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DOUGTAS AIRCRAFT CO. , INC.
EC.9MAINTENANCE MANUAT
C H A P T E R 2 7
F L I G H T C O N T R O L S
P r i n f e d i n U . S . A
DOUGTAS AIRCRAFT CO. , INC.
DC.gM A I N T E N A N C E M A N U A L
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27-00CODE 3P a g e 2
H O R I Z O N T A L S T A B I L I Z E R
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DOUGTAS AIRCRAFT CO., INC.
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P r i n f e d i n t l S A
AILERON CONTROLWHEEL
DOUGTAS AIRCRAFT CO. , INC.
DC.SIMAINTENANCE MANUAT
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.ERON BUSBLE SYSTEM
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CONTROLTAB SECTOR
AILERON BUS SECTOR CONTROL TAB
TRIM TAB ACTUATOR
BB2- I I43 A
DOUGTAS AIRCRAFT CO. , INC.
DC.SIMAINTENANCE MANUAL
CONTROLCOLUMN
I . T U R N B U C K L E S
16 . ADJUSTMENTSCREWS
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Aug L/ 66
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DOUGTAS AIRCRAFT CO., INC.
DC.9MAINTENANCE MANUAT
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DOUGLAS AIRCRAFT CO. , INC.
DC.g'MAINTENANCE MANUAT
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ATTACH LONGEST CABLE TO OUTBOARDHOIST POINT .
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(2 ) Check tha t t r im tab push rod i s ad j us ted to L2 .4L2 ( t 0 . 010 )inches, measured f rom center o f a f t bear ing to center o fforward bear ing.
(3 ) Remove p lugs f rom s l i ng a t tach ho les and i ns ta l l s l i ng onupper sur face o f a i le ron.
(4) Move a i le ron wi th s l ing and ho is t to a pos i t ion above ands l i gh t l y a f t o f i ns ta l l ed pos i t i on .
(5) Pos i t ion damper l inks so they wi l l a l ign wi th damper crankson a i le ron when a i le ron is moved in to p lace.
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27-10-1CODE 1P a g e 4 0 q
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Aug L /66
DOUGTAS AIRCRAFT CO., INC.
DC.SIMAINTENANCE MANUAT
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DOUGTAS AIRCRAFT CO. , INC.
DE.STM A I N T E N A N C E M A N U A T
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DOUGTAS AIRCRAFT CO., INC.
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DOUGIAS AIRCRAFT CO. , INC.
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DOUGIAS AIICIAFT CO., INC.
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DOUGLAS AIRCRAFT CO., INC.
DC.9MAINTENANCE MANUAI
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27-20 -0CODE 1
Page 50 3
6 . P T S T o N
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Aug L /66
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Aug l /66
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DOUGTAS AIRCRAFT CO. , INC.
DC.9MAINTENANCE MANUAT
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A R UDDERPOWERVALVE
HYDRAULICS H U T O F F
C LOSED
Rudder Hydraul ic Power Shutoff ControlSystem Adjustment
F igu re 507
I I . C R A N K
3 . B O L T
4 . P U S H R O D
8 . R I GM A R K ( O N S E C T O R )
I O . G U A R D P I N( O N B R A C K E T A R M )
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OPEN
27 -20 -0CODE I
Page 5L7Aug L/66
Pr ln fcd in U.S.A.
DOUGIAS AIRCRAFT CO., INC.
DC.gIfrIAINTENANCE IAANUAL
T/4 INCH MINIMUMA T U P P E R E N DT/2INCH MAXIMUMAT UPPER END3 / L 6 I N C H M I N I M U MAT LOWER END7 /76 INCH MAXIMUMAT LOWER END
3i8 INCH MINIMUMAT LOWER END5/8 INCH MAXIMUMAT LOWER ENDT/4 INCH MINIMUMAT UPPER ENDT/2INCH MAXIMUMAT UPPER END
1 3 / 3 2 I N C H M I N I M U M17/32INCH tr4AXtMUM
5/32INCH MINIiTUM9/32INCH MAXIMUM
7/8 INCH MINIMUML I /8 INCH MAXIMUM
--- M I N I M U MMAXIMUM
5/32INCH MINIMUML3/32INCH MAXIMUM
SECTION A-A
7/8 INCH MINIMUML L /8 INCH MAXIMUM
BB2-1814A
27-20-0CODE 1
Page 603
1/8 tNCH3/8 rNCH
SECTION B-B
Rudder and ControlFigure
Tab Clearances501
VERTICAL STABIL IZER
Aug L/66
RUDDER
DAMPERLINK
HINGE FITTING
RUDDERSTRUCTURE
EYEBOLT
COVER PLATE
VIEW ARUDDER HINGE POI NT (TYPICAL 3 PLACES)
DOUGIAS AIRCRAFT CO., INC.
DC.9MAINTENANCE MANUAT
H O I S TFIXTURE
FAIR INGS
VERTICALSTABIL IZER
RUDDER STRUCTURE
RETAINER
WASHER
BOLT (4 PLACES)
Rudder Instal lat ionF igu re 401
H0RlZ0l ' ITALSTABILIZER
TAB TORQUE TUBECRAt{K
BARREL I{UT
RUDDER DRIVETORQI.JE TUBE
BB2-9408
27 -20 -1CODE 1
Page 40 3
PUSHROD
STABILIZER STRUCTURE
FITTINGS
A u g L / 6 6
P r i n t e d i n U . S . A .
