DC9 - Control Surfaces OM

D O U G T A SA I R C R A F TC O . , I N C .

EC.9 M A I N T E N A N C EM A N U A T

CHAPTER

FLIGHT

27

CONTROLS

P r i n f e di n U . S . A


DC.g M A I N T E N A N C EM A N U A L

ELEVATOR H O R I Z O N TSATLA B I L I Z E R

/ G E A R E DT A B z ELEVAT0R

. \(

\-/Eo'iYfioL rAB

Ij"?, _

RUDDER

AILERON

RUDOER C O N T R OT LA B

A I L E R OTNR I M TAB A I L E R OC NO N T R O L T AB

G R O U NSDP O I L E R F L I G H TS P O I L E R W I N GF L A P

SL A T S

BB2-2658

27-00 CODE 3 Page 2

Flight

Controls Figure

Control I

Sur fa ces Aug L/ 66

D OU GTA SA IR C R A FTC O., IN C .

DC.S' }IA IN TE N A N C EMA N U A I TAB AILEROI{ COI{TROL REFEREI{CE LIiIE RIGGIilG TRIMTAB AILEROI{ RIGGI'{G REFEREI{CE LIt{E

TAB GEARED ELEVATOR REFEREIICE LIt{E RIGGII{G

RUDDERTAB RIGGING LIITIE R E FE R E N C E

COI{TROL TAB ELEVATOR REFEREIICE RIGGII{G LII{E

R IGGINRGE FE R E I{C LIl E {E S

Of{TROL URFACE

BB2- 936A

Tab Rigging Prot ract o r Figur e 2 0 2

Aug L/ 66

Prinfed in tl S A

2 7- O O CODE 4 Page 209


DC.SI M A I N T E N A N CMEA N U A T

A I L E R OTNR I M ( I NR I G H T DRUM LATERALCONTROL MIXER )

AILERONCONTROL WHEEL

C O N T R OL PEDESTAL

A I L E R OTNR I M CONTROL KNOB

AILERON CO NTRO L CABLES A I L E R OC NO N T R O I

sYsfEurr^t:

A I LE R ON T O R Q UTEU B E ANDOVERRIDEMECHANISM

Aileron

and Tab Centrol Figure I

Aug L/66

P r i n t e di n U S . A

System

27-L0- 0 CODE 1 Page 3

A I L E R OINN P U T ( INLEFT DRUM A NDRI G } I T M I X E R)S

AILERONOUTPUT DRUM

A I L E R OBNU SS E C T O R .E R ON BU S B LES YSTEM

CONTROLTAB

CONTROL

TABSECTOR

TRIM TAB ACTUATOR

B B 2 - I I 4 3A


DC.SI M A I N T E N A N C EM A N U A L INDEXMARKS CONTROL

COLUMN

I. TURNBUCKLES

CONTROL WHEEL

ts|

TURNBUCKLES 2. TURNBUCKLE

16. ADJUSTMENT SCREWS

R I GP I N (RP.- 2)

AILERONSERVO 3. TURNBUCKLES V IE W B

UP LOOKING ANDAff

AILERON B U SC A B L E

AILERO TAB CAB II.

TURNB

B U SS E C T O R

T A BS E C T O R

4 L5 ___€

L3. FIX

Aileron

and Tab Control Figure

System 501

Aug L/ 66

P r i n l e di n U . S . A

Ad j ustrnent

27-10-0 CODE 1 Page 503

SPRING SCALE

AILERON CONTROL TABSECTOR

7. ROLLER

vtEwc-c RIG PIN ( RP - 3)

vtEw c MIXER

R I GP I N (RP-7)

9 . E Y E B OLT 8. LAMINATED SHIM

\ I } . A I L E R OBNU SC A B L E S TURNBUCKLES IO. PUSHROD

URNBUCKLES ITROL

vtEw E _ES

TAB SECTOR

RHEOSTAT

ACTUATOR ROLLER

n'-ei} l{'@".@'}i

t L/32)lNcHEs-|_.*l

rTN

I

vtEwB-B CABT"E INSTALLATION

Ne/ vrEw A-A

ALIGNMENT MARKS

BB2-705D

D O U G T A SA IRC R A FTC O., IN C .

DC.9 M A I N T E N A N CM EA N U A T t". \

,1 >6. TURNBUcKTTTZ\)/ 49

)

T,RNBU.KLES

..t/t

3, TURI{BUCKLES

=-\

1. DRUM-

2. DRUM 4. D R U fvl

iD

L ATE R A LC ON TR OL MIX E R R I G H TW H E E LW E L L

\ \

CONTROL PEDESTAL

P OII{TER

AILERON TRIM C O N T R OKLN O B

vEw T2, EYEBOLT 9. JAMNUT

AILERON

vEw A

1 0 . A C T U A T OSRC R E W

I1. BOLT

L ftL/32 ) INCH*' T R I MT A B AILERON

27-10-0 CODE 1 Page 5L2

AcruAToR HouslNG srcrrox c-c Adjustment Trim Tab Control System Figur e 504

L E F TD R U M RIGHTDRUM

PUSHROD

Aileron

B B 2 - 1 2C 0

Aug

PrintedinUSA

L/ 66

DouGLA'#^H;*;;" MAINTENA} ACC E S SD OOR

A C C ESSDOOR

0oo$rz \ccEss

I I

/

J.,

J

4 HINGE

2 HINGE TRIMTAB HOUSING TRIIUTAB ACTUATOR CONTROLTAB EYE BOL T

EHIE?EI Ft%ilt[$l;il#[?'*"' \-

rZ'412

( ! 0 ' 0 1 0 )l N * t

BussEcToR \ sEcrloNA'A

DAMP

\71i83'J^-l3lF''o* 6

4

EIE\'i''] Kr ,,..,{/) *\',

1,

\z\LW X',

/t //t lt ,74ry

\,il',

vt:w B

'.-DAMPER

-d"-, 'W [sso.-' %/

W 27-L0- r coDE 1

Page 402

vlEw

/ .-./\ \ '.\

\

? . \

il

: I

,F/ ;-mEp53;*ti} 5B0Lr-ffiffi c

D

6. LINK

An ero"

i on r r;,r::' ttlt"t

BB2-9B

Aug L/66

D O U G L A SA I R C R A F TC O . , I N C .

DC.g' M A I N T E N A N CM EA N U A T B.

Insta ll NOTE:

Ai Ie ron Aileron must be properly balanced (see Structural Repair Manual).

before

installation

(1)

Clean eontact area between base of eyebolt and ai leron fitting at each hinge to provide good electrical bond.

(2)

Check that trim tab pushrod is adjusted to L2.4L2 (t 0. 010) inches, measured from center of aft bearing to center of forward bearing.

(3)

Remove plugs from sling attach upper surface of aileron.

(4)

Move aileron slightly aft

(5)

Position damper links so they will align with on aileron when aileron is moved into place.

holes

and install

with sling and hoist to a position of installed position.

sling

on

above and damper cranks

U N I V E R S AS LLING

b

L O N GC A B L E

AILERON

NOTE AT EACH 1 . R E M O V ET W OS C R E W S H O I S TA T T A C HP O I N TA N DA T T A C H W I T HA N 4 . 1 OB O L T S . FITTING S T O WC E N T E RC A B L EW H E NU S E DF O R L I F T I N GA I L E R O I { " A T T A C HL O N G E S C T A B L ET O O U T B O A R D H O I S TP O I N T . BB?-283

27-10-1 CODE 1 Page 40q

Aileron

Sl ing Installa Figure 402

tion Aug L/66

DOUGTAS A I R C R A FC T O . ,I N C .

DC.SI M A I N T E N A N CM EA N U A T

1 AILERO]TTRIM TAB ACTUATOR

AILERON TRIM TAB

CONTROLTAB

vtrw c AILTRON HINGE (TYPICAU

2 vnw A AILERON

CONTROL TABHINGE (TYPICAU 2 7- 1 0 - 1 CODE 1 Page 408

BB2-738

Aileron

and Tabs Lubr i ca t i. on Cha rt F i g u r e 4 0 3 (Sheet f) Aug

P r i n t e di n U . S A

L/ 66


DC.SI M A I N T E N A N C EM A N U A T

\i I

L i 4 I N C HM l N . L 5 / 3 2 l N c HM A X

t; ''

EA\

lr/4 fNcH MrN.J*,, I L 3 / 3 2t N c H M A X .- - -

, / o t N c HM t N .

