[Link] Ι [Link].

eu CONTROL SYSTEM

Title:

Control system assembly manual

Document no.:

D2_R0_00
Revision:

R03

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 1 150
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Table of revisions
Revision Affected pages Short description of change
00 All Original issue
02, 60, 67, 76, 80, 84 Table of revision added, nuts in pushrod BOMs corrected, connection
104 – 107 deleted of pushrods to ailerons (pages 105 – 108) and elevator (pages 121 –
01 124 – 126 deleted 123) and rudder cables to rudder (pages 150, 151) removed – as it´s a
156,157 deleted part of final assembly manual – D2_00_00.

02 150 – added Added a step with the installation of a foot rest to the rudder pedals.

03, 88, 89, 91, 92, 93, General instructions updated, bushing PCMF was replaced with a
03 94 bushing D2_SP_01.

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Control system assembly manual D2_R0_00 Rev. 03 2 150
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General instructions:
• Mark all bolt connections
• It is the responsibility of each assembler, to check that the thickness of riveted parts
matches the lenght of the rivet – follow
“Permissible joint lenght of the rivets“:

Joint lenght

Blind rivet type: Manufacturer Can be also marked as: Min. Max.
part number: length: length:

AVEX Φ3,2x7,9 Al/St 16910410 Al 3,2x7,9 AVEX Φ3,2x7,9 Al/Fe 0,8mm 4,8mm
AVEX Φ3,2x9,5 Al/St 10013209 Al 3,2x9,5 AVEX Φ3,2x9,5 Al/Fe 2,0mm 6,5mm
AVEX Φ3,2x11,2 Al/St 16910414 Al 3,2x11,2 AVEX Φ3,2x11,2 Al/Fe 4,0mm 7,9mm
AVEX Φ4x9,5 Al/St 16910512 Al 4x9,5 AVEX Φ4x9,5 Al/Fe 1,0mm 6,0mm
AVEX Φ4x12,7 Al/St 16910516 Al 4x12,7 AVEX Φ4x12,7 Al/Fe 4,0mm 9,6mm

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Control system assembly manual D2_R0_00 Rev. 03 5 150
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Control stick + Control stick base

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Control system assembly manual D2_R0_00 Rev. 03 6 150
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Control stick + Control stick base

Washer 102a-034-18x2,5/5,2

Washer 102a-034-18x2,5/5,2

Washer 102-003-32x3,4/8,2

Washer 102-003-32x3,4/8,2

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Control system assembly manual D2_R0_00 Rev. 03 7 150
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Control stick + Control stick base

Control stick

Control stick base

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Control system assembly manual D2_R0_00 Rev. 03 8 150
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Control stick + Control stick base

Part: D2_R_04
Quantity: 1 piece

Part: D2_R_06
Quantity: 2 piece

Part: D2_R_18
Quantity: 1 piece

Part: D2_R_02N
Quantity: 1 piece

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Control system assembly manual D2_R0_00 Rev. 03 9 150
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Control stick + Control stick base

Part: D2_R_03N
Quantity: 2 piece

Part: D2_R_01N
Quantity: 1 piece

Part: Washer 102-003-32x3,4/8,3

Quantity: 2 piece

Part: Washer 102a-034-18x2,5/5,2

Quantity: 4 piece

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Control system assembly manual D2_R0_00 Rev. 03 10 150
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Control stick + Control stick base

Standard Parts
Detail picture Part Quantity

Nut Nyloc DIN 985 M5 2

Bolt DIN 912 M6x70 D46 1

Washer flat DIN 125 M6 1

Bolt DIN 912 M5x50 D28 2

Nut Nyloc DIN 985 M6 1

Washer flat DIN 125 M5 2

Blind rivets
10
AVEX Ø 4,0x9,5 AL/St

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Control system assembly manual D2_R0_00 Rev. 03 11 150
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Control stick + Control stick base

Step 1

Washer 102a-034-18x2,5/5,2

Washer 102a-034-18x2,5/5,2

Washer 102a-034-18x2,5/5,2

Washer 102a-034-18x2,5/5,2

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Control system assembly manual D2_R0_00 Rev. 03 12 150
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Control stick + Control stick base

Step 2

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Control system assembly manual D2_R0_00 Rev. 03 13 150
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Control stick + Control stick base

Step 3

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Control system assembly manual D2_R0_00 Rev. 03 14 150
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Control stick + Control stick base

Step 4

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Control system assembly manual D2_R0_00 Rev. 03 15 150
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Control stick + Control stick base

Step 5
5x Ø4

5x Ø4

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Control stick + Control stick base

Step 6

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Control system assembly manual D2_R0_00 Rev. 03 17 150
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5x Rivet Control stick + Control stick base
AVEX 4x9,5 Al/St
Step 7