DOUGTAS AIRCNAFT CO., INC.
oc-9,MAINTENANCE IAANUAI
RUDDER SLINGMONORAIL.
------I
I . HOIST ING BRACKETS
Rudder SlingFigur e
A,ss emblyq02
3. HOIST CABLE
2 . SL ING CABLE
BB2-t436A
Aug L / 66
27-20-1CODE 1P a g e 4 0 4
Prinfsd in U.S.A.
DOUGLAS AIRCRAFT CO. , INC.
DE.9AAAINTENANCE MANUAT
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27-20 -1CODE 1Page q 06
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ytrw CRUDDER TAB
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BB2-7 6C
Aug L /66
o r i ^ r a i i n l l Q A
Chart
DOUGIAS AIRCRAFT CO. , INC.
DC.9, IAAINTENANCE AAANUAL
1 / 4 I N C H M I N I M U MA T U P P E R E N DT/2 INCH MAXIMUMA T U P P E R E N D3 / L 6 I N C H M I N I M U MAT LOWER END7 /L6INCH MAXIMUMAT LOWER END
3 i B I N C H M I N I M U MAT LOWER END5 /B INCH MAXIMUMAT LOWER END1 / 4 I N C H M I N I M U MA T U P P E R E N DI/2 INCH MAXIMUMA T U P P E R E N D
7/8 INCH MINIMUMT L / 8 I N C H M A X I M U M
L3/32INCHL7 /32INCH
M I N I M U MMAXIMUM
s/32INCH9/32INCH
M I N I M U MMAXIMUM
7/8 INCH MINIfuIUMI L / 8 I N C H M A X I M U M
1 / B I N C H M I N I M U M3/8 INCH MAXIMUM
- 5 /32 lNcH MINIMUML3/32INCH MAXIMUM
5ECTION A-A
SECTION B-B
27 -20 -LCODE 1Page 602
Rudder and Control Tab ClF igure 6 01
8 8 2 . I 8 1 4 A
A u g L / 6 6
VERTICAL STABIL IZER
P r i n t e d i n U S A
ea rances
DOUGI.AS AIRCRAFT CO., INC.
DC.E'iIAINTENANCE ftIANUAT
FORWARDFAIRING
27 -20 -2CODE 1Page 402
R U D D E RCONTROLTAB
LOWER HINGE EYEBOLT
CONTROL TAB CRANK
Rudder Control Tab Instal lat ionFigure 4 0 1
B82-9418
Aug L /66
- .-.-_/
AFT FAIRING
U P P E R H I N G EEYEBO LT
RUDDER
Pr in ted in U.S.A
DOUGTAS AIRCNAFT CO., INC.
DC.9TAAINTENANCE }IANUAL
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vttw BLOWER RUDDER TAB
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27 -20-2CODE IPage 404
BB2-76c
Aug L/ 66
P r i n l e d i n U . S . A .
Chart
DOUGTAS AIRCTAFT CO., INC.
DC.gMAINTENANCE MANUAT
SUPPORT FITTIITIG
FI-AT PI-ATE ALUMINUMOR STEEL AT LEAST0.L25 THICK
BUTT PLATE TO ALIGNMEASURING ROD WITHTOPS OF FI..AI{GEBUSHllt lcS
WASHERSPACER
WASHER
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4 . 0 0HES
VIEW BRudder Drive Torgue Tube
Instal lat ionFigure 202
/:,/ 4 4
RUDDER DRIVETORQUE TUBE
INDEX HOLE IN CENTEROF PI-ATE TO LOCATETUBING (DRILL HOLEO.OTO LARGER THAI{RoD S|ZE )
0 .3845 | l {CHDIAMETER(4 PLACES)
BB2-1835
27 -20 -3CODE 1
Page 205
4 . 0 0
Aug L/66
Itlea suri ng Tool
P r i n t e d i n U . S . A .
DOUGIAS AIRCRAFT CO., INC.
DC.S'AAAINTENANCE MANUAI
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27 -20-sCODE 1Page 202
Rudder DamperF igur e
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BB2-948
Aug L /66
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P r i n i e d i n U . S . A
DOUG| AS AtncnAFT CO., tNc.DC.SI
IAAINTENANCE MANUAT
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Aug L / 66
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27 - 20-2CODE 1Page 602
Fr tn tad In U.S.A.
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ATTACH BOLT (4 PLACES'S
DOUGIAS AIRCRAFT CO. , INC.
ac-gtMAINTENANCE MANUAT
SUPPOR T
D R I V EC R A N K
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P U S H R O D
vrEw A
VIEW B-B
27 -20 -6CODE 1Page 202
Rudder Throw-L imi ter Actuator andL inkage f ns ta l l a t i on
F igu re 201
B B 2 - 1 0 7 4 B
BULKHEAD
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P I T O T L I N E
Aug I / 66
LIMITERBELLOWS
6 . P R E S S U R EIN LET
DOUGTAS AIRCRAFT CO., INC.
DC.SIMAINTENANCE MANUAT
I 3 . H O O K
5 . P U S H R O D
STOP sOLT
L 2 . S P R I N G S
9 . S T o P
3. CRANK
vlEW A-A I 6 . STOP SCREW
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5 . P U S H R O D
4 . BOLT
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I O . T U R N B U C K L E
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2. PUSHRoD RtG PtN (RP- l )
I I . SERRATED WASHER
Rudder Throw-Limiter Actuator andLinkage Adjustment
Figure 202
BB2-1004C
27 -20 -6CODE I
Page 203
1 4 . P I S T O N R O D
STOP HOOK
Aug L/ 66
P r i n t e d i n U . S A
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DOUGIAS AIRCRAFT CO., INC.
