WT9 Dynamic LSA. AIRCRAFT MAINTENANCE MANUAL (AS-AMM-01-000, 22. 05. 2017) - page 17

AILERON AND ROLL TRIM

FLIGHT CONTROLS

Torsion tube with control sticks installation:

(a) Before assembling check push rods for cracks and condition of

rivets. Check parallel alignment of swivel bearings; on new push
rods, release lock nuts.

(b) Assemble connecting push rod (1, Fig. 27-4) with control sticks (2; 3)

and torsion tube (6), using bolts (9; 17), washers (20, 21), ground
wires (10) and nuts (19). Check free movement of control sticks. If
using new connecting push rod:

•

Adjust the length by screwing bearings ending (24) so that the

distance between tops of control sticks (2; 3), is the same as the
distance between bolts (15) connecting control sticks (2; 3) with
torsion tube (6) (575 mm).

•

Use new washers (23) and tighten nuts (18).

•

If using new torsion tube (6):

•

Screw aileron stop bolts (14) with nuts (18).

(d) If previously removed, install front part of bushing (7) on left and right

side of main beam using washers (22; 23) and screwing bolts (15).

(e) Insert torsion tube (6) into front bushings, put aft part of bushing (8)

using washers (21, 23) and screwing bolts (16). Put ground wire (12)
under washers (21, 23) and bolt (16) in bottom part of right aft bushing
(8).

(f)

Put the PTT buttons (25) on the top of left handle with stick shaker
(4) and right handle (5). Route wires through the control sticks and
solder the wires to left handle with control stick shaker (4)
(Chapter 31-50) and to PTT buttons (25) (Chapter 23-50).

(g) Put the left (4) and right (5) handles on the control sticks and screw

hexagon head bolt (13).

(h) If necessary, install stop bolts:

•

Screw front stop bolt (29, Fig. 27-11) with nut (28).

•

Slide the rear stop of elevator (25) into central tunnel, put bolt

(30), washer (31) and screw the nut (32).

•

Screw the rear stop bolt (26) on rear stop of elevator (25) with

washer (12) and nut (17).

•

Adjust stop bolts (14, Fig. 27-4).

•

Install the pedestal panel (Chapter 27-50, 2.B.(2)).

(i)

Carry out test and check:

•

That the castle nuts and pins are secured with cotter pins.

•

If all bolt connections are tight.

•

Plays.

•

Free movement of elevator control system.

•

Neutral position and max displacements.

•

Equal division of threads on push rods.

•

Operation of push button on stick.

•

No foreign objects remain in the aircraft.

Effectivity:

ALL

04. 07. 2019

FLIGHT CONTROLS

Fig. 27-4 Torsion Tube with Control Sticks Removal / Installation (page 1 of 2)

AILERON AND ROLL TRIM

FLIGHT CONTROLS

– Connecting push rod

– Bolt M6x16

– Left control stick

– Bolt M6x26

– Right control stick

– Bolt M6x45

– Left handle with stick shaker

– Bolt M6x46

– Right handle

– Nut M6

– Torsion tube

– Self-locking nut M6

– Front part of bushing

– Washer ø6.4x12x1.6

– Aft part of bushing

– Washer ø6x12x0.5

– Bolt M6 x 22

– Washer ø6.4x18x1.6

– Ground wire

– Serrated locking washer ø6.4

– Ground wire

– Bearing ending

– Bolt M4x10

– Push-To-Talk (PTT) Button

Fig. 27-4 Torsion Tube with Control Sticks Removal / Installation (page 1 of 2)

Effectivity:

ALL

04. 07. 2019

FLIGHT CONTROLS

Roll trim system

For removal / installation, see the Chapter 57-60.

RUDDER

FLIGHT CONTROLS

27-20 RUDDER

1. DESCRIPTION

The rudder is controlled by foot control pedals. The position of pedals for pilot and co-
pilot is remotely adjustable. The rudder is controlled through steel cables. Nose gear
steering is controlled through push-pull rods. The range of rudder deflections is limited
by stops glued to the fin root.