5x Rivet
AVEX 4x9,5 Al/St

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Control system assembly manual D2_R0_00 Rev. 03 18 150
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Control stick + Control stick base

Step 8

Washer 102-003-32x3,4/8,2

Washer 102-003-32x3,4/8,2

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Control stick + Control stick base

Step 9

Washer 102-003-32x3,4/8,2

Washer 102-003-32x3,4/8,2

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Control stick + Control stick base

Step 10

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Control system assembly manual D2_R0_00 Rev. 03 21 150
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Control stick + Control stick base

Step 11

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Control system assembly manual D2_R0_00 Rev. 03 22 150
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Aileron lever

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Control system assembly manual D2_R0_00 Rev. 03 23 150
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Aileron lever

Aileron lever
Quantity: 2

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Control system assembly manual D2_R0_00 Rev. 03 24 150
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Aileron lever

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25
Control system assembly manual D2_R0_00 Rev. 03 25 150
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Aileron lever

Part: D2_R_12N
Quantity: 2+2

Part: D2_R_07N
Quantity: 1+1

Part: D2_R_23N
Quantity: 1+1

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Control system assembly manual D2_R0_00 Rev. 03 26 150
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Aileron lever

Standard Parts
Detail picture Part Quantity

Bearing 626-2Z 2+2

Blind rivets
6+6
AVEX Ø 3,2x9,5 AL/st

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Aileron lever

Step 1

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Aileron lever

Step 2

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Aileron lever

Step 3

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Aileron lever

Step 4

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Aileron lever

Step 5

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Control system assembly manual D2_R0_00 Rev. 03 32 150
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Aileron lever

Step 6

Ø3,0

Ø3,2

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Control system assembly manual D2_R0_00 Rev. 03 33 150
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Aileron lever

Step 7

3+3 x Rivet
AVEX 3,2x9,5 Al/St

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Control system assembly manual D2_R0_00 Rev. 03 34 150
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Elevator lever 1

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Control system assembly manual D2_R0_00 Rev. 03 35 150
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Elevator lever 1

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Control system assembly manual D2_R0_00 Rev. 03 36 150
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Elevator lever 1

Part: D2_R_08N
Quantity: 2 piece

Part: D2_R_07N
Quantity: 1 piece

Part: D2_R_23N
Quantity: 1 piece

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 37 150
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Elevator lever 1

Standard Parts
Detail picture Part Quantity

Bearing 626-2Z 2

Blind rivets
AVEX Ø 3,2x9,5 AL/st 6

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Control system assembly manual D2_R0_00 Rev. 03 38 150
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Elevator lever 1

Step 1

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Control system assembly manual D2_R0_00 Rev. 03 39 150
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Elevator lever 1

Step 2

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Elevator lever 1

Step 3

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Elevator lever 1

Step 4

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Elevator lever 1

Step 5

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Elevator lever 1

Step 6

Ø3,0
Ø3,2

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Control system assembly manual D2_R0_00 Rev. 03 44 150
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Elevator lever 1
3+3 x Rivet
AVEX 3,2x9,5 Al/St
Step 6

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Control system assembly manual D2_R0_00 Rev. 03 45 150
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Elevator lever 2

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Control system assembly manual D2_R0_00 Rev. 03 46 150
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Elevator lever 2

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Control system assembly manual D2_R0_00 Rev. 03 47 150
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Elevator lever 2

Part: D2_R_11N
Quantity: 2

Part: D2_R_07N
Quantity: 1

Part: D2_R_23N
Quantity: 1

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 48 150
 [Link] Ι [Link] CONTROL SYSTEM
Elevator lever 2

Standard Parts
Detail picture Part Quantity

Bearing 626-2Z 2

Blind rivets
AVEX Ø 3,2x9,5 AL/st 6

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 49 150
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Elevator lever 2

Step 1

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Elevator lever 2

Step 2

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Elevator lever 2

Step 3

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Elevator lever 2

Step 4

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Control system assembly manual D2_R0_00 Rev. 03 53 150
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Elevator lever 2

Step 5

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Control system assembly manual D2_R0_00 Rev. 03 54 150
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Elevator lever 2

Step 6

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Elevator lever 2

Step 7

Ø3,0

Ø3,2

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 56 150
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Elevator lever 2

Step 8

3+3 x Rivet
AVEX 3,2x9,5 Al/St

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Control system assembly manual D2_R0_00 Rev. 03 57 150
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Pushrods

Aileron pushrod 1
65

Aileron pushrod 2
1520

Elevator pushrod 1
960

Elevator pushrod 2
1760

Elevator pushrod 3
940

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 58 150
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Aileron pushrod 1

Aileron pushrod 1
Quantity: 2

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 59 150
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Aileron pushrod 1