/

MAX' 3/8rNcH

I/

\./

c o N T R or A LB

\'> \/

V

Ynw B-B

WING

FLAP

(

I

Ir

CONTROL

FAIRING

il

l-

r3/32 1 7/ 3 2 1 3 / 3 2 | N C HM t N . t 7 / 3 2 I N C HM A X .

r 3 / 3 ? I N C HM t N . T 7/ 3 2 I N C HM A X .

7 / 8 I N C HM l N . I I / 8 I N C HM A X .

vnw A L 3 / 3 2 I N C HM I N . L 7/ 3 2 I N C HM A X .

I / B I N C HM I N . } / 4 l N C HMAx.\.,

-

,/r'\ lr-

A IL E R O N

I / 4 I N C HM I N . L 5 / 3 2 I N C HM A X .

{' t. r l\ \ l/-

T R I MT A B

1 , ' 4 I N CH M I N . l ' 2 I N C HM A X .

l-

vuw C.C 27-10-t CODE 1 Page 602

Ai leron

Clearances Figure 60 I

B B 2 - 1 5 6A 9

Aug

L/ 66

D O U G I A SA t R C i

'Nc

oE:';'' MAINTENANCE

MAruUAI

c

.\

t2

E \/> -'--^}-

-o\

iliiilil3il#lI \ vrtwD-D

A I L E R O N R I GP I N RP-7 BUS S E CT O R

lll::,,#3#,ilil: ...\ \' 3. BOLT

vfgw A I Y P I CA (3 L P L AC ES )

if?Fl,'J]fi3'

SECTOR

R E A RS P A R PUSHROD

vtEw C

N

2 . B 0L I ( L O C K W ' R E )

vrrw B 27-10-2 CODE I P ag e 2 0 2

Aileron

Control Tab f Figure 20I nstalla

BB2-IOB

tion

Aug I/66



I AILERONTRIM TAB ACTUATOR

AILERON TRIM TAB

CONTROLTAB

vtEw c AILERONHINGE (TYPICAU

2 v|lw A A I LTRON

v|lw B TAB HINGE CONTROL (TY PICAU 27-10-2 CODE 1 Page 20q

Aileron

and Tabs Figure 202

BB2.738

Lubrication (Sheet f ) Aug

I/66


DE.ST MAINTENANCE MANUAT

AILERONHINGELINE

15.SECTOR 1 5 .S E C T o R

TURNBUCKLES

-_-<1

NN-\

AILERON B U SC A B L E S

S

12, SECTOR

A IL E RO N CONTROLTAB CABLES

DOOR

CABLEINSTALLATION l 4 L 5 / 3 2( ! L / 3 2 ) I N C H E- S (\ai.

t 9 .s T 0 P

I

2 . T U R N B U C K( D LE )S

vEw A

2 0 ,s T o P

1 1 ,S H T M S 4 PLACES

v

R I GP I N ( R P - 7) LOCIOVIRE

S PAR

ziE

:r(\

RIGPIN (RP-3)

---\

,..

t \ \

& .? 'J/

\ \\\\ \ \\

,J

LATERAL COilTROL M I XE R L O C A T E D I N M A I NG E A R WHEEL WELL

7.EYEBOL

o NUT

7=:ot'.

o)

4 PLACES

I 2 . A I L E R OC NO N T R O L T A BS E C T O R

6 B U SS E C T O R LINK

_1

I. spRrNG

-\-r T A B s E CT o r i L I N K

N ;A_ -

} 7 LAIi4INATEI) S HII\1

ATLERON

I D L E RC R A N K

vrEw B

ld"z

] . ) R O L L E Rt -

(a-_

:'.v, I

CRANKS

(G /v SPRING S C AL E

.,I OPS iTOPS

B B 2 - 1I 9 3

21-I0-3 C O D EI Page U02

Ai Ler()n Sectors

dr)(l Lo.rd-F'eel Cr.rrrk:; Inst.rIl.rtiort Iriryure q01 Aug L/ 66

D OU G T A SA I R C R A FTC O., IN C .

DC.9 }IAINTENANCE MANUAT

'./ --,/

AILERON D AMP ER

ATTACHBOLI2 (3 PLACES) :

MS20470A06 RIVET

4

h$[Ah'A'ilEl' I NA R M

lt

I

R ING GTTRAIL w lNl G rGE ED

A C C E S0S0 0 R

[trlotHcEDcE

27-10-q CODE 1 Page 202

B BB2-1099

Aileron

Damper Figure

I ns tal I a tion 201 Aug L/ 66

D O U G I A S A I R C R A F TC O . , I N C .

DC.SI M A I N T E N A N CM EA N U A T

,as

I / 8 I N C HM I N , I/4 IN C HMA X ,

,{r^

'ry)

=./7

T R I MT A B

1 / 4 t N C HM t N . L7/32 | N C HMA X . 1 / 4 t N C HM t N . 1/2 IN C HMA X .

D,

Yuw D-D

Dc>-r /

/

1 3 / 3 2r N C HM l N . L 7 /3 2 I NCHM A X

/ / ( T RIMT A BA C T U AT OR O* ' "

D

4.JAMNUT

r 3 / l z l N c HM l N . L 7 / 3 2 I N C HM A X C O N T R OTLA B

TAB EYEBOLT

TRIM TAB PUSHROD

EYEBOLT 5. ACTUATOR S C R EW vtEw A

I. BOLT C

-*\\

7 "- )l ;3it \r

i"

u-l-

(,

2.NUT TORQUE: 50 T0 70 lN. LBS.

//

T R I M,0, P U SR HO D

vrEw B

TAB PUSHROD A F TF A I R I N G

B B 2 - 1I C

27-10-5 CODE 1 Page 202

Aileron

Trim Tab Installation F ig urrl 2 0 1 Aug

PrinfedinUSA

L/66

* DouGrA'DH:'i* iAAINTENAI TAB AILERONTRIM

ACTUATOR

AILERON TRIMTAB TAB CONTROL

vtrw C $INGE AILER0!{

2J

vll,w A AILERON

vll'w B

BB2-138

coNll$*lllu*'*t z1-L0:5

;:?: "ou

niI eron

li "" ?1iJ:",71'':?::?"

chart

66 Aug L/

O O U G T A SA I R C R A F TC O . , I N C .

DC.g M A I N T E N A N C EM A N U A T

@

r. TURNBUCKLES

CABLES

BLOCKS

vtEw 2 . BoLT( HE A D M U S TB EI N S T A L L E D FACI NG O UT B O A R D I

N OTE : USEWOODBLOCKSAS SHOWN TOC LA MPC A B LE S

CRANK

W I N GR E A RS P A R AILERON

1't

T A B P U S HR O D TAB

.ttt

tv

ACTUATOR -1

--'1

-'t'

-t-'

f\e

7. EYEBOLT 6, JAMNUT

r(tLn?)lNcH

T R I MT A B CONTROL CABLES

5 . A CT U A T O R SCREW

3 .B O L T S B PLACES)

ACCESS DOOR (OPEP NO S I T I O N )

VIEW A

ACTUATOR INSTALLATION LOOK INGUPWARD, FORWARD ANDOUTBOARD 2 7- L 0 - 6 CODE 1 Page 202

Aileron

Trim Tab Actuator Figure

B B 2 - 6 6 5B

Insta llation

201 Aug L/66

P r i n t e di n U S . A .

DOUGIASAIICIAFT CO., INC.

ac-s,

MAINTENANCE IIANUAI

2. CAM

AILERON WHEEL CONTROL

3. ADJUSTIvIEI{T SCREW (4 PI-ACE5)

L COLUMN B R E A K O UF TO R C E= F O R C El N P O U N D (SF ) (L) = INCH-P0UNDS X LENGTH lNINCHES I . C A MF O L L O W E R

VICW B

./,/

'r/

,/

---Yllw4

OV€RRIDE MECHANISM AFT LOOKING

L O A D- F E E L CRANKS

R I GP I N( R P - 3) ( 2 P L A C E )S

vtE w D LE FTW IN GLOA D .FE E CLR A N K S SHOWN R ,I G HW T ING C R A N KSSI M I I - A R . LEFT I-ATERALCONTROL M I X E RS H O W N .R I G H T MIXERSIMII..AR.

2 7- 1 0 - 9 CODE 1 Page 502

Aileron

Torque

NorE: i b!'g3Bf-'?3.'?'31' "

Tube and Override Adj ustment Figure 501

BB2-I 2668

l'techanism Aug I/65

PrlnladIn U.S.A.

D OU G L A SAIR C R A FTC O., IN C .

