "filudder Control Rigging/Adjustmenf check.
5. ~ Torque tube assembly (18) installation.
—NOTE—
For new torque tube installation, the adapter plate must be removed from
tube prior to installing tube.
A. Refer to Figure 27-10, when installing tube assembly.

B. With tail stand installed, place torque tube in position at fuselage station 349.60 with horn
on right side, and temporarily secure pillow block with two No. 6 machine screws at
opposite corners. Also, temporarily secure base support assembly with three No. 6
machine screws at opposite corners.
C. Use a #14 drill, and drill out the free holes in pillow block and base support.
27-22-02
Page.27-32
Issued: June 1,1995 3G12

V
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
....
•B455
o
(TYPICAL 3 PLACES)
1. BELLCRANK
2 . BOLT
3. WASHER
4. NUTPLATE
5. BOLT
6. BUSHINGS-SPACERS-
7. WASHER
8. NUT
9. PUSHROD
10. PUSHROD
Figure 27-11. Rudder Bellcranic F.S. 77.60
27-22-02
Page 27-33

> AEROSTAR AIRCRAFT g
600/601/601P/602P/700P
MAINTENANCE MANUAL
B456
1. BELLCRANK
2. BOLT
o
(TYPICAL 4 PLACES)
3. U'ASHER
4. NUTPLATE
5. BOLT
6. BUSHING-SPACER
7. WASHER
8. NOJT -
9. PUSHROD
10. PUSHROD, INTERCONNECr
11. PUSHROD
12. BOLT, STOP
13. NUT, JAM
14. BRACKET STOP
Figure 27-12. Rudder Bellcrank F.S. 97.00 " *
27-22-02
Page 27-34
Issued: June 1,1995 3G1 4

AEROSTAR AIRCRAFT
600/601/60TP/602P/700P
MAINTENANCE MANUAL
B457
NOTE:
USE AN960-416 / 416L
WASHERS TO SHIM FOR
END PLAY.
(T^TICAL 2 PLACES)
1. IDLER ARM
2. BOLT
s! SHIM VÂSHERS
4. l^HER
5. NUT
6. BOLT
7. BUSHING -SPACER
8. \t^SUER
9. M J T
10. PUSHROD
11. PUSHROD
Figure 27-13. Rudder Idler Arm F.S. 202.80
27T22-02
Page 27-35

AEROSTAR AIRCRAFT
600/601/601 i=»/6p2P/700P
MAINTENANCE MANUAL
B458
i : IDLER ARM
2. BOLT
*3. SHIM WASHERS
4-; WASHER
5. NUT
6. " BOLT
* ^7.'BUSHING-SPACER
8. ; WASHER
'! "HvC --AI \ 9. NUT
10. PUSHROD
11. PUSHROD
*NOTE:,
' USE AN 960-416 / 416L
WASHERS TO SHIM FOR
END PLAY.
O
(TYPICAL' 2 PLACES,) 0^
•
•' 6 •
•
Figure 27-14. Rudder Idler Arm F.S. 330.90
27-22-02
Page 27-36
Issued: June 1,1995
3G16
••.t:-\
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL . ,
. .D. = Ream drilled holes to 3/16 inch (.1875 inch). Install AN 173 (close tolerance) bolts; with
washers under bolt-head and nut, and apply standard torque for MS nuts.
E. Remove No. 6 machine screws from pillow block and base support, and repeat Steps C
and D.
F. Install adapter plate on tube assembly.
—NOTE—
If required, one size larger rivets are approved. Spot face rivet mating
surfaces for larger rivet application. ,
G. Install rudder per Chapter 55.

H. Perform all steps under Paragraph 1
6. Bellcranks (6) and (9) installation
• A. Install bellcrank (6) per Figure 27-11.
'B. Install bellcrank (9) per Figure 27-12.
7. Idler arms (14) and (16) installation.
A. Install idler arm (14) per Figure 27-13. Shim, as required, to reduce idler arms and bell-
crank endplay on mounting bolt.
B. Install idler arm (16) per Figure 27-14. Shim, as required, to reduce idler arm end-play on
mounting bolt.
RIGGING AND ADJUSTMENT OF RUDDER CONTROLS. (Refer to Figure 27-9.)
1. Torque tube (18) free play check.

The rudder is connected to a torque tube assembly, incorporating one universal joint. The free
play across the universal joint should be checked with a dial indicator, prior to rudder
rigging/adjustment.
B. Gain access to torque tube connection with pushrod (17) by removing aft curtain in bag-
gage compartment.
C. Disconnect pushrod (13) from arm on torque tube. Install a "C"-clamp and block fixture
. device on torque tube arm to prevent tube from rotating.
D. Set up a dial indicator measuring arrangement on rudder trailing edge. Applying approxi-
mately five lbs. of force at trailing edge, measure free play indication. If measurement
exceeds 0.050 inch, replace the torque tube, per 'Torque Tube Assembly (18)
Removal/Installation", this Chapter. Refer to Figure 27-15, for free-play check.
E. Remove holding fixture from torque tube, and connect pushrod (17) to torque tube.
2. Rudder travel check/adjustment (Figure 27-9).
The mdder rigging check is made with a rigging template placed on the right hand side of the
vertical stabilizer and extending around rudder trailing edge. The template may be fabricated
from the dimensions given in Chapter 91.
—NOTE—
Adjustment to change the fore and aft static neutral position of the rudder
pedals is not recommended. Pedal alignment, static neutral position, and
freedom of pedal movement is determined by the pushrods nominal lengths
which are set prior to installation.
27-22-03
Page 27-37
2Q-^y Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B459
NOTE
THE STATED TOLERANCE IS FOR UNIVERSAL " " ,
JOINT ONLY. UNDER NO CIRCUMSTANCE IS
THE MEASURED TOLERANCE TO INCLINE " ' ' :
MOVEMENT ACROSS ANY TORQUE TUBE
FASTENER. ^ '
. APPLY 5 LB. FORCE ON HINGE

OPPOSITE SIDE , . . LINE,
,050 INCH
MAXIMUM PLACE DIAL INDICATOR HERE
Figure 27-15. Rudder Torque Tube Free-Play Check
A. Secure rudder pedals in neutral (aligned across) position.