DC.S'MAINTENANCE MANUAT
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27-20-8CODE 1P a g e q 0 6
Lu bri cat i on(Sheet 1)
P r i n l c d i n l l S A
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Aug I / 66
DOUGLAS AIRCRAFT CO., INC.
DC.9}IAINTENANCE 'IAANUAL
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CONTROL TAB SECTOR
v, I
Hi\t,
TORQUE TUBE CRANK
CONTROL TABPUSHROD
ELEVATOR FOLLOWUPPUSHROD
FOLLOWUP BALANCE LINK
ELEVATOR
HORIZONTALSTABIL IZER
CONTROL VALVEPUSHROD
27-30 -0CODE 1Page 10
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Elevator Power Control Followup l"lechanismFigure 4
t B2-969A
Aug L /66
COIITROL VALVE
P r i n t a d i n t l S A
!1
DOUGTAS AIRCNAFT CO., INC.
DC.9MAINTENANCE TAANUAT
TAB DOWN
ELEVATORTAB UP
RETURN PRESSUREINLET PORT
NEUTRAL
PRESSUREOUTLET PORT
SYSTEMPRESSUREINLET PORT
\ /
SYSTEM PRESSUREINLET PORT
I' PRESSUREI OUTLET PORTl lI I RETURN PRESSUREI I INLET PORTt t l
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SECTION A-A
Elevator Power Control Valve CutawayF igu re 5
A
BB2-965A
' 27 -30 -0
CODE 1Page I tAug l / 66
P r i n t e d i n i - J S A
DOUGTAS AIRCRAFT CO. , INC.
DC.S'f r1AINTENANCE MANUAT
N O T E :ALL CLEARANCES ARE FOR FAIRED( N E U T R A L ) P O S I T I O N .
7 /16 INCH MINIMUM9/T6 INCH MAXIMUM
L T /A INCH MIN IMUML 3/8INCH MAXIMUM
7/32 INCH MINIMUMLI/32 INCH MAXIMUM
ELEVATOR
7/32 INCH MINIMUMLL/32 INCH MAXIMUM
1 / 1 6 I N C H M I N I M U M3 / T 6 I N C H M A X I M U M
9/32INCH MINIMUML3/32INCH MAXIMUM
9/32INCH MINIMUML3/32INCH MAXIMUM
5/B INCH7/8 INCH
M I N I M U MMAXIMUM
r/16 INCH MINIMUM3/T6INCH MAXIMUM
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SECTION B-B
27 - 30 -0 E leva to r ,CODE IPage 602
Control Tab, and GearedF igu re 6 0 I
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Aug I / 66
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27 -30 -2CODE 1Page 40 2
B B 2 . I 0 4 B B
Aug L /66
H I N G EN 0 . 6
H I N G E } I I N G E H I N G EN 0 . 3 N 0 . 4 N 0 . 5
7 REAR SPAR
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GEARED TABP U S H R O D
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MAINTENANCE MANUAT
DOUGTAS AIRCRAFT CO., INC.
EC.9
(ELEVATOR FOLLOWUPP U S H R O D
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FOLLOWUP BALANCEL l N K
TORQUE TUBEE N D F I T T I N G
ELEVATOR F ITT ING
CONTROL TABPUSHROD
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Insta l la t ion(Sheet 2l
BB2.LI37 A
27 -30 -2CODE I
Page 40 3
\@
Aug L/ 66
P r i n i e d i n U . S . A
DOUGTAS AIRCTAFT CO., INC.
oc-s,TAAINTENANCE 'ITANUAL
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\ - - -\--- -
ELEVATOR
NOTE:
SUITABLE FOR INSTALLA.TION AND GENERAL HAND-LIT{G OF LEFT OR RIGHTELEVATOR.
STOW CEt.ITER CABLE WHENUSED FOR LIFTING ELEVA.TOR.
3. ATTACH LONGEST CABLE TOINBOARD HOIST POINT.
VIEW A
REMOVE TWO SCREWSAT EACH HOIST ATTACHPOIilT AI{D ATTACHFITTING WITH AN4-10BOLTS
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Sl ing Ins ta l l a t ionF igure 402
BB?-e99A
2 7 - 3 0 - 2CODE I
P a g e 4 0 5Aug L/ 66
Elevator
P r i n t e d i n U . S . A
DOUGTAS AIRCRAFT CO. , INC.
DC.S'M A I N T E N A N C E M A N U A T
ELEVATOR
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27 -30 -2CODE 1Page 4 08
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27 -30 -2CODE IPage 41 0
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GEARED TAB
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DOUGTAS AIRCRAFT CO. , INC.
DC.9AAAINTENANCE MANUAT
1 3 . C O N T R O LVALVE I . C O N T R O L C A B L E
SECTOR
2. ELEVATOR
5 . CONTROL TAB
R I G P I NHOLES (RP-4)
4 G]/32'.)I N C H E S
TAB
9 . B O L T
BB2-2LI4
A u g L / 6 6
CONTROLPU S HROD
1 5 . GEARED TABPU SHROD
27 -30 -2CODE 1Page 502
6 , J A M N U T S
1 4 . B O L T
CONTROL VALUEPU S HROD
8 . B O L T
1 0 . B O L T
T2 . FOLLOWUPBALANCEL I N K
Elevator AdjustmentF igu re 501
ELEVATORFOLLOWUPPU S HROD
P r i n t e d i n U . S . A
DOUGTAS AIRCRAFT CO. , INC.