The

rudder pedal’s torsion tubes (1, Fig. 27-5) are attached to the floor in four holders

(2). The motion of pedals (3) is transferred through torsion tubes arms and control
cables (4) to the rudder root rib (5). The polyurethane casings are attached to the
fuselage structure to guide the control cables. There are turnbuckles (6) for adjusting
tension in control cables.

The rudder control pedals are connected to the nose landing gear leg (7) through two
push-pull rods (8).

Pedal positions can be adjusted with control handles (9) that release locking pins.
Three possible positions are available. Pedals are fitted with springs to return to the
rearward position during adjusting.

Effectivity:

ALL

22. 05. 2017

FLIGHT CONTROLS

– Torsion tube

6 -

Turnbuckle

– Holder

7 -

Nose landing gear leg

– Pedal

8 -

Push-pull rod

– Control cable

9 -

Control handle

– Rudder root lever

Fig. 27-5 Rudder Control System

RUDDER

FLIGHT CONTROLS

2. MAINTENANCE PRACTICES

Type of maintenance:

Heavy

Personnel qualification:

Independent certifying staff qualified in accordance
with Part-66 or higher.

Recommended tools, materials, persons and documentation:

ITEM

QUANTITY

Wrench 10

2 pcs

Wrench 9

1 pc

Hex key 5

1 pc

Nicopress tool

1 pc

Steel wire cutter

1 pc

Solder set

1 pc

Heat gun

1 pc

Pliers

1 pc

Combination pliers

2 pcs

Screwdriver

1 pc

Tensiometer

1 pc

Sleeve 3.0 - 3.2

4 pcs

Steel cable

ø3.2

Cotter pin

ø1.6 x 25

2 pcs

Serrated locking washer

ø6.4

6 pcs

Cable tie 3.2

4 pcs

Vaseline

Lubrication oil

Adhesive tape

Loctite 243

Loctite 270

Contact adhesive

Solder

Safety wire

ø0.8 mm

Shrink tube

ø12.4 mm

Persons

Tab. 27-3 Recommended tools, materials, persons and documentation

Effectivity:

ALL

04. 07. 2019

FLIGHT CONTROLS

Control cables

Control cables removal:

(a) On both ends of steel cable (1, Fig. 27-7), remove nuts (11; 12),

washers (9; 10) bolts (6; 7) and distance tubes (15; 16); cut steel
cable (1) and pull it out.

(b) Remove second steel cable (1).

washers (8; 9) and bolt (5).

(d) Remove second turnbuckle assembly (4).

Control cables installation:

(a) Connect turnbuckle assembly (4, Fig. 27-7) with foot control using bolt

(5), washers (8; 9) and cotter pin (14).

•

Remove safety wire if it is present.

•

Connect turnbuckle barrel to turnbuckle fork and turnbuckle eye

bolt with half a turn of thread.

(b) Connect second turnbuckle assembly (4).

(2) and shrink tube. Press sleeve (2) closely to thimble (3) with
Nicopress tool

at 3 points

and shrink the shrink tube on sleeve (2).

(d) Connect steel cable eye (1) with turnbuckle fork (4), by using

distance tube (15), bolt (6), washer (10) and nut (11); tighten nut (11)
so that the turnbuckle (4) assembly rotates easily.

(e) Lubricate steel cable (1) with oil on entire length.

(f)

Slide free end of steel cable (1) through plastic tube to tail end.

NOTE

Plastic tube is located in central tunnel.

(g) Install second steel cable (1).

(h) Put aircraft on lift jacks (Chapter 07-10), align foot control and set nose

wheel and rudder to neutral position.

(i)

On rudder operating levers, put a temporary thimble (3), bolt (7) and
screw a nut.

(j)

On free end of steel cable (1), slide shrink tube and sleeve (2).

(k) Fold steel cable (1) around thimble (3) and strain cable to approx.

160-180 N. Move sleeve (2) closely to the thimble (3) and fix them with
combination pliers (Fig. 27-6).