B. Place and hold rigging template bn right hand side of vertical fin, positioning it perpendic-
ular to the rudder hinge line. Refer to Figure 27-9 for location.
C. Measure rudder neutral position on template scale opposite trailing edge. For rigging pur
poses, rudder neutral (flush) position with stabilizer is 0°. Perform Step D, if adjustment
is required.
D. With airplane tail stand in place, remove aft curtain from baggage compartment, and
adjust length of pushrod (17) to set rudder angle 0°.
E. Release rudder controls, and by pushing pedal controls full forward against right and left
stops, measure oidder travel on template scale opposite trailing edge. For rigging purpos-
es, the rudder travel should be 30° ± 1° left and right from 0°, unless the tail modification
kit (Kit No. 764 969v) has been installed. If this kit has heen installed, the rudder travel
should be 30° ± 1 ° left and 35° -^1 °, -0° right.
F. Adjust mdder travel stops (20). Two travel stops are located on fonward side of bellcrank (9),
fuselage station 97.00. Gain access to bellcrank by removing first access cover aft of
console from aisle floor.
—NOTE—
Due to tfie geometry of rudder linkage system, tfie thread exposure on stop
bolts will not be the same when adjusting rudder travel stop limits. See
"Note" in figure 27-12.
27-22-03
Page 27-38
Issued: June 1,1995
3G18
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
R U D D E R TRIM T A B , . J ' * "
R E M O V A L / I N S T A L L A T I O N O F R U D D E R TRIM T A B . ' •
1. , Remove andjnstall trim tab per Chapter 55. . . .
R I G G I N G A N 5 A D J U S T M E N T O F R U D D E R TFflM T A B . (Refer to Figure 27-16.)
1. Disconnect pushrod (3) from trim tab. ,

2. Remove access cover from over tab actuator on right side of rudder, and disconnect actuator
clevis from bellcranl< (4).
3. Operate tab actuator (2), and measure amount of travel on screwjack from full retract to full
extended positions. Travel should be 0.75 inch -f-.05 inch -.00 inch. If not, replace actuator, and
repeat Step No. 3. .
4. Adjust clevis position on actuator screw-jack, per Figure 27-16.
5. Connect actuator clevis to bellcrank (4). Operate trim actuator through full range of travel. Ensure
bellcrank (4) does not bottorn-out (contact) with structure in rudder.
6. . Operate trim actuator to full center position indication (middle of "0" on position indicator).
7. HolcJing trim tab in neutral (flush) position with rudder, adjust length of pushrod (3), as required,
and connect pushrod to trim tab.
8. Operate trim actuator to run tab full right from rudder. Right travel on tab is 24° -i- 2°/-0° for the
700P or 9° + 4°/-1° for all other models. Adjust length of pushrod (3) to obtain this measurement.
9. Operate trim actuator to run tab full left from rudder. Left travel on tab is 20° -f- 2°/-1° for the 700P
or 37° +4%0° for all other models. If left travel is not within limits, repeat Step No. 8, and adjust
pushrod (3) as required within the right travel limits given, to obtain correct tab travel left from
flush positions with rudder.
—NOTE—
For pushrod (7), minimum rod end thread engagement in witness hole is
one half hole.
.10. Operate trim tab through full range of travel, and then position tab flush with rudder. Check nee-
dle position on the trim tab position indicator to be between top edge and bottom edge of the "0"
mark on indicator.
27-23-02
Page27-3S
3Q-j g Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE: M A N U A L
B460
1. TRIM TAB
2. ACTUATOR
3. PUSHROD
4: BELLCRANK
5. JAM NUT
6. CLEVIS
7. SCREW-JACK
8. TORQUE TUBE
9. RUDDER
o
RIGGING DIM. ONLY
— .60"
Figure 27-16. Rudder Trim Controis
27-23-02
Page 27-40
Issued: June 1,1995
3G20
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
— ; i s—: ^
ELEVATORJXND T A B . ^
REMOVAL/INSTALLATION OF ELEVATOR.
1. .For removal/installation of elevator, see Cfiapter 55.
ELEVATOR CONTROLS.
REMOVAL OF ELEVATOR CONTROL LINKAGE. (Refer to Figure 27-17.)
—NOTE—
Additional requirements for Model 601P, 602P and 700P are indicated by
an asterisk (*).
1. ; Pusfirod (3) and down spring (18) removal. "
A. Disconnect pushrod from sleeve assembly (2) and torque tube (4). Note hardware loca-
tions. Remove down spring from bulkhead bracket.
A. Remove trim panel(s) from side of console.
B. Disconnect pushrod from torque tube (4) and bellcrank (6), and remove out through light-
ening hole in console structure.
3. Pushrods (7) and/or (9) removal.
A. Remove trim panel(s) from side of console.
B. • Remove center aisle carpet from over second access cover aft of console and remove
access cover fuselage station 146.00.
* C. Remove four aft seats, four aft sections of seat tracks, "Royalite" trim panel from pres-
sure bulkhead fuselage station 176.88, and aft floor panel. Note hardware locations.
D. Disconnect pushrods (7) and (9) from idler arm (8).
* E. Disconnect arm link from arm bracket (19), and remove rivets attaching bracket to
pushrod (9).
* F. Remove fonvard clamp from pressure boot (15).
G. Defuel airplane (all tanks) per Chapter 12, and jack airplane per Chapter 7.
H. Open left wheel well door per Chapter 32, and remove "kidne/' panel from aft bulkhead
in wheel well.
I. Disconnect fuel sump drain/vent lines from skin panel between fuselage station 204.00
J. Remove rivets from left bottom skin panel between fuselage station 204.00 and fuselage
station 224.00. Rivets should be removed from bottom centeriine outward to halfway
around skin panel's bottom radius attachment.
K. Disconnect pushrod (9) from idler arm (10). Support boot (15), and slide pushrod aft
through the boot and out through bottom skin opening between fuseiage station 204.00
L. Remove boot (15) from bulkhead; note clamp position.
M. , Remove balance boot assembly (20) as required.
N. . Disconnect pushrod (7) fiom bellcrank (6). Slide pushrod aft through bulkhead, fuselage
station 176.88, and out through bottom skin opening between fuselage station 2G4.00
and fuselage station 224.00
27-32-01
Page 27-41

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
1. CQNTROL COLUMN 11. PUSHROD (131.40 INCHES)