DC.STMAINTENANCE MANUAT
N O T E :ALL CLEARANCES ARE FOR FAIRED( N E U T R A L } P O S I T I O N .
7 /16 INCH MINIMUM9/ I6 INCH MAXIMUM
L I / 8 I N C H M I N I M U ML 3 /8 INCH MAXIMUM
7/32 INCH MINIMUMLL/32 INCH MAXIMUM
ELEVATOR
7 /32 INCH MIN IMUM
LT/32 INCH MAXIMUM
1 / I 6 I N C H M I N I M U M3 / L 6 I N C H M A X I M U M
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9/32 INCH MINIMUML 3 / 3 2 I N C H M A X I M U M
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5/8 INCH MINIMUM7/8 INCH MAXIMUM
1 / 1 6 I N C H M I N I M U M3 / T 6 I N C H M A X I M U M
GEARED TAB
1 / I 6 I N C H M I N I M U M3 / L 6 I N C H M A X I M U M
sEcnoN A-A
ELEVATOR
sEcnoN B-B
27 -30 -2CODE IPage 602
\'\ \---- r/r6 INcH
- - \ \ 3 /16 INCH
lrl(tLfcoNTRoL
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M I N I M U MMAXIMU I /
Elevator , Cont ro l Tab, and GearedTab Clearances
F igu re 6 0 l
B B 2 - t 1 3 6
HORIZONTALSTABIL IZER
P r i n t c r { i n t i S A
Aug L / 66
OOUGIAS A|RC,
oEA"" fNc'A,IA INIENANCE iE r.rUAt
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27 -30 -3CODE IPage 202
Cont ro l TabFigure 20L
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Aug I / 66
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CONTROL TAB
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EIe va tor
P r i n f e d i n U . S . A
DOUGTAS AIRCRAFT CO. , INC.
DC.SIMAINTENANCE MANUAT
VIEW AG E A R E D T A B(TYPtCAL)
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vtEw DTAB H INGE(TYPICAL}
27 -30 -3CODE 1Page 204
CONTROL TAB I NBOARDHINGE (TYP ICAL)
Elevator Tabs Lubr ica t ionFigure 202 (Sheet 1)
BB2-t8278
A u g L / 6 6
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DOUGTAS AIRCRAFT CO. , INC.
DC.9MAINTENANCE MANUAT
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21 - 3 0 -4CODE IPage 202
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Figure 20L
8,82-9678
Aug L/ 66
EYE BOLT
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ELEVATOR
ARED TAB
ll ,/|r-- e/32INCH M|N|MUM
L3 /32 INCH MAXIMUM
- ELEVATOR
f L /L6 INCH MtNtMUM:. 3/16INOH MAXIMUM
VIEW AG E A R E D T A B(TYPTCAL)
o
DOUGTAS AIRCRAFT CO. , INC.
DC.9MAINTENANCE MANUAT
CONTROL TAB I NBOARDHINGE (TYP ICAL)
Elevator Tab Lubr ica t ionFigure 202 (Sheet 1)
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vtEw DTAB H INGE(TYPICAL)
27 -30 -4CODE 1Page 204
BB2-18278
Aug L /66
GEARED TAB
vtEw BGEA RED TA B(TYPICAL}
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Elevator DamperF i gure
DOUGTAS AIRCRAFT CO. , INC.
DC.S'MAINTENANCE MANUAT
3. MOUNTING PLATE
27 - 30 -sCODE IPage 2O2
I ns ta I l a t i on2 0 1
BB2-9688
HORIZONTALSTABILIZERREAR SPARl
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D O U G T A S A I R C R A F T C O . , I N C .
DC-9MAINTENANCE MANUAT
ELEVATOR
VIEW A
TLEVATOR INBOARDHI NGE
VIEW B
EUVATOR H I NGE(ryPICAU
2 7 - 3 0 - BCODE IP a g e 2 0 4
vtEw C
HYDRAULI CPOWER BOOST
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A u g L / 6 6
( 4 )
(s)
( 6 )
DOUGTAS AIRCRAFT CO. , INC.
DC.9f rTAINTENANCE MANUAT
Connect e lec t r ica l connectors to t ransformer- rec t i f ie rbox and actuator . Safe ty connectors wi th lockwi re .
Close two pr imary long i tud ina l t r im c i rcu i t b reakers andthree autop i lo t and a l ternate long i tud ina l t r im c i tcu i tbreakers located on upper main circui t breaker panel.
Check al ternate longi tudinal t r im a ctuator motor (seeInspeet ion/Check) .
5 . Removal / Ins ta l la t ion Lonql tud ina l Tr im Gearbox
A. Remove Gearbox
(1) open two pr imary longi tudinal t r im circui t breakers andthree autopi lot and al ternate longi tudinal t r im circui tbreakers located on upper main circui t breaker panel.
WARNING: TAG AND SAFETY CIRCUIT BREAKER,S.
,r,43
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Hor izonta l Stab i l i zer Rest ra in ingIns ta l l a t i on
Figure 402
B B 2 - L 7 5 ? A
27 -40 -1CODE 1
Page 405
H O R I Z O N TS T A B T L I Z E
R E S T R A I NF I X T U R E
(21 Remove primaryparagraph 3) .
longi tudinal t r im aetuator motor (see
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V E R T I C A LSTABIL IZEI
Aug L /66
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/(
D O U G T A S A I R C R A F T C O . , I N C .