DC.9 MA IN T E N A N C EMA N U A I

/z

a

\t

D-----___..\

tla

z 2 . CA

3. ADJUSTMENT SCREW (4 PLACES)

I

AILERON C O NT R OL W H E E L

tlt t \:,i

c\

CONTROL B R E A K O UFI O R C E F O R C E I N P O U N D(SF ) X L E N G T IHN I N C H E(SL ) . I N C H - P O U N D S

./, I. CAM FOLLOWER

t

VIEW B

''t' ..

ar'

,.a'

/a

vtcw A

O V E R R I D EM E CI I A N I S M L O O K I N GA F T

L O A D- F E E L CRAK NS

R I GP I N( R P - 3) ( 2 P L A C E S)

il

".N ' t

\/t SPRING

VIEW D L E F T W I N GL O A D - F E E LC R A N K S S H O I V NR , I G H TW I N GC R A N K SS I M I L A R . L E F T L A T E R A LC O N T R O L M I X E RS H O W N .R I G H T MIXER SIt\,IILAR.

Aileron

27-I0-9 CODE 2 P a g e 5 02

Torque

N O T E :A I L E R O NB U S S E C T O R NOT SHOI^/N FORCLAIIITY

Tube and Override Ad j us tment Figure 501

B B 2 -1 2 6 6B

Mechanism

Aug L/ 66


DC.gI M A I N T E N A N C EM A N U A I

R U D D ETRH R O W . LIMITERACTUATOR DIAPHRAGM

] NEL E T A I RP R E S S U R ACTUATING CYLINDER PISTON ROD

IDLE R CRANK

L I N E A RC R A N K

HOOK

F I R S TS T A G E LIMITINS GP R I N G S

D R I V EC R A N K

PISTON

SECOND STAGE SPRINGS LIMITING

vrEw A

BB2-10738

27-20-0 CODE I Page I

Actuator Rudder Throw-Limiter Figure 4

and Linkage Aug I/ 66

P r i n t e di n U . S . A .


DC.9 M A I N T E N A N C EM A N U A T

,$, \rr^ ? ll

CONTROL TAB

RUDDER

C O N T R OTLA B TORQUETUBE RUDDERDRIVE T O R Q UTEU B E

,i*{6 ."ffi

=ffi--;;;;;'L,c PowER PACKAGE

hb

v'

>V\Jffis"

D R I V ES E C T O R

)Y

RUDDER T R I MC O N T R O L

KNOB HYDRAL UI C RUDDER VALVE P O W E RS H U T O F F

CONTROLLEVER

^m"V[l / I8T8x;o'H'"* v*w #KMQ \*t\

CONTROL /' PEDESTAL /'

RUDDER PEDALS

-\

J--,/' 'lltJ -

27-20-0 CODE I Page 2

Rudde r

BB2-LT44

and Tab Control SYstem Figure I

S chemat i c

Aug L/66

Printad in Il S A


DC.g

M A I N T E N A N C EM A N U A T 6. PTSToN

7 . S T O PS C R E W

VIEWA.A

T4. JAMNUTS

:i.5. TA8PUSHROD

RUDDERTRIMAND LOA D .FE ESLPRI I {G C A B L ED R U M

CONTROL TAB I . O R Q UT EU i ] E

ACTUATING CYLINDER 8. JAMNUT 9. EYEBOLT

R I GP I N ( R P - 5)

R U ODER PO WER COI{TROL VALVE

rl. PUSHRoD lA 13. JAMNUT YAW DAMPER 6. PISTON ROD ACTUATOR

I. BOLT 3 , CRANK

2. PUSHROD

BB2-t0030

Rudder Hydraulie Aug L/66

Power package Figure 501

P r l n t c di n U S . A

Adjustment

27-20-0 CODE 1 Page 503


DC.9 MA IN TE N A N C EA A A N U A T

3. PUSHROD ADJUSTER ARM R I GP I NR P - 5

DRIVE SECTOR RIGBRACKET

V l E WC 3/4 INCHES RUDDER PEDAL ADJUSTMENT KNOB

BRACKET

2. TURN BUCKLES 7. RETAINER

L- ?3/ 32 TO r-13/16 INCHES

R U D D EPRE D A L A D J U S T M ECNATL B E 3 1/2 P 0U N D)g M N S I0N i l ' ,tA l i tvtUTE

6. SPRING

PRESSUR SE A L S V I E WB . B

I. TURNBUCKLES

4. SToPS

/* Fr'

,\./ [-"

B

u

L

c

\I

1,r','

(-1. 5 . E Y EE N D

,^ VIEWA

Rudder Control System Figure 503 Aug l/66

P r t n l c dI n U . S . A .

Adjustment

BB2-IOOOC

27-20-0 CODE I Page 509

D O U G L A SA | R G R A F TC O . , t N C .

DC.SI M A I N T E N A N C EM A N U A L I4.

PISTON ROD

q I5.

T3. HOOK

5 . P U S H R O D VIEW A-A

S T O PH O O K

L 6 . S T O PS C R E W

LIMITER BELLOWS

CR A N K 13. HOOK

S T O PS O L T 12, SPRINGS

5. PUSHROD

9. STOP 3, CRANK

BOLT

I

6. PRESSURE ! NL E T

BELLCRANI(

I. BOLT 10. TURNEUCKLE VIEW A

27-20-0 CODE 1 Page 5Lz

R I GP I N( R P - 1 )

2. PUSHROD I1.

S E R R A T EWDA S H E R

Rudder Throw-Limiter Actr:ator Ad j us tment F i g u r e 5 05

B 8 2 -I 0 0 4 C

and Linkage Aug L/66

D O U G I A SA I R C R A F TC O . , I N C .


6. SECToR

2. TURNBUCKLES TR IM 1 { D tC A T g R /,R U D D ER ROLKNO PLACARD /,/ CONT

R I GN E U T R A L NOTCH

C A B L EB A L L E N DS O C K E T S PRES

TURNBUCKLES

EEL LOA DF-FE ESLP R I N G HOUSING

3. DRUM GUARDPINS

Y|rW I

BB2-10058

Rudder Trim Control System Figure 506 Aug L/66

P r i n t e di n U . S . A

Ad justment

27-20-0 CODE I Page 515


DC.9 M A I N T E N A N C EM A N U A T 5 . C O N T R OLLE V E R P 0S l Tl Ol tl ) ru AN U A L

P R E S S U RS EE A L S

R U D D EHRY D R A U L I C P O W ES RH U T O F F VALVE CONTROLLEVER 2. TURNBUCKLES

-tJ

A

RUDDERH Y D R A U L I C POWER SHUTOFF V A LVE I. TURNBUCKLES

r2. YOKE II.

9. SECTOR

CRANK

3. BOLT OPEN 4 . P U S HR O D 8 . R I GM A R K( O N S E C T O R )

CLOSED

PIN IO. GUARD ( O N B R A C K EA TR M )

vrEw B-B BB2-1075.A

Power Shutoff Rudder Hydraulic Adjustment System Figure 507 Aug L/66

Prlnfcdin U.S.A.

Control 27-20-0 CODE I Page 5L7

D OU GIA S A IR C R A FTC O., IN C .

DC.gI

frIAINTENANCE IAANUAL

7/8 INCHM I NI M UM L L / 8 I N C HM A X I M U M

13/32INCH MINIMUM 17/32IN CHt r 4AXt M UM

5/32INCHMINIiTUM 9/32INCHMAXIMUM

7 / 8 I N C HM I N I M U M L I / 8 I N C HM A X I M U M

V E R T I C ASLT A B I L I Z E R T/4 IN C HMIN IMU M ATUPPEE RN D T/2IN C HMA X IMU M AT UPPER END 3 / L 6 I N C HM I N I M U M A T LOW E R END 7/76 INCHMAXIMUM A T LOW E R END

---

1/8 tN C HM I N I M U M 3/8 rN C HM A X I M U M

5/32IN C HMI NI M UM L 3 / 3 2 I N C HM A X I M U M S E C TIONA -A

SECTIONB-B

3 i 8 I N C HM I N I M U M A T LOW E R END 5/8 IN C HMA X IMU M A T LOW E R END T/4 IN C HMIN IMU M AT UPPER END T/2IN C HMA X IMU M ATUPPER END BB2-1814A

Rudder and Control Figure Aug L/66

Tab Clearances 501

27-20-0 CODE1 Page 603

D OU GIA S A IR C R A FTC O., IN C .