2. SLFFVE ASSY. 12. IDLER ARM
3. PUSHROD (FIXED LENGTH) 13. PUSHIiOD (36.95 INCHES)
4. FORWARD TORQUE TUBE ASSY. 14. AFT TORQUE TUBE ASSY.
5. PUSHROD (11.85 INCHES) *15. PRESSURE BOOT '
6. BELLCRANK 16. UP STOP AUTUSTNENT (2)
7. PUSi-IROD (82.40 INCHES) 17. DOIVN STOP ADJUSTMENT (1)
8. IDLER ARM 18. DOWN SPRING
. 9.PUSHROD (56.15 INQffiS) 19. ARM
10. IDLER ARM *20. BALANCE BOOT ASSY.
*MODEL 601P. 602P AND 700P
Figure 27-17. Elevator Control Linkage Schematic
27-32-01
Page 27-42
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
4. r Pushrod (11) removal. .. „ . - .
A. Gain access for pushrod removal per Steps A through H under Paragraph .3, i='ushrod (15)
Removal; in the section titled Removal of Rudder Control Linkage.
B. Disconnect pushrod (11) from idler arms (10) and (12). Slide pushrod aft and out frame
opening fuselage station 378.50.
C. Remove batteries and fonward "Royalite" barrier panel from battery compartment.
D. Disconnect pushrod (13) from elevator torque tube (14) and idler arm (12). Remove
pushrod out through baggage compartment.
6. Fonward torque tube (4) removal.
A. Remove right and left trim panels, from console.
B. Refer to Figure 27-18 for Steps C through E.
C. Disconnect pushrods (2) and (8) from torque tube assembly (1).
D. Remove access cover (7) from console structure.
E. Remove bolts from left and right support plate assemblies (3) and remove torque tube
from console.
7. Bellcrank (6) removal.
A. Remove left and right trim panels from console.
B. Disconnect pushrods (5) and (7) from bellcrank (6).
C. Remove mount bolt from bellcrank noting hardware locations.
A. Remove center aisle carpet from over access cover at fuselage station 146.80 and
remove access cover.
B. Disconnect pushrods (7) and (9) from idler arm (8).
C. Remove mount bolt from idler arm; noting hardware locations.
A. Jack airplane per Chapter 7.
B. Open right main landing gear wheel well door per Chapter 32.
C. Remove access cover from inner panel inside wheel well.
D. Disconnect pushrods (9) and (11) from idler arm (10).
E. Remove mount bolt from idler arm noting hardware locations.
.10. Idler arm (12) removal.
C. Disconnect pushrods (11) and (13) from idler arm (12).
D. Remove mount bolt from idler arm noting hardware locations.
11. Aft torque tube (14) removal.
B. Remove batteries and forward "Royalite" barrier panel from battery compartment.
C. Remove both elevators per Chapter 55.
D. Remove Ty-raps securing electrical leads to aft torque tube.
E. Disconnect pushrod (13) from aft torque tube.
27-32-01
Page 27-43
3 G 2 3 Issued: June 1.1995

mEROSTAR AIRCRAFT
600/601/601 P/602P^00P
MAINTENANCE MANUAL
B462
1. F O R W A R D TORQUE TUBE
2. P U S H R O D ( F I X E D LENGTH)
Figure 27-18. Elevator Forward Torque Tube Assembly
27-32-01
Page 27-44
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B463
1. TORQUE TUBE ASSY.

2. ADAPTER PLATE
3. PILLOW BLOCK
* REPLACE WITH .^\N173 BOLTS, AM 1\ASIIERS, AND MS .N'UTS,
** FOR REPLACEÊNT, RIVETS O.NE DIAMETCR L\RGER M E

AI-'PROVED. SPOITACE HOLES, AS REQUIRED, TO SE-\T RIVTiTS.
Figure 27-19. Eievator Aft Torque Tube
27-32-01
Page 27-45
gj-j-j Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE'MANUAL
F. Refer to figure 27-19 for Steps G through I. . . ;;
G. Remove "blind" rivets securing adapter plate (2) to torque tube. Only one adapter plafe must be
removed from tube assembly in order to remove torque tube out through fillet opening.
H. Remove "Huck" fasteners from both pillow blocks (3).
I. Slide torque tube assembly out through skin fillet opening opposite from the side of removed con-
trol plate fitting.
INSTALLATION OF ELEVATOR CONTROL LINKAGE (Refer to Figure 27-17 and as Referenced.)
—NOTE—
' • ' Additional requirements for Model 601P, 602P and TOOPare indicated t>y an
asterisk (*). All pushrods must tjeset to nominal lengths specified prior to
installation, per Figure 27-17.
1. Pushrod (3) and down spring (18) installation. \ .

A. Connect pushrod (3) to torque tube (4). Connect the pushrod opposite end clevis and
' elevator down spring (18) to control column sleeve assembly per Figure 27-17. Connect
opposite end of down spring to stand-off bracket aft side of bulkhead fuselage station 54.25.
2. Pushrod (5) installation.
A. Insert pushrod through suitable lightening hole in console structure, and connect pushrod
to torque tube (4) and bellcrank (6). . .
B. Afterriggingcheck, install items renioved for access.
3. Pushrods (7) and/or (9) installation. • _ •
A. Insert pushrod (7) through bottom skin opening between fuselage station 204.00 and
fuselage station 224.00, and slide pushrod forward through respective routing to bell-
crank (6).
B. Connect pushrod (7) to bellcrank (6) and idler arm (8).
*C. If removed, install balance boot assembly (20). Boot must overiap bulkhead mating duct
1.50 inches. Clamp forward end of boot on pushrod with edge of boot one inch back from
aft end of clevis. ;
*D. Install pressure boot on bulkhead mating duct with 1.25 inches overiap. The boot must
be supported by hand to prevent tearing when inserting pushrod (9).
E. Insert pushrod (9) through bottom skin opening between fuselage, station 204.00 and
fuselage station 224.00, and slide it forward through respective routiiig. Connect pushrod
to idler arms (8) and (10).
- —NOTE—
Prior to clamping pressure boot (15) to pushrod, elevator controls
must be in rig and control surface in neutral position.
*F. Clamp boot (15) to pushrod (9) with fonward edge of boot six inches from bulkhead fuse-
lage station 176.88.
*G. Ensure that all boot clamps are free from interference with adjacent components.
H. Afterriggingcheck, close up skin opening, and install items removed for access.
27-32-02
Page 27-46
Issued: June 1,1995
3H2
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
..^4. Pushrod (11) installation. . -
* . A?- Insert pushrod (11) through'^frame opening fuselage station 378.50 and slide forward to
' - fuselage station 202.80
B. Connect pushrod to idlerarms (10) and (12).
C. - After rigging check, install items removed for access.
5. Pushrod (13) installation. •
A Install pushrod (13) through baggage compartment. Connect pushrod to idler arm (12).
B. Through-battery compartment,-connect pushrod'to torque tube (14).
C. After rigging check, install items removed for access.
6. Fonward torque tube (4) installation.'
A. Insert torque tube into position in console structure and install mounting bolts in support
plate assemblies (3) per Figure 27-18.
B. Install structural access cover (7).
C. Connect pushrods (2) and (8) to torque tube.
D. After rigging check, install items removed tor-access.
7. Bellcrank (6), fuselage station 64.87,-.installation (Figure 27-20). .
. A . Install bellcrank with long arm down. Use AN 960-416/416L washers as required to shim
for bellcrank end-play on mount bolt.
B. Connect pushrods (10) and (11) to bellcrank. - .
.8. Idler arm (8), fuselage station 146.80, installation.
A. Install idler arm per Figure 27-21.
B. After rigging check, install items removed for access.
9. Idler arm (10) fuselage station 202.80, installation.
10. Idler arm (12), fuselage station 330.90, installation.
"11. • Aft torque tube (14) installation (Replacement Tube).
• ^. —NOTE—
One adapter plate must t>e removed from tube assembly prior to installing.
'•••._^-,>'^k. • Refer to Figure•27-19 to install.