Part: D2_R_13N
Quantity: 1+1

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 60 150
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Aileron pushrod 1

Standard Parts
Detail picture Part Quantity

MM4 2+2

DIN 439B M6 2+2

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 61 150
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Aileron pushrod 1

Step 1

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Control system assembly manual D2_R0_00 Rev. 03 62 150
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Aileron pushrod 1

Step 2

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Aileron pushrod 1

Step 3

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Control system assembly manual D2_R0_00 Rev. 03 64 150
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Aileron pushrod 1

Step 4

65

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Control system assembly manual D2_R0_00 Rev. 03 65 150
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Aileron pushrod 2

Aileron pushrod 2
Quantity: 2

1520

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 66 150
 [Link] Ι [Link] CONTROL SYSTEM
Aileron pushrod 2

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 67 150
 [Link] Ι [Link] CONTROL SYSTEM
Aileron pushrod 2

Standard Parts
Detail picture Part Quantity

MM4 2+2

Blind rivets
AVEX Ø 4x9,5 Al/St 6+6

DIN 439B M6 2+2

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 68 150
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Aileron pushrod 2

Step 1

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Control system assembly manual D2_R0_00 Rev. 03 69 150
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Aileron pushrod 2

Step 2

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Control system assembly manual D2_R0_00 Rev. 03 70 150
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Aileron pushrod 2

Step 3

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Control system assembly manual D2_R0_00 Rev. 03 71 150
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Aileron pushrod 2

Step 4

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Aileron pushrod 2

Step 5

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Aileron pushrod 2

Step 6

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Control system assembly manual D2_R0_00 Rev. 03 74 150
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Aileron pushrod 2

Step 7

1520

1600

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 75 150
 [Link] Ι [Link] CONTROL SYSTEM
Elevator pushrod 1

Elevator pushrod 1
Quantity: 1

D2_R_15N

D2_R_15N

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 76 150
 [Link] Ι [Link] CONTROL SYSTEM
Elevator pushrod 1

Standard Parts
Detail picture Part Quantity

MM4 2

Blind rivets
AVEX Ø 4x9,5 Al/St 6

DIN 439B M6 2

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 77 150
 [Link] Ι [Link] CONTROL SYSTEM
Elevator pushrod 1

Step 1

D2_R_15N

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 78 150
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Elevator pushrod 1

Step 2

D2_R_15N

960

1040

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 79 150
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Elevator pushrod 2

Elevator pushrod 2
Quantity: 1

D2_R_16N

D2_R_16N

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 80 150
 [Link] Ι [Link] CONTROL SYSTEM
Elevator pushrod 2

Standard Parts
Detail picture Part Quantity

MM4 2

Blind rivets
AVEX Ø 4x9,5 Al/St 6

DIN 439B M6 2

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 81 150
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Elevator pushrod 2

Step 1

D2_R_16N

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 82 150
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Elevator pushrod 2

Step 2

D2_R_16N

1760

1840

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 83 150
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Elevator pushrod 3

Elevator pushrod 3
Quantity: 1

D2_R_17N

D2_R_17N

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 84 150
 [Link] Ι [Link] CONTROL SYSTEM
Elevator pushrod 3

Standard Parts
Detail picture Part Quantity

MM4 2

Blind rivets
AVEX Ø 4x9,5 Al/St 6

DIN 439B M6 2

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 85 150
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Elevator pushrod 3

Step 1

D2_R_17N

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 86 150
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Elevator pushrod 3

Step 2

D2_R_17N

940

1020

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 87 150
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Aileron control assembly – part 1

D2_SP_01
D2_SP_01

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 88 150
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Aileron control assembly – part 1

D2_SP_01
2 pcs

Standard Parts
Detail picture Part Quantity

Bolt DIN 912 M6x50 1

Nut Nyloc DIN 985 M6 1

Washer, flat DIN 125 M6 1

Bolt DIN 912 M6x30 2

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 89 150
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Aileron control assembly – part 1

Step 1

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Control system assembly manual D2_R0_00 Rev. 03 90 150
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Aileron control assembly – part 1

Step 2 D2_SP_01

D2_SP_01

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 91 150
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Aileron control assembly – part 1

Step 3
D2_SP_01
D2_SP_01

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Control system assembly manual D2_R0_00 Rev. 03 92 150
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Aileron control assembly – part 1

Step 4

D2_SP_01

D2_SP_01

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Aileron control assembly – part 1

Step 5

D2_SP_01

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Aileron control assembly – part 1

Step 7

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Control system assembly manual D2_R0_00 Rev. 03 95 150
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Aileron control assembly – part 2

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 96 150
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Aileron control assembly – part 2