RUDDER

FLIGHT CONTROLS

Fig. 27-6 Straighten of Steel Cable

(l)

Disconnect steel cable (1, Fig. 27-7) with sleeve (2) and thimble (3)
from rudder operating lever by removing bolt (7).

NOTE

Take care to not move positions of items (1; 2; 3) during removal
of bolt.

(m) Press sleeve (2) with Nicopress tool

at 3 points

, cut unnecessary

end of steel cable (1) and shrink the shrink tube on sleeve (2).

(n) Make eye on second steel cable (1).

(o) Connect control cable eye with rudder operating lever, using distance

tube (16), bolt (7), washer (9) and nut (12).

(p) Connect second control cable eye.

(q) Strain the control cable at value 70 N with turnbuckle barrel (4).

(r)

Swing the rudder few times.

(s) Adjust the tension force in the steel cable (1), by turnbuckle barrel (4)

at value 61-65 N.

(t)

Secure turnbuckle assembly (4) with safety wire.

(u) Carry out test and check:

•

That the bolts (5) are secured with cotter pins.

•

If all bolt connections are tight.

•

Plays.

•

Alignment of rudder with nose gear

•

Equal division of threads on push rods and turnbuckle.

•

Tension of control cables.

•

That no foreign objects remain in the aircraft.

Effectivity:

ALL

04. 07. 2019

FLIGHT CONTROLS

Adjustment / test - rudder deflections:

Deflections of rudder are mentioned in Tab. 27-6. These deflections are
not adjustable. The neutral position of the rudder can be adjusted.

CONTROL SURFACE DEFLECTIONS

Control surface

Left

Right

Distance measurement point

from the point of rotation

Rudder

25 ±2°

320 mm

135 ±10 mm

Tab. 27-6 Rudder Deflections

(a) Lift the aircraft on jacks (Chapter 07-10).

(b) Set the pedals to middle position.

position.

(d) If it

isn´t, align rudder screwing one turnbuckle barrel (4, Fig. 27-7)

and simultaneously unscrewing second turnbuckle barrel (4).

(e) Check if tension on steel cables (1) is between 61-65

N. If it’s not,

screw turnbuckle barrel(s) (4) to adjust to correct tension.

(f)

Secure turnbuckle assembly (4) with safety wire.

(g) Carry out test and check:

•

Alignment of rudder with nose wheel and pedals in neutral

positions.

•

Tension on control cables.

•

That no foreign objects remain in the aircraft.

RUDDER

FLIGHT CONTROLS

– Control cable ø3.2

9 -

Washer

ø6.4 x 12 x 1.6

– Sleeve 3.0-3.2

10 - Washer

ø5.3 x 10 x 1

– Thimble 3.1-4.0

11 - Self-locking nut M5

– Turnbuckle assembly

12 - Self-locking nut M6

– Pin ø6x18

13 - N/A

– Bolt M5 x 20

14 - Cotter pin

ø1.6 x 25

– Bolt M6 x 22

15 - Distance tube

ø8 x 1 - 4.5

– Washer ø6.4 x 10 x 1.6

16 - Distance tube

ø8 x 1 - 8.5

Fig. 27-7 Control Cable Removal / Installation

Effectivity:

ALL

04. 07. 2019

FLIGHT CONTROLS

Remote control of pedals

Remote control of pedals removal:

(a) Remove spiral hoses (14, Fig. 27-8) and cable ties.

(b) Remove control handle (9), by unscrewing nuts (8; 10), removing

washers (6; 7) and remove ground wire (18).

(d) Remove screw shackles (3), nuts (4), washers (5), by unscrewing

nuts (4).

Remote control of pedals installations:

(a) Install screw shackles (3, Fig. 27-8), washers (5) nuts (4) on holder

(17) under instrument panel.

(b) Slide bowdens (1) and inner cables (2) through bayonets (15) and

screw shackles (3).

NOTE

Install correct length of bowdens (1) on correct positions:

LENGTHS OF BOWDENS

Left side, left pedal

500 mm

Right side, left pedal

500 mm

Left side, right pedal

660 mm

Right side, right pedal

650 mm

If using new control handle:

•

Assemble control handle (9; 10; 11; 12) leaving a free end of

thread on rod of 12 mm (see Fig. 27-8).