: ; B. With tail stand installed, insert end of tube without adapter plate into fillet opening and
position on aft side of frame, fuselage station 362.90.
C. Temporarily secure each pillow block (3) with two No. 6 machine screws at opposite cor-
• " ners on pillow blocks. -
D. From forward side of stabilizer carry-through, spar, use #14 drill to drill out free holes in
spar and pillow blocks.
27-32-02
Page 27-47
^1^2 Issued: June 1,1995
AEROSTAR ArRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B464
11
* USE AN960-416L WASHERS

AS REQUIRED TO SHIM BELLCRANK
END-PLAY ON MOUNT BOLT.
Figure 27-20. Eievator B^lcranit F.S. 64.87
27-32-02
Page 27-48
issued: June 1,1995 3H4
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B465
1. IDLER ARM
.2. BOLT
.3. SPACER (2)
* 4. SHIM WASHERS (AS REQUIRED)
"5. WASHER
6. NUT
7. BOLT
8. BUSHINGS-SPACER
9. WASHER
10. NUT
11. PUSHROD
* USE AN960-416 / 416L WASHERS TO SHIM

FOR END-PLAY AND TO CENTER ARMS.FOR
STOP-BOLT CONTACT..
Figure 27-21. Elevator Idler Arm F.S. 146.80
27-32-02
Page 27-49
3H5 Issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B466
if
1. IDLER ARM
2. BOLT
* 3. SHIM WASHERS, (AS REQUIRED)
• 4. WASHER
5..NUT
6. BOLT
7. BUSHING-SPACER
8. WASHER (TYPICAL
9. NUT 2 PLACES)
10. PUSHROD
11. PUSHROD
27-32-02
Page 27-50
Issued: June 1,1995
3H6
(TYPICAL 2 PLACES) Q
1. IDLER .MIM
2. BOLT
* 5. SHIM l\7VSPERS, AS REQUIRED
4. WASIER
5. NUT
6. BOLT
7. BUSHING-SPACER
8. WASHER
9. NUT
10. PUSHROD
11. PUSHROD
* USE AN960-416L WASHERS

TO SHIM FOR IDLER ARM
END-PLAY ON MOUNT BOLT.
27-32-02
Page 27-51
3H7 Issued: June 1,'1995

AERDSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE.MANUAL
E. Ream drilled holes 3/16 inch (.1875 inch). Install AN 173 (Close Tolerance) bolts, with
washers under bolt-head and nut, and apply standard torque for MS nuts.
F. Remove No. 6 machine screws from pillow blocks and repeat Steps D and E.
G. Install adapter plate (2) on torque tube.
' —NOTE—
If required, one size larger rivets are approved. Spot face rivet mating
surface for larger rivet application.
H. Install devator assemblies per Chapter 55.
I. After rigging check, install iterris removed for access.
RIGGING AND ADJUSTMENT OF ELEVATOR CONTROLS. (Refer to Figure 27-17.)
1. Torque tube (14) free play check.

The elevators are linked together by a common torque tube assembly, which incorporates two
universal joints. The free-play across each universal joirit should be checked with a dial indicator,
prior to elevator rigging/adjustment.
A. Gain access to torque tube connection with pushrod'(13), by removing batteries and the
fonward "Royalite" barrier panel from battery compartment.
B468 NOTE:
DO NOT HOLD ONE ELhYATOR TO .MEASURE FREE-PL^Y

ON OPl'OSITE ELE\'ATOIL im STATED TOLERAN'CE
IS FOR ONE UNRTERS-U JOI.NT ONLY. UNDER NO
CIRCUMSTANCES IS TIE ME.VSURBENT TO INCLUDE
FREE-PLAY ACROSS ROTH UNRTIRS-U JOINTS. OR
AVi' MOVENE.\T ACROSS TIE TORQUE TIBE FASTENERS.
Figure 27-24. Elevator Torque Tube Free-Play Check
27-32-03
Page 27-52
Issued: June 1,1995
3H8
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
;.B. Disconnect pustirod (13) from tfie arm on torque tube. Install a "C'V.CIamp over torque
tube arm and to the carry-through spar, as required, to prevent torque tube from rotating.
C. ; Set-up a dial indicator measuring arrangement on elevator trailing edge. Applying
approximately five pounds of force at trailing edge, measure free-play indication. Repeat
the measurement check bn opposite elevator. If either measurement exceeds .050 inch,
replace the torque tube, per "Torque Tube Assembly (14) Removal/Installation", this
Chapter. Refer to Figure 27-24 for torque tube free-play check.
b. Remove holding fixture on torque tube and connect pushrod (13) to torque tube.
2. Elevator travel check/adjustment.
The elevator rigging check is made with a rigging template placed on the horizontal stabilizer and
extending around elevator trailing edge. The template may be fabricated from the dimensions
given in Chapter 91.
—NOTE—
Adjustment to change control columns static neutral position is not recom-
mended. Elevator travel limits are set by adjustment of the up and down
stops only, when pushrods nominal lengths are set prior to installation.
A. Place rigging template on top of either horizontal stabilizer, locating it 16.7" ± 0.5" from
the inboard elevator hinge and perpendicular to the elevator hinge line.
B. Pull and hold control columns full aft against the stops, [pleasure elevator up travel on
template scale opposite trailing edge. For rigging purposes, the elevator up travel is 30° ±1°
up from 0° neutral (flush) position with stabilizer (for all models except the 700P)
and 29°-30° up from neutral (for 700P trailing edge on wing reference plane).
C. Adjust up travel limits by two control column stops (16). Up travel stop adjustments are
, located behind instrument panel on left side of left control column, and on right side of
right control column. Adjust left stop first to set elevator travel, and then while holding left
control column firmly against its stop, adjust right stop, as required, to make contact with
sleeve assembly (2) on right control column.
D. Push and hold control columns full forward against stop. l\/1easure elevator down travel
on template scale opposite trailing edge. For rigging purposes, the elevator down travel
is 10° ± 1° down from 0° neutral position (for all models except the 700P) and 11°-12''
down from 0° neutral (for 700P at trailing edge on wing reference plane).
E. Adjust down travel limit by one idler arm stop (17). Down travel stop adjustment is locat-
ed in front of the left idler arm, fuselage station 146.80, under cabin floor. Remove
access cover from aisle floor for entry.
27-32-03
Page 27-53

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
ELEVATOR TRIM TAB
REMOVAL/INSTALLATION OF ELEVATOR TRIM TABS.
1. Remove and install trim tabs per Ctiapter 55.
RIGGING.AND ADJUSTMENT OF ELEVATOR TRIM TABS. (Refer to Figure 27-25.)
1. ^ Disconnect pustirod (3) from both trim tabs.