DC.SIM A I N T E N A N C E M A N U A L
AFT VANE
\ \S T O P
T O R S I O N B A R
TORQUE TUBE
S U P P O R T L I N K
BUMPER
W I N G F L A P
BB2-r050
FORWARD VANE
I
27 - s1 -0CODE IPage 2
AFT VANE CABLE SYSTEM
FORWARD AND AFT MOVABI.T VANES SHOWN IN EXTENDED POSITION
Flap Movable VanesFigure 1
Aug L /66
ROLLER STOP
FLAP TRACKCARRIAGE
FIXED VANE
27-s1-1CODE 1Page 402
DOUGTAS AIRCRAFT CO. , INC.
oc-slMAINTENANCE MANUAT
FLAP BUS CABLES
CABLE PULLEYS
3 . B O L T(4 PLACES)
, / C A B L E R E T A I N E R
c
VIEW A
l ' /
NG FLAP
VANE
B B 2 - 2 7 7 A
| 4 . B o L T
WING AND F LAP SHOWN
PUSHROI)
2 . B O L T
HINGE T IP FA IR ING
vttw c-c
F lap Ins ta l l a t i onF igu re 4 0 I
vtEw
FORWARDMOVABLE VANE
5 . H I N G E B O L T(3 PLACES)
Aug L /66
DOUGTAS AIRCRAFT CO. , INC.
oc-9MAINTENANCE MANUAT
r \"'t
vrrw BVANE TRACK ROLLER SUPPORT
27-51 -1CODE 1Page 41 0
Flaps Lubr icat ionF igu re 404 (Shee t
Char t1 )
BB2.728
A u g L / 6 6
P r i n t e d i n U . S . A
DOUGIAS AIRCRAFT CO., INC.
oc-9,TIAINTENANCE MANUAT
IIIIE'DIMENSIOT{S MARKEDTHUS * APPLY TO FULLSPAITI OF VANES
SUPPORT LINK
27-s1-1CODE 1P a g e 5 0 2
EYEBOLTS
OUTBOARD END OF VANES (LOOKING INBOARD - FI.APS RETRACTED}
L7 L/8 ltL/4 ) INCH7 3/4 ftL/4 ) |NCH
BOLT
,/'FLAP\ . / , '
Y
Fl apsF i g u r e
OUTBOARD TRACK
Ad jus t ment501 (Shee t 1 )
L6 t/r6 & L/4n NCH_r7 L/4 f.tl./4'.)
INCH
* o. r z5(i$'|f!lrrucrr
INBOARD END OF VANES (LOOKING OUTBOARD - FLAPS RETRACTED)
BUMPER
6 . S T o P
BUMPER
7 . W A S H E R S
EYEBOLT
BB2-624A
2 . W A S H E R S
LAMINATED SHIMS
R O L L E RF I T T I N G
P r i n t e d i n U S A
Aug L / 66
OUTBOARD TRACK
4.ADJUSTMENT NUT
TURNBUCKLES
ACCESS DOOR
DOUGTAS AIRCRAFT CO. , INC.
DC.9MAINTENANCE MANUAT
Flaps AdjustmentF igure 501 (Sheet 2 l
WING FLAP
BB2-6234
27 -5L -LCODE 1
Page 503Aug L/ 66
Pr in ted in U .s .A .
DOUGTAS AIRCRAFT CO. , INC.
DC.9MAINTENANCE I , IANUAI
3 /B INCH MIN .5 /B INCH MAX.
c0vER \.
I N C H M I N .I N C H M A X .
5/8 tNCH MtN.7 /8 tNCH MAX.
FLAP
AI LERONFAIRING
HORN
PERMISSABLE MISMATCH1/4 INCH UP OR DOWN
VIEW E-EF l a p a n d M o v a b l e V a n e C l e a r a n c e s
F i g u r e 6 0 1 ( S h e e t 1 )
W I N GT R A I L I N GE D G E
F A I R I N G
A I L E R O N
r / 2 I N C H M I N . hl3/4 INCH MAX.
\
FAIR ING FAIR ING
\
JcD
FU SE LAGE
21 -s l - 1CODE 2Page 602
B B 2 - 2 0 6 7 B
A u g L / 6 6
LIrI
FORWARD MOVABLE VANE
MOVEABLE VANE
1 lt ll l' l /t r /
' , - !rH
\-t
7 3 /4 ( tT /$ INCHES AT INBOARD END7 I /4 ITI /4 ' I INCHES AT OUTBOARD END
OOUGTAS AIRCRAFT CO. , INC,
DC.SIMAINTENANCE MANUAT
0 . r25(+0 . t25 , -0 .063) tNcHE SAT FORWARD END0. 100(+0 . t25 , -0 .063) tNcHEsAT VANE TRAIL ING EDGE
L6 I /16 f tL/q INCHES AT OUTBOARD ENt)L7 L /8 ( * , t /4 ) tNCHES AT INBoARD END
W I N GTRAILII{GEDGE
FORWARDMOVABLEVANE
HORN
5/16 |NCH MtN7/16 INCH MAX
0 . 1 0 0 ( + 0 . t 2 5 , - 0 . 0 6 3 )I N C H E S
VftW A-A
FAIR ING
FILLET
F l a p a n d M o v a b l eF i g u r e 6 0 1
- -
//UPPER
ACE
AFTMOVABLEVANE FILLET
VltW D-D
FLAP
LAGE PANEL
r /8 INCH MINr/4 INCH MAX
FAIR ING
FILLET
i/df,* ,-r/8)
FLAPS U R F
vftw B-B vltW C-C
V a n e C l e a r a n c e(S hee t 2 l
BB2-2068
27-sL-LCODE 2
P a g e 6 0 3A u g L / 6 6
P r i n f c d i n U . S . A
DOUGLAS AIRCRAFT CO., INC.