•

Unscrew the nut (12).

•

Secure handle (10) with Loctite 270.

(d) Insert the pair of inner cables (2) through holes in washer (7) and

connect to control handle (9)

Connect the ground wire (18).

Tighten

the nut (12).

NOTE

Control handle must have 3 mm backslash.

(e) Cut ends of inner cables (2) to 150 mm length from washer (7) and

solder cable ends.

(f)

Wrap spiral hoses (14) and secure bowdens (1) with 2 cable ties
(3.2 mm) to parachute board.

(g) Check operating of pedals remote control.

(h) Carry out test and check:

•

If all bolt connections are tight.

•

That pedals lock in all three positions.

•

That no foreign objects remain in the aircraft.

RUDDER

FLIGHT CONTROLS

– Bowden

10 - Black handle

– Inner cable ø1.2

11 - Thread rod M5 x 42

– Screw shackle

12 - Nut M5

– Nut M6 Low

13 - Distance tube

– Serrated locking washer ø6.4

14 - Spiral hose

ø1

– Washer ø5.3 x 15 x 1

15 - Bayonet socket

– Plain washer ø5.3 x 15 x 1

16 - Control anchor

8 -

Self-locking nut M6

17 - Holder

9 -

Control handle

18 - Ground wire

Fig. 27-8 Control of Pedals Removal / Installation

Effectivity:

ALL

04. 07. 2019

FLIGHT CONTROLS

Foot control

Foot control removal:

(a) Remove control cables (see 2.A.(1)).

(b) Remove remote control of pedals (see 2.B.(1)).

(d) Remove foot control, by unscrewing the nuts (13, Fig. 27-9) and

removing the washers (15).

(e) Pull out consoles (3; 4) with bronze bushings (5).

(f)

Disassemble bronze bushing (5), by unscrewing the nut (13),
removing washer (15) and bolt (11).

(g) Disassemble pedal, by removing cotter pin (14), washer (16) and pin

(10).

(h) Unscrew the bolt (12) from pedal.

Foot control installation:

(a) Before assembling check foot controls for cracks and deformations.

Check bolts laminated in floor.

NOTE

Described is installation of one pedal (6; 7; 8; 9, Fig. 27-9) to a
torsion tube (1; 2). Take care to install correct pedals to correct
positions on torsion tubes (1; 2).

(b) Before assembling clean holes in torsion tubes (1; 2, Fig. 27-9) and

pedals (6; 7; 8; 9).

using pin (10), washer (16) and cotter pin (14).

(d) Put spring (19) and bayonet (20) into socket on torsion tube.

(e) Push down bayonet (20) and turn pedal to fit bayonet (20) into

pedal´s groove.

(f)

Check operation of adjustment in all three positions.

(g) Screw bolt (12) on pedal and secure with Loctite 243.

(h) Assemble other pedal.

(i)

Slide bronze bushings (5) with consoles (3; 4) on ends of torsion
tubes (1; 2).

NOTE

The inner consoles (4) have elliptical holes and have direction
out. Outer consoles (3) have direction in.

RUDDER

FLIGHT CONTROLS

(j)

Connect bronze bushing (5) with console (4), by using bolt (11),
washer (15) and nut (13).

(k) Put foot control on screws laminated in floor; put washers (15) and

tighten nuts (13).

(l)

Install steering push rods (Chapter 32-50).

(m) Install remote control of pedals (see 2.B.(2)).

(n) Install control cables (see 2.A.(2)).

(o) Carry out test and check:

•

If all bolt connections are tight.

•

Alignment of rudder with nose gear.

•

Plays.

•

Free movement of rudder control system (nose wheel must be off

the ground).

•

That no foreign objects remain in the aircraft.

Effectivity:

ALL

12. 06. 2020

FLIGHT CONTROLS

Fig. 27-9 Foot Control Removal / Installation (page 1 of 2)

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