2. Remove access cover from over tab actuator on top of left elevator, and disconnect actuator cle-
vis from bellcrank (4).
3. Operate tab actuator (2), and measure amount of travel on screwjack from full retract to full
extended positions. Travel should be 0.75 inch ± .03 inch (not including end play): If not, replace
actuator, and repeat Step No. 3.
4. • Adjust clevis position on actuator screwjack per Figure 27-25.
5. Connect actuator clevis to bellcrank (4). Operate trim actuator through full range of travel. Ensure
both bellcranks (4) do not bottom-out (contact) with stmcture in elevators.
6. Operate trim actuator to full center position (middle of "0°" on position indicator).
7. Holding trim tabs in neutral (flush) position with elevators, adjust lengths of pushrods (3), as
required, and connect pushrods to trim tabs.
8. Operate trim actuator to run tabs full up. Up travel on tab is 7° ± 1° up. Forriggingpurposes,
adjust length of pushrods (3) to obtain this measurement.
9. Operate trim actuator to mn tabs full down. Down travel from flush position is 37° +9%1 ° down. If
down travel is not within limits, repeat Step No. 8, and adjust pushrod (3) as required within the
up limits given, to obtain correct tab travel down from flush position with elevator.
—NOTE—
For pushrod (3), minimum rod-end thread engagement in witness hole is
one-half hole.
• T •
. 10 Operate trim tabs through full range of travel, and then, position the tabs flush with elevators.
Check needle position on the trim tab position indicator. Needle should be between top edge and
bottom edge of the "0" mari< on face of indicator
27-33-02
Page 27-54
issued: June 1,1995
3H10
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B469
1. LEFT TRIM T.'\B

2. ACrUATOR
5. PUSI-iROD
4. BELLCRyXNK '. -
5. JAM NUT
6. CLEVTS
•7. SCRBV-JACK - : •
8. CABLE, TAJ3 I.NTrERCONNECT
9 . TORQUI: TUBE - " ..
1 , 0 . . ELEVATOR • •'.
NOTE:
L E F T SIDE SHOWN.
RIGHT SIDE MIRROR IMAGE
MINUS ACTUATOR .
RIGGING DIM. ONLY

.60"
.o
Figure 27-25. Elevator Trim Controls
27-33-02
Page 27-55
3H11 Issued:June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL •
FLAPS;'-'. • •• • .• • .. ••
A flap selector lever on instrument panel is linked by cable to a hydraulic control valve under cabin floor.
Positioning the control lever to extend or retract the flaps, allows main hydraulic system pressure to activate the
flaps' hydraulic system. Flap movement can be stopped at any mid position by placing selector lever in "neutral".
The flaps are operated by separate hydraulic actuating cylinders connected directly to each flap. The flaps' rate
of movement during extension is synchronized by two flow control valves which are installed/as a "matched set".
A matched set consists of two valves having the same rate of flow, within .008 gallons per minute (GPM) of each
other. The flow rate for each flow control valve is noted on the valve's data plate. An additional matched set of
flow control valves provide synchronization of flaps movement during retraction.
R E M O V A L A N D INSTALLATION O F F L A P S .
1. Remove and install flaps per Chapter 57.
FLAP CONTROLVALVE.
REMOVAL O F FLAP CONTROL V A L V E . ^
1. Relieve main hydraulic system pressure by cycling flaps. .

2. Remove seats and floor carpet, as required, from over access cover on right side of cabin floor,
fuselage station 125.00.
3. Disconnect flex cable clevis from control valve noting hardware location.
4. 'Disconnect four hydraulic lines from control valve noting their valve port locations. Cap the lines
to prevent loss of fluid.
5. Remove lever arm from control valve shaft.
6. Remove four mount bolts from control valve and remove valve.
—NOTE—
Control valve leaking internally must be replaced. External leakage may be
repaired, by replacing O-rings.
I N S T A L L A T I O N OF F L A P C O N T R O L V A L V E .
For troubleshooting and installation purposes the control valve ports>are marked \
1. "P" for Pressure intovalve.

2. "R" for Return from valve.
3. "F-1" Connects to flap Down line.
- 4. "F-2" Connects to flap Up line.
The control valve has a neutral detent which blocks all flow of fluid at the^.valve.
A. Place control valve shaft in neutral detent position. Withlever arm removed install control
valve, with four mounting bolt heads inboard.
B. Connect pressure, return, down, and up lines to control valve.
C. Install lever armon shaft with arm in vertical position.
D. Connect flex cable clevis to lever arm.
E. Service main hydraulic system per Chapter 12 and perform flaps operational check.
Cycle flaps through full range of travel, as required, to bleed system.
27-52-02
Page 27-56
Issued: June 1,1995
3H12
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL .
5. The maximum allowable leakage from a vented port is 1.5 cc/min with a system pressure of 1500 psi.
6. The maximum operating torque should not exceed 25 inch pounds with a system pressure of
. 1500 psi.- -
FLAP FLOW CONTROL VALVES.
REMOVAL OF FLAP FLOW CONTROL VALVES.
Two flow control valves are mounted in-line for each flap actuating cylinder. The flow valves are mount-
ed on aft outboard side of left and right wing-root ribs. The valves are mounted one over the other on the wing rib.
In each wing the top mounted flow control valve regulates flap extension movement and the bottom mounted flow
control valve regulates flap retraction movement. All valves must be installed with the arrow on data plate pointing
outboard toward the actuating cylinder.
1. Deplete main hydraulic system pressure per Chapter 29.

2. Remove bottom aft fairing piece from wing-root location, and the bottom aft inboard access cover
from wing.
3. Disconnect hydraulic lines from flow control valve(s). If both valves are to be removed andrein"^
stalled note and mark their locations on rib.
4. Remove jam-nut from flow valve bulkhead fitting and remove valve.
INSTALLATION OF FLAP FLOW CONTROL VALVES.
1. Install flow control valve(s) on outboard side of wing root rib with arrow on data plate pointing
towards its respective cylinder. Original valve(s) must be installed in same location removed _
from.
2. Connect hydraulic lines to flow valve(s), ensuring that lines are not crossed.
3. Service main hydraulic system per Chapter 12.
4. Perform flap operational check. Cycle flaps through full range of travel, as required, to "bleed"
• the system and check for fluid leaks at flow control vaives.
5. Install access cover and wing-root fairing.
FLAP ACTUATING CYLINDER.
REMOVAL OF FLAP ACTUATING CYLINDER.
1. Extend flaps.
2. Deplete main hydraulic system pressure per Chapter 29.
3. Drain fuel from affected wing tank per Chapter 12.
4. Remove long aileron pushrod from wing per Removal of Aileron Control Linkage, this Chapter.
5. Remove access cover from below actuating cylinder.
6. Disconnect cylinder rod-end from flap.
7. Disconnect hydraulic lines from actuating cylinder, and cap lines.
8. . Remove rod-end from cylinder, and compress piston in cylinder.
9. Remove mount bolt from cylinder and remove cylinder through access hole.
27-54-01
Page 27-57
3 J-| "I 3 Issued: June 1, 1995
AEROSTAR AIRCRAFT f
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF FLAP ACTUATING CYLINDER.
1. Remove rod-end from cylinder.