DC.9

M A I N T E N A N CM EA N U A T

H 0R l Z0l ' ITA L S TA B ILIZE R HOIST FIX TU R E

RUDDER

FAIRINGS

VERTICAL

STABILIZER TAB TORQUETUBE CRAt{K

DAMPER LIN K

PUSHRO D

S T A B I L IZ ESRT R U C T U R E H IN G E F IT TIN G

FI TTI NG S

RUDDER STRUCTURE

RUDDERSTRUCTURE

E Y E B OLT

BARRELI{UT

RETAINER COVER PLATE

WASHER

RUDDER DRI VE TORQI.JE TUBE

BOLT (4 PLACES)

VIEW A

RUDDER HINGEPOINT(TYPICAL 3 PLACES) Rudder

Installation Figure 401

Aug L/66


BB2- 9408

27-20-1 CODE 1 Page 403

DOUGTAA S I R C N A FC TO.,INC.

oc-9,

MAINTENANCE IAANUAI

RUDDERSLING MON OR A IL.

------I

CABLE 3. HOIST

2.

I.

S L I N GC A B L E

HOISTING BRACKETS

BB2-t436A

27-20-1 CODE 1 Page 404

Rudder Sling A,ssembly Figur e q 0 2 Aug L/ 66

P r i n f s di n U . S . A .


DE.9 AA AIN TE N A N C MA E NUAT

A

B J

!

vnw A POWER RUDDER MECHANISM

l--

t\

vtrw B LOWER RUDDER TAB HINGE ytrw C RUDDER TAB HINGE ffYPICA L) - vlrw D RUDDER HINGE (TYPICA L) BB2-7 6C

27-20-1 CODE 1 P a g e q0 6

Rudder and Tab Lubrication Figure 403 (Sheet 1)

Chart Aug L/66

ori^rai

in llQ

A


DC.9 ,IAA IN TE N A N C A EA A N U A L

7 / 8 I N C HM I N I M U M T L / 8 I N C HM A X I M U M

L3/32IN C HM I N I M U M L7/32IN C HM A X I M U M

s/32INCHM I N I M U M 9/32INCHMAXIMUM

7/8 IN C HMIN IfuIU M I L / 8 I N C HM A X I M U M

V E R T I C A LS T A B I L I Z E R 1 / 4 I N C HM I N I M U M A T U P P E RE N D T/2INCHMAXIMUM A T U P P E RE N D 3 / L 6 I N C HM I N I M U M A T L O W E RE N D 7/ L 6 I N C H M A X I M U M A T L O W E RE N D

1 / B I N C HM I N I M U M 3 / 8 I N C HM A X I M U M

-

5 / 3 2 l N c HM I N I M U M L 3 / 3 2 I N C HM A X I M U M

5ECTION A-A

S E C T IO NB -B

2 7- 2 0 - L CODE 1 Page 602

3 i B I N C HM I N I M U M A T L O W E RE N D 5 / B I N C HM A X I M U M A T L O W E RE N D 1 / 4 I N C HM I N I M U M A T U P P E RE N D I / 2 I N C HM A X I M U M A T U P P E RE N D

882.I814A

Rudder and Control F igure

Tab Cl e a r a n c e s 601 Aug L/ 66

PrintedinUSA

DOUGI.ASAIRCRAFTCO., INC.

DC.E'

iIAINTENANCEftIANUAT

FORWARD FAIRING

RUDDER CONTROL TAB

- .-.-_/

AFT FAIRING U P P E RH I N G E EYEBOLT

LOWERHINGEEYEBOLT C ON TR OL TA BC R A N K

RUDDER B82-9418

2 7- 2 0 - 2 CODE 1 Page 402

Rudder Control Tab Installation Figure 4 0 1 Aug L/66

Printedin U.S.A

CO., INC. AIRCNAFT DOUGTAS

DC.9

}IANUAL TAAINTENANCE

\

-,

I (

vtrw A POWER RUDDER MECHANISM

vttw B LOWER RUDDER TAB HINGE Ytrw C RUDDER TAB HINGE {TYPICAL} J

VI:W D

RUDDER HINGE (TYPICA L)

2 7- 2 0 - 2 CODE I Page 404

Lubrication Rudder and Tab Flgure 4A2 (Sheet 1)

P r i n l e di n U . S . A .

Chart

BB2-76c

Aug L/ 66

DOUGTAS AIRCTAFTCO., INC.

DC.g

MAINTENANCE MANUAT

SUPPORT FITTIITIG FI-AT PI-ATEALUMINUM ORS TE E LA T LE A S T 0.L25 THICK

/:, /44

B U TTP LA TETOA LIGN MEASURING RODWITH TOPSOF FI..AI{GE BUSHlltlcS WASHER SPACER WASHER

RUDDERDRIVE TO RQ UE TUBE

S U P P OR TB E A R IN G

vtEw A

D R I L LR O DO R S TE E LTU B IIIIG

INDEXHOLEIN CENTER OF PI-ATETO LOCATE (DRI LLHO LE TU B IN G O.OTOLA RG ER THAI { R oDS | ZE)

5.00

1 .6 8 7

r{cHEs

lltlC

0.3845|l{CH DI AM ETER (4 PLACES)

4.00 HES

Itlea suri

Aug L/66

ng Tool

VIEW B

Rudder Drive Installat ion Figure 202


Torgue Tube

4.00

BB2-1835

27-20-3 CODE 1 Page 205

D OU G IA S A IR C R A FTC O., IN C .

DC.S' AAAINTENANCE MANUAI

I

,P C4

!PJ\

fV

N L--,

T/ "/:

-----"-/

V E R T IC A L S T AB IL IZ ER

2 7- 2 0 - s CODE1 Page 202

BB2-948

Rudder Damper Installat F igur e 2 0 1

ion Aug L/66

P r i n i e di n U . S . A

D O U GA| S A t n c n A F TC O . , t N c .

DC.SI

IAAINTENANCE MANUAT

r/8 IN C HMIN TMU M

3/8 tNcHMnxlMuM 1

RUDDER CONTROLTAB

RUDDER

vf:w A-A

i?,iilil9,l#ly,$,,$ 5/3 2 tf{cH MttrflMUM 9/3 2 |lrtcHMAxtil,tuM

L.

A ./\

\

RUDDER 5/32 fiCH Mftf tfutf

9/gz ff{cHMAxtiflJM

RUDDER c0r{TR0L TA8

efiriil3il iltii,T,,,lt

27- 20-2 CODE 1 Page 602

Rudder Control Tab CIea rances Figure 601

BB2-2539

Aug L/ 66 FrtntadIn U.S.A.


ac-gt

M A I N T E N A N C EM A N U A T

BULKHEAD

SUPPOR T

A T T A CBHO L T (4 PLACES'S B0LT --r'>-\p -.-J

DRIVE CRANK PUSHROD

vrEw A

PITOT LINE

VIEWB-B 2 7- 2 0 - 6 CODE 1 Page 202

Rudder Throw-Limiter Actuator Linkage fnstallation Figure 201

and

B B 2 - 1 0 7B4

Aug I/66


DC.SI M A I N T E N A N CM EA N U A T ROD 14. PISTON

S T O PH O O K I3. HOOK

5 . P U S H R O D vlEW

A-A

I6.

S T O PS C R E W

LIMITER BE L L O W S

t3. H00K

S T O Ps O L T L2. SPRINGS

5. PUSHROD

9. SToP 3. CRANK

4 . BOLT 6. PRESSURE I NL E T

BELLCRANI(

1. BOLT

IO. TURNBUCKLE V I E WA

2. PUSHRoD II.

R t GP t N( R P - l )

S E R R A T EW DASHER

Actuator Rudder Throw-Limiter Linkage Adjustment Figure 202 Aug L/ 66

P r i n t e di n U . S A

BB2-1004C

and

2 7- 2 0 - 6 CODE I Page 203

D O U G IA S AIR C R A FTC O., IN C .

DC.S' MAINTENANCE MANUAT

I\,r

vnw A POWER RUDDER MECHANISM

l--

-\

v|lw B TAB LOWER RUDDER HINGE

\

Yrrwc RUDDER TAB

)€

HINGE ffYPICAL) r

v|lwD

RUDDE R HINGE (TYPICA L} BB2-76c

27-20-8 CODE1

Page q06

Rudder and Tab Lu bri cat i on Chart Figure 402 (Sheet 1) Aug I/66

PrinlcdinllSA

D O U G L A SA IR C R A FTC O., IN C .

DC.9 }IAINTENANCE 'IAANUAL

-<

CO NT ROTLA BS E C T O R

ELEVATOR

C O N T R OTLA B PUSHROD TORQUETUBECRANK

v

,I

H

FOLLOW U P E LE V A TOR PUSHROD

i\t,

FOLLOWUPBALANCELINK CONTROLVALVE PUSHROD HORIZONTAL STABILIZER

VALVE COIITROL

ytrw A t B 2-969A

27-30-0 CODE 1 Page 10

Elevator

Power Control Figure

Followup 4

Printad in tlS A

l"lechanism Aug L/66

D OU GTA SA IR C N A FTC O., IN C .