Standard Parts
Detail picture Part Quantity

Bolt DIN 912 M6x50 2

Bolt DIN 912 M6x40 4

Nut Nyloc DIN 985 M6 6

Washer, flat DIN 125A M6 10

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 97 150
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Aileron control assembly – part 2

Step 1

Washer, flat DIN 125 M6

Washer, flat DIN 125 M6

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 98 150
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Aileron control assembly – part 2

Step 2

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Control system assembly manual D2_R0_00 Rev. 03 99 150
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Aileron control assembly – part 2

Step 3

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Aileron control assembly – part 2

Step 4

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Control system assembly manual D2_R0_00 Rev. 03 101 150
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Aileron control assembly – part 2

Step 5

Washer flat DIN 125

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 102 150
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Aileron control assembly – part 2

Step 6

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Control system assembly manual D2_R0_00 Rev. 03 103 150
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Aileron control assembly – part 2

Step 7

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Control system assembly manual D2_R0_00 Rev. 03 104 150
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Elevator control assembly – part 1

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 105 150
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Elevator control assembly – part 1

D2_R_19N
Quantity: 2

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 106 150
 [Link] Ι [Link] CONTROL SYSTEM
Elevator control assembly – part 1

Standard Parts
Detail picture Part Quantity

Bolt DIN 912 M6x70 1

Nut Nyloc DIN 985 M6 1

Washer, flat DIN 125 M6 1

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 107 150
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Elevator control assembly – part 1

Step 1

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Control system assembly manual D2_R0_00 Rev. 03 108 150
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Elevator control assembly – part 2

Washer, flat DIN125 M6

Washer, flat DIN125 M6

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 109 150
 [Link] Ι [Link] CONTROL SYSTEM
Elevator control assembly – part 2

Standard Parts
Detail picture Part Quantity
Bolt DIN 912 M6x50 1

Bolt DIN 912 M6x40 2

Nut Nyloc DIN 985 M6 3

Washer, flat DIN 125 M6 5

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 110 150
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Elevator control assembly – part 2

Step 1

Washer, flat DIN125 M6

Washer, flat DIN125 M6

Title Document no. Revision Page Pages

Control system assembly manual D2_R0_00 Rev. 03 111 150
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Elevator control assembly – part 2

Step 2

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Elevator control assembly – part 2

Step 3

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Elevator control assembly – part 3

Washer, flat DIN 125 M6

Washer, flat DIN 125 M6

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Elevator control assembly – part 3

Standard Parts
Detail picture Part Quantity

Bolt DIN 912 M6x50 1

Bolt DIN 912 M6x40 2

Nut Nyloc DIN 985 M6 3

Washer, flat DIN 125 M6 5

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Elevator control assembly – part 3

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Control system assembly manual D2_R0_00 Rev. 03 116 150
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Elevator control assembly – part 3

Step 1

Washer, flat DIN 125 M6

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Elevator control assembly – part 3

Step 2

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Elevator control assembly – part 3

Step 3

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Elevator control assembly – part 3

Step 4

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Rudder control assembly
Rudder control system assembly

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Rudder control assembly

D2_R_20N
Quantity: 1

D2_R_21N
Quantity: 2

D2_R_30N
Quantity: 2

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Rudder control assembly

D2_R_32N
Quantity: 2

D2_R_33N
Quantity: 2

D2_R_35N
Quantity: 2

D2_R_36N
Quantity: 2

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Control system assembly manual D2_R0_00 Rev. 03 123 150
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Rudder control assembly

Standard Parts
Detail picture Part Quantity

Bolt DIN 912 M5x30 2

Bolt DIN 912 M5x40 2

Nut Nyloc DIN 985 M5 6

Washer, flat DIN 125 M5 4

Crimp sleeve 8

Thimble 4

Crimp sleeve 4

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Rudder control assembly

Step 1

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Rudder control assembly

Step 2

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Rudder control assembly

Step 3

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Rudder control assembly

Step 4

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Rudder control assembly

Step 5

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Rudder control assembly

Step 6

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Rudder control assembly

Step 7

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Rudder control assembly

Step 8

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Rudder control assembly

Step 9

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Rudder control assembly

Step 10

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Rudder control assembly

Step 11

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Rudder control assembly

Step 12

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Rudder control assembly

Step 13

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Rudder control assembly

Step 14

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Rudder control assembly

Step 15

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Rudder control assembly

Step 16

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Rudder control assembly

Step 17

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Rudder control assembly

Step 18

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Rudder control assembly

Step 19

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Rudder control assembly

Step 20

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Rudder control assembly

Step 21

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Rudder control assembly

Step 22

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Rudder control assembly

Step 23

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Rudder control assembly

Step 24

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Rudder control assembly

Step 25

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Rudder control assembly

Step 26

Crimp sleeve

D2_R_36N
D2_R_35N

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