2. Compress piston in .cylinder.
. 3 Insert cylinder into access fiole and position forward end of cylinder to install on mount bracket
.4. Connect fiydraulic lines to cylinder. . .
5. Install rod-end on cylinder witfi six ttireads exposed past jam-nut. Do npt connect to flap yet
6. 'iService main fiydraulic system per Cfiapter 12. .
7. Connect portable fiydraulic pump (fiand pump) to main hydraulic system, and pressurize
hydraulic system. Check flap actuating cylinder for leaks.
8. ' Perform flaps operations/rigging check, per tfiis Chapter, before connecting actuating cylinder to
flap.
9. . Install long aijerOn pushrod in wing, per installation of Aileron Control Linkage this Chapter.
10. Install access cover on wing below actuating cylinder.
FLAP POSITION TRANSMITTER. '
REMOVAL OF FLAP POSITION TRANSMITTER.
1. Extend flaps to full down position.

2. fRehiove access cover from left wing close-out fairing on inboard side of center flap track.
3. Loosen "Allen" set-screws in lever arm on shaft of flap position transmitter mounted on aft end of
• wing rib inboard of center flap track. . ,
4. 'Remove locknut and washers from transmitter mount. , .
5. Note and label electrical leads from transmitter, and disconnect leads.
INSTALLATION AND CALIBRATION OF FLAP POSITION TRANSMITTER. (Refer to Figure 27-26.)
1. Connect electrical leads to flap position transmitter.

2. Install transmitter on wing rib with flat washer and lock-washer under locknut. '
^ .3. With flaps full down, energize airplane electrical system and monitor flap position indicator while
rotating transmitter shaft adjustment until the pointer on indicator reads full down;
4. With lever arm .link assembly connected to flap mechanism, install lever arm on transfriitter shaft
. and tighten set-screws ' ,
5. .Retract flaps to full up and monitor indicator pointer position. Calibrate transmitter, as required, to
obtain ± 2° pointer position with flaps up and with flaps down.
6. Cycle flaps to check for transmitter "deadspot." A deadspol is indicated when position indicator
. pointer is moving erratically or abruptly falls. Replace transmitter to eliminate deadspots.
7. Install access cover on wing close-out fairing.
27-55-02
Page 27-58
Issued: June 1,1995 3H1 4
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B470
INDICATOR POINTER UP, AND COUNTER- - TO L A T E S T REVISION O F

CLOCKWISE TO MOVE POINTER DOWN - ' - ' • • _PI_PER S.B. .743.
Figure 27-26.' Flap Position Transmitter (Left Wing)
RIGGING AND ADJUSTMENT OF FLAP CONTROLS. (Refer to Figure 27-27.)
Ttie fiap rigging chiecl<'is accomplistied by using a neutral position template, whicfi may be fabricated per
dimensions in Chapter 91, and a propeller-protractor to check flap travel. The 0° mark on template indicates the
wing reference plane (WRP). All flap rigging limits given are relative to the (WRP).
Pressurize the main hydraulic system with a portable hydraulic power unit, per Chapter 29, for operating
the flaps. Airplanes equipped with an auxiliary hydraulic pump do not need the portable powerunit.
• . —NOTE-
DO not operate flap actuating cylinder on newly installed flap Isefore
performing rigging steps in the order given.
1. Fabricate flap neutral position template per Chapter 91.

2. Disconnect flap cylinder rod-end from flap bracket.
3. Hold and push flap, by hand, to full retract position to seat the inboard and outboard track rollers
against end of slot in tracks. If rollers are fully seated against end of slot in inboard and outboard
tracks, proceed to Step No's. 9 through 23.
4. If flap up position indicates a rocking motion (fore and aft) across center hinge point, the inboard
or outboard track roller is not fully seated in slot, and Steps No's. 5 through 8 must be accom-
plished.
27-56-00
Page 27-59
2 ^ 5 Issued: June 1,1995
ÂEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B471
(W.S. 42.00)
TB1PLATE
IVRP
0°
, 70% SPAR
(W.S. 58.00)
PROTRACTOR-
> IVRR
(PUSH UP)^
ORIGINAL CONTOUR P= 5 TO 10 LBS
OF FLAP TRACK
TRACK
(;FORW^ END
;INSERT^ OF.SLOT)
CBffiNT IN PLACE
WITH EASTMAN 910
FABRICATE FROM 4130 STEEL STOCK, AS REQUIRED
Figure 27-27. Flap Rigging Check
27-56-00
Page 27-60
Issued: June 1,1995
3H16
AEROSTAR AIRCRAFT
' 600/601/601P/602P/700P
MAINTENANCE MANUAL
B472
FLAP TRACK CTYP.)'
Figure 27-27. Flap Rigging Check (cont.)
5. Apply hand force on flap trailing edge between inboard and center flap track points and push flap
firmly into full retract position with rollers contacting end of slots in center and inboard flap tracks.
' At outboard track, mark an index reference point per Figure 27-27.
6. Change position of hand force on trailing edge to midway point between outboard and center flap
tracks, and firmly push flap into full roller contact with end of slot in outboard and center flap
tracks. On outboard track, mark and measure dimension between points per Figure 27-27.
7. From specifications given in Figure 27-27, fabricate 3 shim inserts 1/2 the thickness +.002 inch
-0 inch"; per the dimension, between reference points on outboard track. ' ^
8. Bond shim inserts in outboard track slot and in both slots of inboard track per Figure 27-27.
9. Adjust rod-end connection on cylinder to have.six threads exposed from jam-nut, leaving jam-riut
loose. ' ••
10. Connect cylinder rod-end to flap bracket. '
11. Place flap control lever in neutral position, and pressurize main hydraulic system per Chapter 32.
12. Extend flaps to approximately half-way. Carefully observing flaps for indications of oil canning or
metal under stress, slowly retract flaps until fully retracted. Stop retraction immediately, if skin
wrinkling occurs.
13. Adjust cylinder rod-end, as required, to permit rollers in outboard and inboard tracks to contact
end of slots at same time actuating cylinder is fully retracted. Tighten rod-end jamnut.
14. Extend flaps to full down, check rollers in all track slots to be free from contact with end of slots.
27-56-00
Page 27-61

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
15. Retract flaps to full neutral (Up) position,,and place flap neutral template on wing per Figure 27-27.
16. Read template scale opposite of flap trailing edge and record the degrees indicated. Flap neutral
limits are. 1/2° up from 0°, and 3° down from 0°.
17. \ . Repeat Steps No's. 15 and 16 on opposite flap. • , :
—NOTE^
When "Zeroing" the propeller protractor: The propeller protractor must be
zeroed to include the number of degrees indicated on template when flap
is fully retracted. Flap down travel is always measured from the Wing
Reference Plane (WRP) as indicated by "0"' on template.
18. Place propeller protractor on right flap per Figure 27-27, and "Zero" the protractor to include the
amount of degrees determined on template scale. Record all "Zeroing Actions" in order to reset
protractor later-on for travel checks. • . :. :
19. Repeat Step No. 18 for left flap.
'20:- From full up position," extend flaps to full down. Check:flaps for 45° ± 3° down travel from WRP.
21. From flaps full up position, extend left flap to .20° down from WRP,, as indicated by protractor.
Record protractor setting for left flap down 20°. .- . •
22. Reset protractor for right flap travel check, per guidelines previously obtained in Step No. 18 and
measure amount of right flap down travel from WRP, while left flap is still at 20° down position.
Right flap travel must be within -i-4° -1° of left flap position.
—NOTE—
If right flap down travel exceeds the lead (0) or lag (-) limits, interchange
the down flow control valves, and repeat 20° down travel check. If right flap
is still out of lead or lag limits, with left flap at 20° down, replace the down
flow control valves as required.
23. The lead and lag characteristics between flaps moving up must be determined from conditions
existing with the airplane in flight.
—NOTE—
A test flight is required for flap operation after replacement of a flap flow
control valve.
27-56-00
Page 27-62
Issued: June 1,1995 3H18