DC.9

TAANUAT MAINTENANCE

TAB DOWN NEUTRAL

RETURNPRESSURE I N L E TP O R T

ELEVATOR TABUP

PRESSURE O U T L EP TORT SY ST E M PRESSURE I N L E TP O R T

!1

A \/

PRESSURE S Y S TE M I N L E TP O R T I' PRESSURE I O U T L EP TORT ll R E T U RPNR E S S U R E I II I I N L E TP O R T ttl

ll

SPRING

BB2-965A

SECTIONA-A

Elevator

Power Control Valve Figure 5

Aug l/ 66

P r i n t e d i n i - JS A

Cutaway

'27-30-0 C O D E1 Page I t


DC.S' fr1 AIN T EN A N C E MA N U A T

NOTE: ALL CLEARANCES ARE FORFAIRED ( N E U T R AP L )O S I T I O N .

9 / 3 2 I N C HM I N I M U M L 3 / 3 2 I N C HM A X I M U M

9 / 3 2 I N C HM I N I M U M L 3 / 3 2 I N C HM A X I M U M

5/B INCHM I N I M U M 7/8 IN C HMAXIMUM 7 / 1 6 I N C HM I N I M U M 9 / T 6 I N C HM A X I M U M L T / A I N C HM I N I M U M L 3/8INCH MAXIMUM

HORIZONTAL S T A B I LI Z E R 7/32 INCHMINIMUM L I/3 2 IN C HM AX I MU M

ELEVATOR r / 1 6 I N C HM I N I M U M 3 / T 6 I N C HM A X I M U M 7 /3 2 IN C HMIN IM U M L L / 3 2 I N C HM A X I M U M

5E CT I O NA - A

I.TGEAREDTAB

1 / 1 6 I N C HM I N I M U M MAXIMUM 3/T6INCH f:=---,

(t \J \

\ \_/' ELEVATOR

t(

Lf "l-) t\

\ --\

\\

\

E L E V ATTgORR

I coNTRoLTAB

r/16 l N cHMIN IMU M 3 / I 6 I N C HM A X I M U M

sEcTtoN c-c

1 / 1 6 I N C HM I N I M U M 3/L6lNcH MAXIMUM

SE CT I O NB - B

2 7- 3 0 - 0 CODE I Page 602

Elevator,

B 8 2 - l1 3 6

Control

Tab, and Geared T a b C l e a r a n c e s F i g u r e 60 I Aug I/ 66

O O U G L A SA I R C R A F TC O . , I N C .

DC.9 M A T N T E N A N CM EA N U A T

HINGE N0. 6

/ / -

HINGE }IINGE HINGE N0. 5 N0.3 N0.4

.-

,/

/

S T A B I L I ZRE 7 R E A RS P A R FtTTtNG - -.-.\.- -

-^. - z r ,'Ol \ELE'ATo*\-

\ \Jrr'idErub'. z

N./

ELEVATOR HYDRAULTC A C T U A T I N GC Y L I N D E R

/

/

,,,4.

I,BOLT

\

\

) )

ELEVATOR FRoNTS P A R r-.

tx :( : " - ' .

l.'

EYEBOLT 2. NUT

FS---

$:-_

DAMPER

F\ A{,/

t\

VIEW A

K..\<.4

HINGE B R A CK E T

VIEW B T Y P I C AALT E L E V A T O R H I N G ENSO .3 T H R O U G 6H

GEAREDTAB PUSHROD

GEAREDTAB F I T T IG N

-1 I

)

a

E LEVA TOII

I

LINKS

L 3. BOLT

vrrw C T Y P I C A LI N B O A RADN D O U T B O A REDN D SO F G E A R E IDA B S

2 7- 3 0 - 2 CODE 1 P a g e 4 02

Elevator Figure

40l

Installation (Sheet f )

O,i^r-'.|;^llQ

A

BB2.I04BB

Aug L/66


EC.9

MANUAT MAINTENANCE

(

E L E V A T OFRO L L O W U P PUSHROD FOLLOW UBPA LA N C E LlNK

@@

FITTING ELEVATOR

C O N T R OT LAB PUSHROD

TORQUETUBE E N DF I T T I N G

\@ VIEW A

BB2.LI37 A

Instal lation E I evato r F i g u r e 4 0 1 (Sheet 2l Aug L/ 66

P r i n i e di n U . S . A

27-30-2 CODE I Page 403

AIRCTAFT CO., INC. DOUGTAS

oc-s,

TAAINTENANCE 'ITANUAL

(

- -.-\ \ \---

- ---

VIEW A REMOVE TWOSCREWS AT EACHHOISTATTACH POIilTAI{DATTACH FITTIN G W ITHA N 4- 10 B OLTS

ELEVATOR

N OT E :

t . SU IT AB LFEO RIN ST A L L A. TIONANDGENERALHANDLIT{G OF LEFTORRIGHT EL E VA T O R .

2 . STOWCEt.ITERCABLEWHEN U S EDF ORL IF T IN G EL E VA . TOR. L O N G E ST C A BL ET O 3 . A T T AC H IN B O A RHDOIS TPOIN T .

BB?-e99A

Elevator

Sling Figure

Installation 402

Aug L/ 66


27-30-2 CODE I Page 40 5


DC.S' M A I N T E N A N C EM A N U A T

4

K lr c

4

rr

B

ELEVATOR

vtEw A ELEVAIOR INEOARD H IN G E vrEw B ETTVATOR HI NGT (ryPICAU

3 vtEw C HYDRAULI C POWER BOOST CNINDER 2 7- 3 0 - 2 CODE 1 Page 408

BB2.75C

El evator Chart Lubrieation Figur e 403 (sheer 1) Aug L/ 66

Printar{

in ll (

A


DC.9 MAINTENANCE MANUAL

VIEWA G E A R E DT A B

(TYPtCALI €

C O N T R OTLA B

3

;r

GEAREDTAB

vtEw B GEARED TAB (TYPICAL)

vtEw D TABHINGE (TYPICAL) vrrw C C O N T R OTLA B I N B O A R D H I N G E( T Y P I C A L ) BB2-18278

27-30-2 CODE I Page 410

Elevator

Lubrication Tabs (Sheet I) 4 0 q Figure

C h ar t Aug

l/ 66


DC.9 MANUAT AAAINTENANCE

13. CONTROL VALVE

I.

C O N T R OCLA B L E SECTOR

2. ELEVATOR CONTROLTAB PUSHROD

1 5 . GEAREDTAB

5.

P US H R O D

C O N T R OTLA B

R I GP I N H O L E S( R P - 4 )

6, JAMNUTS

14. BOLT

C O N T R OVLA L U E P USH R O D

4 G]/32'.)

8. BOLT

INCHES

10. BOLT 9.

T2. FOLLOWUP BALANCE LINK

E LE V A TOR FOLLOW U P P USH R O D

BOLT

BB2-2LI4

27-30-2 CODE 1 Page 502

Adjustment Elevator Figure 501 Aug


L/ 66


DC.ST M A I N T E N A N C EM A N U A T

NOTE: A L L C L E A R A N CA ER S EF O RF A I R E D ( N E U T R AP L }O S I T I O N .

-t

tlI

9 / 3 2 I N C HM I N I M U M L3/32INCH MAXIMUM

9 / 3 2 I N C HM I N I M U M MAXIMUM L3/32INCH

5 / 8 I N C HM I N I M U M 7 / 8 I N C HM A X I M U M 7 / 1 6 I N C HM I N I M U M 9 / I 6 I N C HM A X I M U M L I / 8 I N C HM I N I M U M L 3 / 8 I N C HM A X I M U M

HORIZONTAL STABILIZER 7/32 INCHMINIMUM L L / 3 2 I N C HM A X I M U M

EL E VA T O R 1 / 1 6 I N C HM I N I M U M 3 / T 6 I N C HM A X I M U M 7 / 3 2 I N C HM I N I M U M L T / 3 2 I N C HM A X I M U M

sEcnoN A-A

GEAREDTAB

1 / I 6 I N C HM I N I M U M 3 / L 6 I N C HM A X I M U M

EL EVA T O R

tr\

lrl (t

ELEVATOR

LfcoNTRoL

'\ \ \-----\

\

TAB

\ \---

1 / I 6 I N C HM I N I M U M 3 / L 6 I N C HM A X I M U M

sEcnoN C-C

r/r6 INcHM I N I M U M I/ 3 / 1 6 I N C HM A X I M U

sEcnoNB-B 2 7- 3 0 - 2 CODE I Page 602

B B 2 - t1 3 6

Elevator,

Control Tab, and Geared Tab Clearances Figure 60l Aug L/ 66

P r i n t c r {i n t i S A

OOUGIASA|RC,

oEA"" A,IAINIENANCE

fNc'

iE r.rUAt

\:

R I GP I NH O L E S (RP-4)

LEFTELEVATOR

a

40

3. cor{TRoL P U S H R OD 5. E Y E B OLT

6. Htf{cE

t t

I

/)A

a

'\\) -oO\

I l

t. aor-rltz(

7. 80LT

4. i'lur \

a

2. C R A N K FTTTII {G

LEFT CONTROLTAB

vtrw A ELEVATOR CONTROLTAB

ELEVATOR

\7-lz,l6 tNcHMtNtMulr4 3/16 rrucHuAli'la"uiii .zi.

vttw A_A 27-30-3 CODE I Page 202

EIe va tor

ll-

i3iillil8il illyl#.jH vfEw B-B

Control Tab fnstallation Figure 20L

IfIJlitrBB2-9668

Aug I/66 P r i n f e di n U . S . A


DC.SI MAINTENANCE MANUAT

VIEWA G E AR E D T AB

(TYPtCAL) o

C O N T R OTL A B

3

;r

GEAREDTAB

vtEw B

GEARED TAB (TYPICAL}

vtEw D TABHINGE (TYPICAL}

vrsw C C O N T R OTLA B I N B O A R D H I N G E( T Y P I C A L ) BB2-t8278

27-30-3 CODE 1 Page 204

Elevator

Lubrication Tabs Figure 202 (Sheet 1)

Chart Aug

D.;^r6,{i^llqA

L/ 66



4. I.

ITIUT

E Y EB OLT 3. QR,qrur:

rTIilG

BOLT

{ux I

\ -:(

.@9

o')

GEAREDTAB

\-(.q)

3 . CRANK FITTING 4 .N U T

,.1, BoLT \*

oo)

6,

BOLTS

(./-/'a

-/ 5. EYBOLT

ELEVATOR (LOW E R S U R FA C) E

f,ilfi*t8o*t

@\ REMOVABLE FAIR I NG

ELEVATOR AREDTAB -

E LE V A TOR f :.

ll |r--

,/

L / L 6 I N C HM t N t M U M 3/16IN OHMA X IMU M

e/32INCH M|N|MUM L 3 / 3 2 I N C HM A X I M U M

vtEw A-A

2 1- 3 0 - 4 CODE I Page 202

Geared

Tab I nstallat Figure 20L

vttw B_B ion

8,82-9678

Aug L/ 66



VIEWA G E A R E DT A B

(TYPTCAL) o

;r

GEAREDTAB

vtEw B

GEARED TAB (TYPICAL}

vtEw D TABHINGE (TYPICAL) C O N T R OTLA B I N B O A R D H I N G E( T Y P I C A L ) BB2-18278

27-30-4 CODE 1 Page 204

Elevator

Tab Figure

Chart Lubrication ( S h e e t 1 ) 202 Aug L/66


DC.S' M A I N T E N A N C EM A N U A T

HORI Z O NT A L STAB I LI Z E R R EA RS P A Rl \

N0, 2 Hll'lGE

\

a--\\ ,^"rH LATE 3 . M O U N T I NPG

vrEw A

BB2-9688

2 7- 3 0 - s CODE I Page 2O2

Elevator

Damper I nsta I la ti on Fi g u r e 2 0 1 Aug L/ 66


DC-9 M A I N T E N A N C EM A N U A T

ELEVATOR

VIEW A

TLEVATOR INBOARD H IN G E VIEW B

EUVATOR HI NGE (ryPICAU

vtEw C

27- 30-B CODE I Page 204

C HYDRAULI POWER BOOST CYLI NDER Lubr ication Chart Elevator Figure 202 (Sheet 1)

BB2-75C

Aug L/66

P r i n t e di n U S . A


DC.9 frTA IN TE N A N C MA E NUAT

5.

(4)

Connect electrical box and actuator.

(s)

Close two primary longitudinal trim circuit breakers and trim citcuit and alternate three autopilot longitudinal breaker panel. breakers located on upper main circuit

(6)

Check alternate longitudinal Inspeetion/Check) .

Removal/Installation A.

connectors to transformer-rectifier Safety connectors with lockwire.

tr im a ctuator

motor

(see

Trim Gearbox

Lonqltudinal

Remove Gearbox (1)

breakers and open two primary longitudinal trim circuit trim circuit longitudinal three autopilot and alternate breaker panel. breakers located on upper main circuit WARNING: TAG AND SAFETY CIRCUIT BREAKER,S.

(21 Remove primary paragraph

trim

longitudinal

aetuator

motor

(see

,r,

3) .

z4

43

@

o

HORIZON STABTLI

RESTRAI FIXTURE

,.t',, r',/

VERTICA STABILIZ

B B 2 -L 75 ? A

Horizontal

Stabili zer Restraining Installation Figure 402

Aug L/66

O,i^r6,{

i^

| | q. A

Fixture 27-40-1 CODE 1 Page 405



\

<-4i

I

t t ' -<-I 1 'r./ \

.,/

,tt,

4: 1/, A'

ACCE SS DOORS

vrrw A

7 ll,;

HORIZONTAL STABILIZER H IN G E

,i';*'

\t{ {(

,r\ /N:

tl'

\r

Longitudinal

27-q0-1 CODE 1 Page 408

5 vtrw A

BB?- ,;)A

Trim Actuating t"lechanism Lubrication Chart Figure 403 (Sheet f) /rt-r.i L/66


DC.SI MANUAL MAINTENANCE

F I X E DV A N E \ /

tr-F-,

F O R W A RVDA N E

/ (

/ T O R S I OB NA R

TORQUETUBE

S U P P O RLTI N K

BUMPER

AFTVANE \

\ STOP I

W I N GF L A P

A F TV A N EC A B L ES Y S T E M

POSITION FORWARD ANDAFTMOVABI.T IN EXTENDED VANESSHOWN BB2-r050

2 7- s 1 - 0 CODE I Page 2

Flap

Movable Vanes Figure 1 Aug L/66


oc-sl

M A I N T E N A N C EM A N U A T R O L L E RS T O P

F L A PB U SC A B L E S

C A B L EP U L L E Y S

FLAPTRACK CARRIAGE

3. BOLT (4PLACES)

vtEw ,/CABLE

RETAINER FORWARD MOVABLE VANE

VIE W A

c l'/

VANE

N GF L A P

| 4.BoLT

WINGANDFLAPSHOWN FIXEDVANE

5 . H I N G EB O L T

(3 P LA C E S ) PUSHROI) 2. BOLT H I N G ET I P F A I R I N G

vttw c-c B B 2 - 2 7A 7

27-s1-1 CODE 1 Page 402

Flap

Installation F i g u r e 40I Aug L/66


oc-9

M A I N T E N A N CM EA N U A T

r \"'t

vrrw B VANETRACK ROLLER SUPPORT

BB2.728

27-51-1 CODE 1 P a g e 4 10

Chart Flaps Lubr ication Figure 404 (Sheet 1) Aug


L/ 66

D O U G IA S A I R C R A FTC O., IN C .

oc-9,

TIAINTENANCE MANUAT L6 t/r6 & L/4n NCH_r 7 L/4 f.tl./4'.) INCH

IIIIE'

M{ASRK E D DIMENS I O T * AP P LYT OF ULL TH US OFVANES SPAITI LI NK S UP P O RT

* o.r z5(i$'|f!lrrucrr EYEBOLTS

- FI.APSRETRACTED} (LOOKING OUTBOARD ENDOFVANES INBOARD L7 L/8 ltL/4 ) INCH 7 3/4 ftL/4 ) |NCH

2.WASHERS

BUMPER

BOL T 7.WASHERS

EYEBOLT

- FLAPSRETRACTED) (LOOKING INBOARD ENDOFVANES OUTBOARD BUMPER

SHIMS LAMINATED

6 .S T o P

,/'

FLAP\

Y

ROLLER FITTING

./,'

O U T B O A RTDR A C K

BB2-624A

27-s1-1 CODE 1 Page 502

Fl aps Figure

Ad jus t ment 501 (Sheet 1) Aug L/ 66

PrintedinUSA



TRACK OUTBOARD

4 . A D J U S T M EN NU TT TURNBUCKLES A C C ES D S OOR W I N GF L A P

BB2-6234

Flaps Figure

Adjustment 501 (Sheet 2l

Aug L/ 66

Printed in U.s.A.