DC.9MAINTENANCE MANUAT
F IXED VANEINBOARD
FIXED VANEC EN TER
F IXED VANEOUTBOARD
AITACHPOI NT
D I M E N S I O NA
1 3 .128 ( r 0 . 124 |2 2 .866 ( r 0 . I 13 )3 2 . 6 9 6 ( t 0 . 1 0 6 )4 2 .459 ( r 0 . 09 7 )5 2 .455 ( r 0 .097 )6 2 . )16 ( t 0 . 092 )7 2 .177 ( r0 .086 )8 2 .A t 6 ( r 0 . 092 )9 2 .075 ( t0 .082 )
IO 1 .96 I ( t 0 . 078 )l t I . 850 ( r 0 .073 )12 1 .7 47 ( t 0 . 069 )
F IXED VANEA T T A C H P O I N T S( 1 2 P L A C E S )
F L A P
3 / 8 ( + L / 8 , - r / L 6 ) t N C HC L E A R A N C E B E T W E E NV A N E A N D F I X E DS T R U C T U R E O R S P O I L E RT H R O U G H O U T F U L L F L A PT R A V E L
F IXED VANE
II\ 34'
/,l/
vtEw A( T Y P I C A L I 2 P L A C E S )
F L A P
Clearan ces6 0 2
,/
27 -5 1 -1CODE 2Page 604
F l a p F i x e d V a n eF i g u r e
B 8 2 - 1 7 9 4 B
A u g L / 6 6
,)
, MOVABLE VANE
Flap Movable VanesF igu re 401
DOUGIAS AIRCNAFT CO., INC.
oc.g,UTAINTENANCC'IIANUAI.
FORWARD MOVABLE VANE
Insta 1la t i_on(sheet 1)
3 . B O L T
5 .
2. BOLT
EYEBOLT
///
II
lo
WING FtrAP
882-257L
27 -5L-2CODE 1Page 402
D . i ^ , ^ A i ^ t l q / 1
Aug L/66
O O U G T A S A I R C R A F T C O . , I N C .
DC.SIMAINTENANCE MANUAL
VIEW B
6 . B O L T
NUT
SUPPORT LI I {KS
CENTERLINES OF INBOARDAND OUTBOARD SUPPORTLINKS MUST BE INDEXEDTO TORQUE TUBE WITHIN20 OF EACH OTHER.
vtEw c
F lap Movab le Vanes Ins ta l l a t ionF igure 4 0 I (Shee t 2 )
BB2-2s73
27 -5L -2CODE 1
Page 403
FLAP
Aug L/ 66
P r i n t e d i n U . S . A .
DOUGTAS AIRCRAFT CO. , INC.
DC.SIMAINTENANCE MANUAT
L6 L/L6 (t 1/4) INCH- - - - _ _
@,DIMENSIONS MARKEDTHUS * APPLY TO FULLSPAN OF VANES
SUPPORT L INK
EYEBOLTS
ffii1;r'.bH}ff* o.lzs[1$'$.2!]rnor
OUTBOARD END OF VANES (LOOKING INBOARD - FLAPS RETRACTED)
L7 t /8 ( t1 l4 ) lNc7 3/4 $ L/4 ) rNCH SUPPORT FITTING
BUMPER
7. WASHERS
EYEBOLTI
INBOARD TRACK I- - _ _ _ l N E ' u A K u l K A t " K
-
INBOARD END OF VANES (LOOKING OUTBOARD . FLAPS RETRACTED)
BUMPER
27 -5L- 2CODE IPage 502
- \ -
F lap MovableF i g u r e
OUTBOARD TRACK
Vanes Ad j ustment501 (Shee t 1 )
BB2-624A
Aug I / 66
2 . W A S H E R S
LAMINATED SHIMS
P r i n f a d i n t l S A
DOUGTAS AINCRAFT CO. , INC.
DC.SIMAINTENANCE MANUAT
6 . STOP
OUTBOARD TRACK
4.ADJUSTMENT NU
TURNBUCKLES
ACCESS DOOR
r v5 /8( +r /8) tNcHES
WING FLAP
Flap MovableFigure
Vanes Adj ustment501 (Sheer 2 l
BB2-623A
27 -51 -2 ,CODE 1
Page 503Aug L/66
P r i n t e d i n U . S . A .
DOUGTAS AIRCRAFT CO. , INC.
DC.SIMAINTENANCE MANUAT
FLAP IyIOVABLE VANES - I NSPECTT ON/CHECK
l. Inspect ion/Check Flap Movable Vanes
A. Check Vane C learances
(1 ) Wi th f l aps fu l l y re t rac ted , check tha t vane e lea rances a rea s f o l l o w s :
(a) Between lower sur face of wing t ra i l ing edge and uppers u r f a c e o f f o r w a r d m o v a b l e v a n e , 0 . 1 0 0 ( + 0 . L 2 5 , - 0 . 0 6 3 )
i n c h .