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
FLIGHT CONTROL LINKAGE BOOTS (Model 601P, 602P AND 700P).
Five boots are mounted on pressure bulkhead fuselage station 176.88. Three of the boots connect direct
to aileron, elevator, and rudder linkage pushrods to seal in cabin pressure for linkage carry-throughs in the bulk-
head. Pressurization force acting on the boots is transmitted to the pushrods pushing them aft. The pushing effect
is counter balanced by two other boot assemblies-linked through a bellcrank and connected to the aileron and
elevator pushrods. Boot position on, a pushrod must-be set according'to instructions given in related pushrod
installation procedures..'.
. - " ' =• '
' : —NOTE—
Replacement of all pressure boots in the flight control systems is recom-
• 'mended whenever a boot has failed due to normal deterioration.
REPLACEMENT OF PRESSURE BALANCE BOOTS. (Refer to Figure 27-28.) ^
Replacement of boots, mounted on bulkhead fuselage station 176.88, is accomplished in conjunction

with the removal/installation procedures for affected .pushrods. Note position of boot, clamps to prevent interfer-
ence with adjacent components. - •. •
THIS SPACE INTENTIONALLY LEFT BLANK
27-61-00
Page 27-63
3|^-|g Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601 P/iB02P/700P
MAINTENANCE MANUAL
NOTE
1. BOOT, PRESSURE" THIS ILLUSTRATION CONTINUED O N
2. CLAMP FOLLOWING PAGE.
3. CLAMP
4. BOOT, BALANCE "
5. TUBE •
6. CLEVIS BOLT
7. WASHER
8. WASHER
9. NUT .
10. - COTTER PIN
11. SPACER
12. ARM
13. BELLCRANK
14. CLEVIS BOLT
15." CLEVIS BOLT
16. BRACKET
17. RIVET, (CR2249-4)-
18. PUSHROD . • '
•FOR . A I L E R O N PUSH R O D
ONLY. A L L OTHER BOOTS
M O U N T E D ON FRONT O F
BULKHEAD. '
Figure 27-28. Linioge Carry-Through Boots - F.S. 176.88 (typ)

(Model 601P, 602P and 700P)
27-61-00
Page 27-64
Issued: Junel,i995 3H20
AEROSTAR AIRGRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2917
f* " Figure 27-28. Linkage Garry-Through Boots - F.S. 176.88 (typ)

•^V - (Model 601P,602P and 700P)
27-61-00
Page 27-65

AEROSTAR AIRGRAFT ^
600/601/601P/602P/700P
MAINTENANCE MANUAL
STALL WARNING. (Refer to Figure 27-29.)
, Ttie.,700P has a'stall warning system installed as standard equipment. This installation consists ofâ-lift
transducer, a lift computer, a rotary switch, a warning horn (the gear warning horn), a stall warning failure light (in
the annunciator panel), a stall warning system test switch, a stall warning relay, a. stall warning system failure
relay (to annunciator) and a 5 amp circuit breaker.
LIFT TRANSDUCER.
The lift transducer is located in the leading edge of the right wing at W.S. 203.
REMOVAL OF LIFT TRANSDUCER.
1. Remove the four screws and washers which hold the unit in place.
2. , Slowly remove the unit from the leading edge and disconnect the electrical connector.
INSTALLATION OF LIFT TRANSDUCER.
' 1.' Connect the electrical connector.

2. Insert the lift transducer in the leading edge and install the four screws and washers
ROTARY SWITCH.-,
The rotary switch is located on a rib fastened to the-70% spar of the right wing. The switch is connected
to the center flap pushrod by a link and an arm. •'
REMOVAL OF THE ROTARY SWITCH. .
1. Lower the flaps to gain access to the rotary switch by way of the access panel in the trailing edge
of the wing. .' " '
2. Remove the nut and screw which connects the link to the arhri.
3. Loosen the two set screws which connect the arm tp the shaft of the rotary switch.
4. Remove the rotary switch retaining nut and washers. .
5. Disconnect the electrical connector and remove the rotary switch.
INSTALLATION O F ROTARY SWITCH.
1. ' Insure that flaps are cycled fuH down.

2. Insert the rotary switch in the hole in the rib, aligning the switch anti-rotation key with the anti-
. rotation hole in the rib. ,''\ '
' 3 . • Rotate the rotary switch shaft to its clockwise stop. Back off the rotary switch shaft 10° counter
clockwise.
4. •• Install the link and arm to the rotary switch shaft.
5. Cycle flaps and run a continuity check per Chart 2702.
'•• 27-90-06
Page 27-66
Issued: June 1,1995
3H22
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
3273
. DETAIL A DETAIL B
WASHER.
SCREW
UFT
COMPUTER
VIEW LOOKING A F T A T F . S . 2 0 4
Figure 27-29. Stall Warning System (700P Only)

27-90-06
Page 27-67

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
, CHART 2702. ROTARY SWITCH CONTINUITY CHECK
PIN CONTINUITY . . FLAP ANGLE TOLERANCE
.'.. C to 1 . 0°to10° ±1°

• C to 2 •
' 10° to 30° . ±1'°
C to 3 30° to 40° ±1°
PRE-STALL WARNING SYSTEM GROUND C H E C K PROCEDURE. (Refer to Figure 27-30.)
, 1. Bypass tfie airplane, squat switcti to simulate an airplane in fligfit.

2. Attacfi tfie Safe Flight 990 force applicator with the specified gauge to the lift transducer (per the
. instructions contained in the 990 Force Applicator Kit and the following):
A. Insert the gauge shaft and alignment pin of the force gauge into the positioner sockets.
Snap gauge in place. ' :
B. Turn screws (1) and (2) fully counterclockwise.
C. Orient "positioner" with screw (1) toward wing leading edge.
D. Insert "positioner" anchor tab (3) into opening fonward of vane (9).
E. Hook anchor tab (3) onto two fonward vane stop pins (4).
F_. . Keeping anchor tab (3) engaged, shift "positioner" until cone points (5) enter recesses in
screw heads (6). . . ^
G. ^, Turn screw (1) clockwise until knob clutcfi slips. .
' , H. . Tum screws (2) and (7) as required to'bring gauge pressure arm (8) to bear on surface of
vane (9) within .032 inches of tip.
I. Apply pressure to aft surface, of vane (9) for negative (-) tipgrams and forward surface for
positive (+) tipgrams. ..."
J. " Turn screw (7) to adjust force (tipgrams) as required.. .
3.... Turn on the airplane DC power. Ensure that tfie stall warning circuit breaker is pushed in.
—CAUTION—
Ensure that the stall warning heat switch is not activated.
4. Place airplane flaps in up position. , • • .