2 7- 5 L - L CODE 1 Page 503


DC.9 MA IN T E NA N C EI,IA N U A I

3 / B I N C HM I N . 5 / B I N C HM A X .

L

I

r

5 / 8 t N C HM t N . 7 / 8 t N C HM A X .

I c0vER

\.

WING TRAILING EDGE

FAIRING

AILERON

MIN. r/2 INCH 3/4 INCHMAX.

hl

M O V A B L EV A N E FORWARD

\ FLAP

MOVEABLEVANE

FAIR ING

Jc

FAIRING

D

\ 1l

tl

'l l

tr/

'

I N C HM I N . I N C HM A X .

rH

l/

,-!

\-t

AI LERON FAIRING

HORN

P E R M I S S A B LM EI S M A T C H 1 / 4 I N C HU P O R D O W N

21-sl-1 CODE2 Page 602

Flap

VIEWE-E and Movable Vane Clearances Figur e 6 01 (Sheet 1)

FUSELAGE

B B 2 - 2 0 6B 7 Aug

L/ 66

O O U G T A SA I R C R A F TC O . , I N C ,


L6 I/16 ftL/q IN C H EA ST OU TB O ARD ENt ) L 7 L / 8 ( * , t / 4 ) t N C H EAST I N B o A REDN D

7 3 / 4 ( t T / $ I N C H EAST I N B O A REDN D AT O U T BOA RED ND 7 I / 4 I T I /4 ' I IN C H ES

WING T RA I L II{ G EDGE FLAP

LAGE PANEL

0 . r 2 5 ( + 0. t 2 5 , - 0 . 0 6 3 ) t N c HSE A T FOR W A REDN D 0 . 1 0 0 ( + 0. t 2 5 , - 0 . 0 6 3 )t N c H E s A T V A N ET R A I L I NEGD G E

FORWARD MOVABLE V A NE

0.100(+0 .t25,-0.063) INCHES

AFT MOVABLE V AN E

r / 8 I N C HM I N r/4 INCHMAX

VftW A-A FILLET

FAIRING

VltW D-D HORN

5 / 1 6 | N C HM t N 7/16 INCHMAX

i/df,*,-r/8)

-/ / F L A PU P P E R S U RACE F

FAIRING

FILLET

FILLET

vltW C-C

vftw B-B

B B2- 2068

Flap

and Movable Vane Clearance F i g u r e 6 0 1 ( Sh e e t 2 l

Aug L/66

27-sL-L CODE2 Page 603

P r i n f c di n U . S . A

D O U G L A SAIR C R A FTC O., IN C .

DC.9 MAINTENANCE MANUAT

F I X E DV A N E INBOARD

FIXED VANE CE NT E R

F I X E DV A N E OUTBOARD

AITACH P ON I T

F I X E DV A N E A T T A C HP O I N T S (12 PLACES)

1 2 3 4

FLAP

5 6

3/8 (+L/8, -r/L6) tNCH C L E A R A N CBEE T W E E N V A N EA N DF I X E D S T R U C T U ROER S P O I L E R THROUGHOF UU T L LF L A P TRAVEL

7 8 9 FLAP

IO lt

12

F I X E DV A N E

DIMENSION A

3 . 1 2 8 ( r 0 . 1 2 4| 2 . 8 6 6( r 0 . I 1 3 ) 2 . 6 9 6 ( t 0 . 1 0 6)

2 . 4 5 9 ( r 0 . 0 97 ) 2 . 4 5 5 ( r 0 . 0 9 7) 2 . ) 1 6 ( t 0 . 0 9 2) 2.177(r0.086) 2 . A t6 ( r 0 . 0 9 2) 2.075(t0.082) 1 . 9 6 I ( t 0 . 0 7 8) I . 8 5 0 ( r 0 . 0 7 3) 1 . 74 7 ( t 0 . 0 6 9)

I

I \

34' / ,l/ vtEw A

( T Y P I C A LI 2 P L A C E S )

,/ B 8 2 - 17 9 4 B

2 7- 5 1 - 1 CODE 2 Page 604

Flap

Fixed Vane Clearan ces Figure 602 Aug L/66

DOUGIAS AIRCNAFTCO., INC.

oc.g

,UTAINTENANCC'IIANUAI.

FORWARD MOVABLEVANE

3. BOLT 5 . EYEBOLT

,) // / I

I

2. BOLT

, MOVABLEVANE

lo

WINGFtrAP

882-257L

2 7- 5 L - 2 CODE1 Page 402

Flap

Movable Vanes Insta 1la ti_on F i g u r e 4 0 1 (sheet 1) Aug L/66

D.i^,^Ai^tlq/1

O O U G T A SA I R C R A F TC O . , I N C .

DC.SI M A I N T E N A N C EM A N U A L 6. BOLT

NUT

FLAP

VIEW B

S U P P O R TL I I { K S

CENTERLINES OF INBOARD A N DO U T B O A R SD UPPORT L I N K SM U S TB EI N D E X E D T OT O R Q UTEU B EW I T H I N 2 0 O FE A C H OTHER.

vtEw c Flap Aug

Movable Vanes Installation 40I (Sheet 2) Figure

L/ 66


BB2-2s73 27-5L-2 CODE 1 Page 403



L6 L/L6 (t 1/4) INCH

----__ @, MARKED DIMENSIONS THUS* APPLYTOFULL SPANO FV A NE S

ffii1;r'.bH}ff

S U P P O RLTI N K

* o.lzs[1$'$.2!]rnor EYEBOLTS

- FLAPSRETRACTED) (LOOKING OUTBOARD ENDOFVANES INBOARD L 7 t/8 (t1 l4 ) l N c 7 3/4 $ L/4 ) rNCH

S U P P O RFTI T T I N G

2.WASHERS

BUMPER

7 .W A S H E R S E Y E B OLT I

lI N u D KK NEB' uOAAK R Tl KRAAt "C

--___

I

-

. FLAPSRETRACTED) (LOOKING INBOARD OUTBOARD ENDOFVANES BUMPER

LAMINATEDSHIMS

-\-

TR OU TB OA R D ACK BB2-624A

27 -5L- 2 CODE I Page 502

Flap

Movable Figure

Vanes Ad j ustment 501 (Sheet 1) Aug I/66

Prinfad in tl S A

D O U G T A SA I N C R A F TC O . , I N C .

DC.SI

MAINTENANCE MANUAT

6 . ST O P

TRACK OUTBOARD

r( + rv/ 85)/ 8

tNcHES

4 . A D J U S T M EN NU T TURNBUCKLES AC C E SS D OOR WINGFLAP

BB2-623A

Flap

Aug L/66

Movable Figure

Vanes Adj ustment 501 (Sheer 2l


27-51-2, CODE 1 Page 503


DC.SI

M A I N T E N A N CMEA N U A T FLAP IyIOVABLE VANES -

l.

Inspection/Check A.

Flap

Movable

I NSPECTTON/CHECK

Vanes

Check Vane Clearances (1)

With flaps as follows:

fully

retracted,

check

vane elearances

that

are

(a)

Between surface inch.

(b)

Between lower surface of forward movable vane trailing edge and upper surface of aft movable vane, 0.100 (+0.t.25, -0.063) inch.

(c)

Between lower surface of aft movable vane and upper surface of flap, 0.125 (+0.L25, -0.063) inch at forward end, decreasing to 0.100 (+0. L25, -0.063) inch at vane trailing edge.

lower surface of wing trailing of forward movable vane, 0.100

edge and (+0.L25,

upper -0.063)

16 L/L6 ( ! I/4) IN C H EAST OU TBO ARD END L7 L/8 ( TL/4) IN C H EAST IN B OARD END

WING

FORWARD MOVABLE VANE AFT

MOVABLE VANE 0.100( t0.L25,I N CH E S

0.063)

0 . r 2 5 ( + 0 . 1 2 5, - 0 . 06 3) l N cH E S A T FOR W A REDN D 0 . 1 0 0( + 0 . 1 2 5 ,- 0 . 0 6 3) l N c H E s A T V A N ET R A I L I NEGD G E

SECIION

A-A BB2-2r09

Movable

Vane Clearances Figure 60I

Aug L/66

P r i n t e dI n U . S . A .