Between lower surface of forward movable vane trai l ingedge and upper sur face o f a f t movable vane, 0 .100(+0 . t . 25 , - 0 .063 ) i nch .
Between lower surface of af t movable vane and uppersu r f ace o f f l ap , 0 .125 (+0 .L25 , - 0 .063 ) i nch a t f o rwa rdend , dec reas ing t o 0 .100 (+0 . L25 , - 0 .063 ) i nch a t vanet ra i l i ng edge .
16 L/L6 ( ! I /4) INCHES AT OUTBOARD END
L7 L/8 ( TL/4) INCHES AT INBOARD END
WING
FORWARDMOVABLEVANE
AFTMOVABLEVANE
(b)
(c)
0 . 1 0 0 ( t 0 . L 2 5 , - 0 . 0 6 3 )INC HES
SECIION
Movab le Vane C learancesF i g u r e 6 0 I
0 . r 25 ( +0 . 125 , -0 .0 63 ) lNc HESAT FORWARD END
0 . 1 0 0 ( + 0 . 1 2 5 , - 0 . 0 6 3 ) l N c H E sAT VANE TRAIL ING EDGE
A-AB B 2 - 2 r 0 9
27 -5L -2CODE 1
Page 601Aug L /66
P r i n t e d I n U . S . A .
DOUGIAS AIRCRAFT CO. , INC.
DC.gTMAINTENANCE lrtANUAt
,/YllW A-A
NOTATED 18OO}
YIEW C-C
27-51-3CODE IPage 202
PATCHt{0TE: BOI{D METAL PATCHESTO VAI{E 8 PLACES
WASHERS,4 UI I IDERT{UT AND 4 UNDERCLEVIS O{ORMAL)SEE NOTE 2
VIEW D
F lap F i xed Vane fns taL la t i onF igu re 2 01
NOTE:
1. ADJUST VANE TO WIiIG CLEARAT{CEBY PLACEMEI{T OF WASHERS.
2. ADJUST VAiIE TO WIT{G CLEARAfTCEBY ADDING (OR REMOVII{G) WASHERSFROM UNDER CLEVIS. AN EQUALAMOUNT OF WASHERS MUST BE RE-MOVED (OR AODED) UNDER I{UT.
BB2- t958
WASHERS, I MIN|MUM,5 MO(IMUM (SEE NOTE T)
WASHERS, 1 MINIMUM,5 MAXIMUM (SEE I{OTE 1)
WASHERS, 2 Mil t i lMUM,5 MAXIMUM (SEE NOTE I )
Aug L /66
DOUGTAS AIRCIAFT CO., INC.
DC.g'AAAINTENANCE 'VIANUAL
tt-4
F IXED VANEA T T A C H P O I N T S( i 2 P L A C E S )
FIXED VANEC E N T E R
F L A P
3/B (+L /8 , - r /L6) INCHCLEARANCE BETWEENVANE AND FIXEDS T R U C T U R E O R S P O I L E RTHROUGHOUT FULL F I -APTRAVEL
. - - -a.- '-,
VIEW A( T Y P I C A L T 2 P L A C E S )
FIXED VANEOUTBOARD
FLAP
FIXED VANE
34'
)
Flap Fixed VaneFigure
C learances2 0 2
B B 2 - 1 7 9 4 8
27-s1-3CODE I
Page 2O3
ATTACHPOI NT
DIMENSIONA
I 3.129 ( r0 .724 |2 2 .966 ( *0 .113 )3 2 ,686 ( t 0 . 106 I4 2.459 t r0 .097 )5 2 .455 ( r 0 .097 )6 2.316 ( r0 .092 )7 2 .177 ( t0 .086 )8 2.476 ( r0 .092)I 2 .075 (10 .082 )
l 0 I . 961 ( r 0 .078 )t t 1.850 ( r0 .073 )12 1 .7 47 ( t 0 . 069 )
Aug L/ 66
Printed in U.S.A.
WING
DOUGTAS AIRCRAFT CO. , INC.
DC.9MAINTENANCE iAANUAL
FLAP
2
Car r i ageF igu re 402
vtrw BVANE TRACK ROLLER SUPPORT
vrEw ACARRIAGE
27-51-sCODE IP a g e 4 0 4
Lubr i ca t i on Char t(Shee t 1 )
BB2-7') 3
A u q I / 6 6
F lap T rack
Pr in ted in U .S .A
DOUGIAS AIRCRAFT CO. , INC.
DC.SIMAINTENANCE MANUAT
HINGEBRACKET
PISTON ROD
ATTACH BOLT
JA MNU T
FLAP FOLLOWU PCABLES
F L A P C O N T R O LCABLE S
BUS CABLES H R O U D S
F L A P B U ST U R N B U C K L E
vtEw
A d j u s t m e n t
S T O P B O L T
\MvPU S HROD
FI-APU P P E RSURFAC E
vtEw
vtEw A
FI LLET
v f E w B
B L O C K \
D
F L A P B U ST U R N B U C K L E
B B 2 - I 0 4 9 8
21 -52 -0CODE 2
Page 20 3
F l a p A c t u a t i n g C y l i n d e rF i g u r e 2 0 1
1t'Vlul-Ilii
tD
STOP BOLT
FLAP TRACK
o'
0
Aug I / 66
F r i n t e d i n L l 5 A
AFT HII{GE PIN
ATTACH PIN
TRUI{l'll0N
DOUGTAS AIRCNAFT CO., INC.
