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Flight Controls DA 40 Series
AMM
Page 202
20 Sep 2007 27-00-00 Doc # 6.02.01
Rev. 5
3. Remove/Install Bellcranks and Levers
The DA 40 has standard attachments for bellcranks and levers in the flight control systems. Refer to
the tables at the end of each Section for access data. Refer to the Figures in the related Section for
the correct orientation.
A. Remove a Bellcrank or Lever
Detail Steps/Work Items Key Items/References
(1) Release the bolts attaching the push-rods to the
lever or bellcrank.
(2) Remove the pivot bolt from the lever or bellcrank.
(3) If necessary, remove the mounting bracket:
S Remove the attaching bolts and washers.
Where you have access to both sides of
the attachment, bolts with washers and
nuts are used. In all other cases,
anchor-nuts are used.
B. Install a Bellcrank or Lever
Detail Steps/Work Items Key Items/References
(1) Put the mounting bracket in position. If removed.
Note: You must always use new self-locking nuts when installing control levers or
bellcranks. Do not use a self-locking nut more than once.
(2) Install the attaching bolts, washers and nuts. Torque: 6.4 Nm (4.7 ft.lb).
(3) Put the bellcrank or lever in position in the
mounting bracket.
Make sure that the bushes and spacer
are in position.
(4) Install the pivot bolt, washer and nut. Torque: 6.4 Nm (4.7 ft.lb.).
(5) Install the bolts, washers and self-locking nuts
which attach the push-rods.
Torque: 6.4 Nm (4.7 ft.lb.).
(6) Do a test of the control system. Refer to the related Section.
(7) Do an inspection of the control that you have
installed or adjusted.
S If necessary for your airworthiness authority,
do a second inspection of the control.
AIRCRAFT
DA 40 Series
AMM
Flight Controls
Doc # 6.02.01
Rev. 5 27-10-00 Page 1
20 Sep 2007
Section 27-10
Flight Controls - Ailerons and Tabs
1. General
The DA 40 has two control sticks that operate the ailerons. The aileron control system uses push-rods
and bellcranks.
Figure 1 shows the aileron controls in the fuselage. Figure 2 shows the aileron controls in the wing.
AIRCRAFT
Flight Controls DA 40 Series
AMM
Page 2
20 Sep 2007 27-10-00 Doc # 6.02.01
Rev. 5
Control
Bulkhead
Front Bulkhead
Rear Bulkhead
Control Stick Mounting Block
Torque Tube Assy
Adjustable Aileron Stop
Front Bellcrank
Push Rod to
Left Stick
Push Rod to
Right Stick
Left Stick
Push Rod to
Idler Lever
Idler Lever
Rear Bellcrank
Push Rod from
Idler Lever
Push Rod to
Left Wing
Push Rod to
Right Wing
Rigging
Pin Hole
Rigging
Pin Hole
Rigging
Pin Hole
Rigging
Pin Hole
Rigging
Pin Hole
Flap Torsion Tube
Balance Springs
Figure 1: Aileron Controls in the Fuselage
AIRCRAFT
DA 40 Series
AMM
Flight Controls
Doc # 6.02.01
Rev. 5 27-10-00 Page 3
20 Sep 2007
2. Description
The DA 40 has a control stick for each pilot for the aileron and elevator controls. Aileron push-rods
connect to the bottom of the control sticks. The push-rods connect to the aileron front bellcrank at the
control bulkhead. The front bellcrank at the control bulkhead connects to a short push-rod under the
center console.
The push-rod under the center console connects to an idler lever attached to the front main bulkhead.
A push-rod connects the idler lever to the rear aileron bellcrank on the rear face of the rear main
bulkhead.
The rear bellcrank connects to the two push-rods in the center section. Each rod connects to a long
push-rod in the wing.
Each long push-rod has three push-rod guides. The first push-rod guide attaches to the root rib. The
second attaches to the flap-control rib. A small rib holds the third push-rod guide. The two long pushrods
connect to the two aileron bellcranks, one in each wing.
Short push-rods connect the aileron bellcranks to the aileron horns. You can adjust the short push-rods
to move the range up or down.
The aileron stop which limits the stick movement to the right side (right aileron up, left aileron down)
is located left of the pilot's control stick (refer to Figure 1). The aileron stop which limits the stick
movement to the left side (left aileron up, right aileron down) is located right of the co-pilot's control
stick. Each aileron stop consists of a nut which is welded to the torque tube assembly, a bolt which is
held by that nut, and a jam-nut which secures the bolt.
Additional, non-adjustable stops are located in front of the leading edge of the LH and RH aileron.
　
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