27-5L-2 CODE 1 Page 601


DC.gT

MAINTENANCE lrtANUAt

W A S H E R IS ,M I N | M U M , (SEENOTET) 5 MO(IMUM

WASHERS 1 ,M I N I M U M , (SEEI{OTE1) 5 MAXIMUM

,/ YllW A-A NOTATED 18OO}

NOTE: 1. ADJUST VANETOWIiIGCLEARAT{CE T WASHERS. B Y P LA C E ME I{OF 2. ADJUST CLEARAfTCE VAiIETOWIT{G (ORREMOVII{G) WASHERS BY ADDING FR OMU N D E C R LE V IS .A N E QU A L A MOU NOF T W A S H E RMU S S TB E R E (ORA OD E DU)N D E I{ MOV E D R U T. PATCH t{0TE:BOI{DMETALPATCHES TOVAI{E8 PLACES

WASHERS,2 MiltilMUM, 5 M A X I M U M( S E EN O T EI )

W A S H E R S ,U4I I I D E R T{U T A N D4 U N D E R CLEVISO{ORMAL) S E EN OTE2

YIEWC-C

VIEW D BB2-t958

27-51-3 CODEI Page 202

Flap Fixed Vane Figure

fnstaLlation 201 Aug L/66

DOUGTAS AIRCIAFTCO., INC.

DC.g' AAAINTENANCE 'VIANUAL

tt-4 FIXEDVANE CENTER

FIXED VANE OUTBOARD

ATTACH POINT I 2

3

FLAP

F I X E DV A N E A T T A C HP O I N T S (i2 PLACES)

3/B (+L/8, -r/L6) INCH BE ETWEEN CLEARANC V A N EA N DF I X E D S T R U C T UO RR ES P O I L E R UTL LF I - A P T H R O U G H OFU TRAVEL FLAP

FIXED VANE

DIMENSION A

3 . 1 2 9( r 0. 7 2 4| 2 . 9 6 6 ( * 0 . 1 1 3) 2 , 6 8 6 ( t 0 . 1 0 6I

4 5 6 7 8

2 . 4 5 9t r 0 . 0 9 7)

I

2 . 4 5 5 ( r 0 . 0 9 7)

2 . 3 1 6( r 0 . 0 9 2) 2.177(t0.086)

2 . 4 7 6( r 0 . 0 9 2 )

l0

2.075(10.082) I . 9 6 1 ( r 0 . 0 7 8)

tt

1 . 8 5 0( r 0 . 0 7 3)

12

1 . 74 7 ( t 0 . 0 6 9)

-a .- . - -'-,

34' ) VIEW A ( T Y P I C ATL2 P L A C E S ) BB2-17948

Flap

Fixed

Vane Figure

C learances 202

Aug L/ 66


27-s1-3 CODE I Page 2O3


DC.9 M A I N T E N A N C Ei A A N U A L

WING

FLAP

vtrw B ROLLER SUPPORT VANETRACK

vrEw A CARRIAGE

2 B B 2-7' 3 )

27-51-s CODE I Page 404

Flap

Track

Lubrica tion Carr iage Figure 402 (Sheet 1)

in U.S.A Printed

Chart Auq

I/ 66


DC.SI M A I N T E N A N CMEA N U A T S T O PB O L T

HINGE BRACKET P I S T O NR O D

A T T A C HB O L T

\M

v

1t'

Vlu l-I li

i

tD

PUSHROD JA MNUT

vtEw A vfEwB FI LLET

FI-AP

UPPER S U R F AEC

B L O C K\

vtEw

FLAP FOLLOWU P CABLES F L A PC O N T R O L C A B L ES F L A PB U S TURNBUCKLE S T O PB O L T o' 0

B U SC A B L E SD SHROU FLAPTRACK

F L A PB U S T UR N B U C K L E

vtEw Flap

Actuating

Cylinder Figure 201

Aug I/ 66

F r i n t e di n L l 5 A

Adjustment

D

BB2-I0498

2 1- 5 2 - 0 CODE 2 Page 203

D OU GTA SA IR C N A FTC O., IN C .

DC.g'

MAINTENANCE MANUAI A F TH II{ GE PIN

IDLER LINK

?-/ .-

-/

ATTACHPIN

Y9 @

DRIVELIIIK

VALVE Lt]iIK P USHRO D TRUI{l'll0N FLIGH T S P OILE R ACTUATOR

-/ REACTIOI{ BOLT

((

ffi'^

CAM

TORSIONBAR ALIGNMET{T GROOVE

I

REACTIONLEVER

0.343t t O.OrS) tNCH--+ll* HYDRAULIC Llt{Es

vrEw B

o)

HYDRAULIC FITTII{GS

vrrw A Flight Aug L/ 66

Spoi.ler

Actuator Figure 401

P r t n l e di n U . S . A .

BB2-t0I7C

Installation

27- 6L- 2 CODE 1 Page 403

D OU G T A SAIR C R A FTC O., IN C .

DC.9 MA N U A T AA AIN T EN A N C E

ROLLER

HERMETIC S W ITC H ELECTRICAL CONNECTOR

\,2\

Ye)

,r%

SCREW B PLACES)

t I

WASHER

vtrw A BB2-2030

2 7- 6 2 - 6 CODE I Page 202

Ground Spoiler

Takeoff Warning Switch Installation Figure 20L Aug L/66

PrintedinUSA

D O U G I . A SA I R C R A F TC O . , I N C .

DC.9 M A I N T E N A N C EM A N U A L

F R O N TS P A R

L E A D I N GE D G E S L A T DR I V E

H Y DR A U L I C C Y L I N DR ES

ICE PROTECTION T E L E S C O P I NDGU C T

L E A D I NE GD G E SLA TS

L E A D I [ i GE D G E

I C EP R O T E C T I O N DUCT BB2-2962

27-80-0 CODE 1 Page 2

Lift

Augrnenting

Wing Figure 1

Slat

System Aug


L/ 66


DE.SI M A I N T E N A N C EM A N U A T

I

IDLERTRACK

VIEWA

3. PINS

4. BOLTS

v|lw B IDLER TRACK

vltw D

RETAINERS

tu 5 . BOL T

BOLTS

WASHER ADJUSTMENT BUSHINGS

VIEW E

882-3008

27-80-1 CODEI Page 402

Attach Slat-to-Track 401 Figure

Har dwa re

Aug L/ 66


DC.g

MA IN TE N A N C EMA N U A T

+'+.-

AA

L/2 ft L/Ld INCH(TYPTCAL)

) /4ftt/8 ,-l/32) tNCH / /

0.062-0.125

4 ( + /8 , - t / L 6 ) CH

-.-'tt,/

-c:13 /

V

J

/

I \J

F I X E DW I N G

VllW A-

vtrwc-c

A

\ Ft) IXED wll ING

M A X . M I S M A T C HB E T W E E NS I . A T S 0 . 0 1 5 I N C HR E T R A C T E D O" 0 6 2 I N C HE X T E N D E D ( E N T I R EP E R I P H E R) Y

1 I . F I X E DS T O P

0.0 T0 0.045 ilrcH, MA X IMU M

1 0 . A D J U S T A B LSET O P (EXTENDE )D

7. RIGGING SPACER

( 0 .r 8 8 l N c H )

\.

12. BOLT \ --...-.--13. LA TC HF| TT| NG

TR A C KD OOR

BB2- 3028

Wing SI at Aug

L/66

Cl earances fnstallation q02 Figure


27-80-t CODE I Page t{03

DOU GIA S A IR C R A FTC O., IN C .

DC.gI MAINTENANCE AAANUAT

N ACTUATING CYLINDER

r. BOLT

8. C R A i l K

3 . R O DE N D 7. JAMNUT

7. JAMNUT r. BOLT El{D 4. ROD

2. ACTUATING C Y LItID E R

10.sToP

5. DRUM

9. STOP BOLT

6 . G U A RP DI N

vEw A

BB2- 3010

Wing

S lat

Drive

t"lechanism Figure 502

Aug V66

P r i n t a di n U . S . A .

Ad justment

27-80-2 CODE 1 Page 503


DC-g M A I N T E N A N C EM A N U A T

(4) TURNBUCKLE

z

( 5 )T U R N B U C K L E EXTEND

B) TURNBUCKLE SL A T N O . 3

(?_)TURNBUCKLE

RETRACT

s r.-ATN0. 2

EXTEND EXTEND

RETRACT

(B)TURNBUCKLE

s ] - A TN 0 . 5

RETRACT (I) TURNBUCKLE (9) TURNBUCKLE S I - A TN O . 1 EXTEND ( 6 ) T U R N B UKCL E EXTEND S L A TN O . (7) TURNBUCKLE

vtEw c

?)

RETRACT

S L A TN O . 3

ADJUS T AB L E BRACKET

t& RETRACT

2't-80-2 CODEI Page 504

vrtw B Wing Sl at Cabl e System Figure

Ad j ustrnent

B B2-3009

503 Aug

L/66

DC9 - Control Surfaces OM

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