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2. Push-rod Adjustment
WARNING:  IF YOU DO AN ADJUSTMENT OF A PUSH-ROD, YOU MUST MAKE SURE THAT THE PUSH-ROD IS STILL IN SAFETY. IF YOU DO NOT DO THIS, THE PUSH-ROD CAN DISCONNECT. THIS CAN CAUSE DEATH OR INJURY TO PERSONS.
Detail Steps/Work Items  Key Items/References 
(1)  Release the bolt attaching the push-rod to the lever or bellcrank.  At the end with an adjustable end fitting. 
(2)  Loosen the jam-nut on the adjustable end fitting.  Refer to Figure 1. 
(3)  Turn the eye-end to adjust the length of the rod.  Turn clockwise to make the rod shorter. Turn counter-clockwise to make the rod longer. 
(4)  Do a test for safety of the eye-end. Push a piece of lock-wire through the safety test hole.  The wire must not go through the hole and out the other side. 
(5)  Tighten the jam-nut.  Torque: 16 Nm (11.8 ft.lb.). 
(6)  Put the end-fitting in position in the lever or bellcrank. 
(7)  Install the bolt, washer and self-locking nut.  Torque: 6.4 Nm (4.7 ft.lb). You must always use a new self-locking nut. 
(8)  Do an inspection of the control that you have adjusted. S If necessary for your airworthiness authority, do a second inspection of the control. 

Doc # 6.02.01 Page 201
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AMM

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. 

Page 202 Doc # 6.02.01 09 Jan 2003 Rev. 4
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Flight Controls
AMM

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.
Doc # 6.02.01 Page 1
Rev. 4 09 Jan 2003

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AMM
AIRCRAFT
Flap Torsion Tube
Push Rod to Right Wing
Balance Springs 
Push Rod to 
Rigging  Left Wing 
Pin Hole 
Rear Bellcrank 
　
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