DC.g'MAINTENANCE MANUAI
IDLER LINK
FLIGHT SPOILERACTUATOR
- /
( (
CAM
@
0.343 t t O.OrS) tNCH--+ll*
VALVE Lt]iIK
REACTIOI{ BOLT
TORSION BAR
ALIGNMET{T GROOVE
vrEw B
DRIVE LIIIK
PUSHROD
BB2- t0 I7C
27- 6L- 2CODE 1
Page 40 3
HYDRAULICLlt{Es
HYDRAULIC FITTII{GS
vrrw A
Fl ight Spoi. ler Actuator Instal lat ionFigure 401
o)
I
? - /.- -/
Y9
ffi'^
REACTION LEVER
Aug L/ 66
Prtnled in U.S.A.
DOUGTAS AIRCRAFT CO., INC.
DC.9AAAINTENANCE MANUAT
R O L L E R
HERME TICSWITCH
ELECTRICALCONNECTOR
SCREWB PLACES)
\ , 2 \ IYe) t
,r%
27 -62 -6CODE IPage 202
WASHER
vtrw A
Ground Spoi le r Takeof f Warn ing Swi tchIns ta l l a t i on
F igu re 20L
BB2-2030
P r i n t e d i n U S A
A u g L / 6 6
DOUGI .AS AIRCRAFT CO. , INC.
DC.9MAINTENANCE MANUAL
F R O N T S P A R
LEADI[ iG EDGE
L E A D I N G E D G ES LAT D RIVE
HYD RAUL ICC Y L I N D E R S
I C E P R O T E C T I O NT E L E S C O P I N G D U C T
27 -80 -0CODE 1Page 2
LEADING EDGES LATS
ICE PROTECTIOND U C T
L i f t A u g r n e n t i n g W i n g S l a t S y s t e mF i g u r e 1
BB2-2962
Aug L / 66
P r i n t e d i n U . S . A
DOUGTAS AIRCRAFT CO. , INC.
DE.SIMAINTENANCE MANUAT
4. BOLTS
ID LER TRACK
RETAINERS
IDLER TRACK
VIEW A
vltw D
3 . P I N S
5. BOLT
v| lw B
BO LTStuWASHER
ADJUSTMENTB U S H I N G S
VIEW E
S l a t - t o - T r a c k A t t a c hF i g u r e 4 0 1
27 -80 -1CODE IPage 402
882-3008
Aug L / 66
I
Ha r dwa re
+'+.- L/2 ft L/Ld INCH( TYPTCAL )
DOUGTAS AIRCRAFT CO., INC.
DC.gMAINTENANCE MANUAT
MAX. MISMATCH BETWEEN SI .ATS0 . 0 1 5 I N C H R E T R A C T E DO "062 INCH EXTENDED( ENT IRE PERIPHERY )
ADJUSTABLE STOP( EXTENDED )
AA
) /4ftt/8 ,-l/32) tNCH/
/
,/ -.-'tt-
-c:13 V/
/F IXED WING
vtrw c-c Vl lW A-
, - t /L6)
BB2-3028
27 -80 - tCODE I
Page t {03
/8
DIXEING
4 ( +CH
J
\Ft)wl l
I
\J
A
7 . R I G G I N GSPACER(0. r88 lNcH)
TRACK DOOR
A u g L / 6 6
1 0 . 0 .0 T0 0 .045 i l rcH,MAXIMUM
\.
12. BOLT
W i n g S I a t C l e a r a n c e sF i g u r e q 0 2
\ 13. LATCH F|TT|NG--...-.--
0 . 0 6 2 - 0 . 1 2 5
1 I . F I X E D S T O P
P r i n t e d i n U . S . A
f n s t a l l a t i o n
DOUGIAS AIRCRAFT CO., INC.
DC.gIMAINTENANCE AAANUAT
8. CRAi lK r . B O L T
3 . R O D E N D
7 . J A M N U T
7 . JAMNUTr. BOLT
4. ROD El{D
10 . sToP
2. ACTUATINGCYLIt IDER
5 . D R U M 9 . S T O P B O L T
6. GUARD PIN
vEw A
Wing S la t Dr ive t " lechanism Ad justmentF i g u r e 5 0 2
BB2-30 10
27 -80 -2CODE 1
Page 50 3
NACTUATINGCYLINDER
Aug V66
Pr in tad in U.S.A.
DOUGTAS AIRCRAFT CO. , INC.
DC-gMAINTENANCE MANUAT
B ) T U R N B U C K L E
(?_)TURNBUCKLE
( B ) T U R N B U C K L E
RETRACT
( 4 ) T U R N B U C K L E
s r.-AT N0. 2
( 5 ) T U R N B U C K L E
RETRACT
vtEw c
S LAT NO. 3
RETRACT
s ] -AT N0 . 5
z
EXTEND
( I ) T U R N B U C K L E
SI -AT NO. 1
( 6 ) T U R N B U C K L E
SLAT NO.
( 7 ) T U R N B U C K L E
?)RETRACT
S L A T N O . 3 ADJUS TA BLEBRACKET
RETRACT
2 ' t - 80 -2CODE IPage 504
BWing
BB 2-3 00 9
A u g L / 6 6
S l a t C a b l e S y s t e mF i g u r e 5 0 3
E X T E N D
EXTEND
( 9 ) T U R N B U C K L E
E X T E N D
E X T E N D
t&
vr twAd j ust rnent