5. Apply a forward force of -11 tipgrams slowly to the tip of the lift transducer vane. The stall warn-
ing should actuate when the -3 gauge reads -11 ± 1 tipgrams.
6. Repeat steps 5 and 6 for 20 degree and 45 degree flaps position. Use the -3 gauge (2.0 to 15.0
tipgram range) to check that the stall waming actuates at -6.5 ±1 tipgram for 20 degrees of flaps.
Use the -1 gauge (0.3 to 3.0 tipgram range) to check that the stall warning actuates at -1.5 ± 1 tip
gram for 45 degrees of flaps. •
V ^ —NOTE—
When changing the trip point, always measure the point at which the stall
warning just turns on, not off, to avoid error.
•27-90-07
Page 27-68
Issued: June 1,1995 3H24
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
7. If the previous calibrations were not met, the computer will havie to be recalibrated per the follow-
.', ing steps: ~ •; • • '•*
J A. Place flaps at 45°, gain.access to the lift computer adiustments and apply a force of -1.5
tipgrams (on the -1 gauge) to the lift transducer with the 990 Force Applicator.
B. Lift up the access cover on the front of the lift computer and slowly adjust the poten-
tiometer labeled R3 so that the stall warning horn just comes on.
^ —wore— - .„
. Turning R1, R2 and R3 cloclmise will cause the stall warning horn to come . .
'on. Turning them counterclockwise will cause the horn to go off. '
C. . Check the calibration by rerribving the fdrce from the vane to turn off'the horn. A force of
plus 5 tipgrams from where the stall waming actuator will be is required to turn off the
horn". Apply a minus force slovyly until the stall warning horn actuates. The gauge should
read -1.5 tipgrams. " J "
-—NOTE— ' :
Tap the gauge lightly while making the reading.'
b. Repeat the procedcire o'f steps A, B and C for 20 degree and 0 degree flap position per
the following steps. . ^ "
E.. Place flaps at 20 degrees and apply a force of -6.5 tipgrams (using the -3 gauge) to the
lift transducer vane.-Adjust the R2 potentiometer slowly so that the stall waming horn just
. comes on. . .
F. Place flaps at 0 degrees and apply a force of -11 tipgrams"(using the -3 gauge) to the lift
transducer vane. Adjust the R1 potentiometer slowly so that the stall warning horn just
comes on. " '^z
NOTE
D164 LIFT DETECTOR GAUGE DASH NO. RANGE IN GRAMS
FOR COtytPANY AQDRESS AND
TELEPHONE NO. REFER TO TftE •' " -1 0.3 • 3
VENDOR-SUPPLIER INFORMATION -2 0.6-6
AT THE FRONT OF THIS CARD. -3 2.0 - 15
-4 3.0 - 30
• -5 5.6 - 50
-6- 10.0 - 100
-7 • , 20 p - 250
1. SCREW
2. SCREW
3. 'POSITIONER" ANCHOR TAB
4. FORWARD VANE STOP PINS
5. CONE POINTS
6. RECESSES IN SCREW HEADS
7. SCREW
8. GAUGE PRESSURE ARM 990 FORCE ACTUATOR
|9. LIFT VANE
Figure 27-30. Lift Transducer Force Applicator
' 27-90-07
• Page 27-69
311 Issued: June 1,1995

Aerostar Maintenance Manual ATA-27-Flight Controls

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FLIGHl CONTROLS

CHAPTER 27 - FLIGHT CONTROLS

27-00-00 GENERAL 3F5

27-10-00 AILERON 3F16

27-20-00 RUDDER AND TAB 3G5

27-30-00 ELEVATOR AND TAB 3G21

CHAPTER 27- FLIGHT CONTROLS

27-50-00 FLAPS • 3H12

27-60-00 FLIGHT CONTROL LINKAGE BOOTS

27-90-00 STALL WARNING SH22

THIS SPACE INTENTIONALLY LEFT BLANK

3F5 Issued: June 1,1995

' CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS)

-Trouble , , . -Cause „ . . . . . . Remedy

AILERON CONTROL SYSTEM •

Frozen or tight'bearing in' Check bearings in bellcranks,

Bent aileron or aileron Replace as required.

..... Linkage interference. Check/repair linkage system as

—NOTE— Bellcrank idler arms Check/adjust all bellcrariks and

Control columns install- Rig control column installation,

Rigging template not Fabricate template, per Chapter 91.

Trouble Cause Re'niedy

. AILERON CONTROL SYSTEM '

Stops put of adjustrnent. Adjust stops.

Bellcrank reversed.' Install correctly.

Pushrod(s) connected to Install pushrod(s) per Figure

Damage to control system. Check/repair, as required.

.Low wing attitude at Aileron_trim tab out of Adjust trim tab.

Excessive rudder pedal Rudder to aileron inter- Check spring connection

RUDDER CONTROL SYSTEM

Lost motion between Linkage loose or worn. Check linkage. Tightener

Loose or worn rudder Repair/replace hinges.

Resistance to rudder Frozen or tight bell- Chock bearings and replace as

Brake cylinder inter- Lengthen pushrods between

Linkage interference Check system and repair as

3F7 Issued: June 1,1995

' ' ' Trouble Cause Remedy

Rigging template not fab- Fabricate template per Chapter

Rudder trim does not Faulty actuator. Replace actuator.

Not enough trim tab Faulty actuator. Replace actuator.

Position indicator does Faulty indicator, Replace indicator.

CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (cont.)

Trouble . . . .Cause ., _ Remedy . ,

ELEVATOR CONTROL SYSTEfil

Resistance to contror [ Interference in linkage Cfieck/i^epair, as required.,

Frozen or tiigfit'bearings Cfieck and replace b'earing(s).

Pusfirod connections on Cfieck connections and correct

Control column binding Lubricate guides witfi silicone.

Incorrect elevator travel. Control stops not .adjusted Adjust stops.

Incorrect bellcrank Install bellcranks per installa-

Reverse pusfirod connec- Cfieck idler arm connections,

Rigging template not Fabricate template per di-

Excessive free-play VJorn universal joints Replace torque tube assembly.

Loose or wom linkage Connections/replace bearings

3F9 Isisued: June 1,1995

Trouble" •.' • Cause Remedy

TRIM TAB CONTROLS '

Trim tab 8des not ' Faulty actuator. Replace actuator.'

Not enough trim tab Faulty actuator. Replace actuator.

Position indicator does ^ Faulty indicator.- Replace indicator.

FLAP CONTROLS '

Flap skin wrinkles in Rod end adjustment on - Adjust rod-end.